Two-Component Block Nozzle Edge Rounding for Scale Reduction
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Solution Overview
Problem
In continuous casting machines, the high casting speed leads to rapid scale accumulation on two-fluid block nozzles, causing blockages and reliability issues due to insufficient distance between strand guide rolls for scale removal.
Innovation Solution
A two-component block nozzle with a cuboid base body featuring rounded or chamfered edges on multiple surfaces to reduce scale deposition, incorporating a mixing chamber for coolant mixing and a detachable spray nozzle attachment, with precise flow control and sealing to minimize scale accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base body has flat surfaces (cuboid shape), then manufacturing is simple, but scale accumulates heavily on the surfaces
Solution Approach 1:
The patent applies curvature by rounding the edges and corners of the cuboid base body. Instead of sharp 90-degree edges, the design incorporates rounded transitions between surfaces. This curvature prevents scale accumulation because scaled material cannot easily adhere to curved surfaces and is more easily removed by the cooling medium flow, directly addressing the scale accumulation problem while maintaining the overall cuboid shape for manufacturing simplicity.
2Productivity
If high casting speed is used, then productivity increases, but scale removal becomes insufficient due to small distances between strand guide rolls
Solution Approach 1:
The patent converts the harmful effect of high casting speed (which causes rapid scale accumulation) into a benefit by designing the rounded base body that actively promotes scale removal. The curved surfaces create favorable flow patterns for the cooling medium that enhance scale detachment, turning the high-speed casting condition from a problem into an opportunity for improved scale management through the specialized geometry.
Solution Approach 2:
The patent changes the geometric parameters of the base body from sharp edges to rounded edges with specific radius values. This parameter change modifies the surface characteristics to reduce scale adhesion. By adjusting the rounding radius and edge geometry, the design optimizes scale removal efficiency while maintaining compatibility with high casting speeds, allowing the system to operate at higher productivity without proportionally increased scale accumulation.
3Object-affected harmful factors
If rounded or chamfered edges are added to reduce scale storage areas, then scale accumulation decreases, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by rounding only specific edges and corners of the base body where scale accumulation is most problematic, rather than making the entire surface complex. The rounding is concentrated at the edges and corners where the cooling medium flow creates favorable conditions for scale deposition, while maintaining simpler geometry in other areas. This localized application reduces overall geometric complexity while effectively targeting scale storage areas.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces scale storage areas on the nozzle surfaces, enhancing the reliability of continuous casting machines by preventing blockages and maintaining operational efficiency.
Implementation Method 1
a mixing chamber for intimate mixing of the liquid cooling medium with the gaseous cooling medium
Implementation Method 2
the size of the surfaces of at least two surfaces, preferably at least three surfaces, from the group of the front surface and the side surfaces, by a rounding or a chamfering of one edge between the front surface and a side surface, be reduced by at least 10% compared to the cuboid initial state of the base body, whereby the storage areas for scale on the surfaces are also reduced
Data Source
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AI summary
The present invention relates to a two-component block die for cooling a strand (30), preferably with a billet or pre-block cross-section, in a continuous casting machine. The object of the invention is to provide a two-component block die such that less scale can be deposited on the outer surfaces of the block die during operation in a continuous casting machine. This object is achieved by a two-component block die according to claim 1, wherein the surface area of at least two surfaces, preferably at least three surfaces, from the group consisting of the end face (3) and the flat side surfaces (4), is reduced by at least 10% compared to the cuboidal initial state of the base body (1) by rounding (15) or chamfering (16) each edge between the end face (3) and a side surface (4), thereby also reducing the areas for scale deposition on the surfaces.