Continuous Casting Copper Tube Diameter Optimization
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Solution Overview
Problem
The existing Hollow Jet Nozzle design in continuous casting equipment often results in irregular steel flow and powder injection, leading to instability and clogging issues during the casting process.
Innovation Solution
The design includes a refractory dome with a sloped upper part deflecting liquid metal towards the inner duct walls, a copper tube with a diameter optimized between Q/3.75 and Q/1.25 kg/min, and support arms to secure the dome, ensuring a stable flow and efficient heat extraction, with a slope of 25-15° and a sharp fillet to maintain a homogeneous steel layer, reducing clogging risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the copper tube diameter is not optimized, then the heat extraction efficiency may be insufficient, but the risk of clogging increases
Solution Approach 1:
The patent applies parameter changes by establishing an optimized diameter range for the copper tube (D = Q/3.75 to Q/1.25) based on the liquid metal flow rate Q. This quantitative parameter optimization ensures that the copper tube diameter is neither too small (causing clogging) nor too large (reducing heat extraction efficiency), thereby resolving the contradiction between heat extraction efficiency and clogging risk.
2Stability of the object's composition
If the dome upper part slope is not optimized, then the steel flow distribution may be irregular, but the powder injection stability deteriorates
Solution Approach 1:
The patent applies parameter changes by specifying an optimized slope range for the dome upper part (α = 25° to 15°). This geometric parameter optimization ensures that the liquid metal flow is properly distributed and directed towards the copper tube while maintaining stable powder injection conditions, thereby resolving the contradiction between steel flow regularity and powder injection stability.
3Loss of energy
If the copper tube diameter is too small, then the heat extraction efficiency increases, but the flow stability decreases leading to clogging
Solution Approach 1:
The patent resolves this contradiction by establishing a lower bound for the copper tube diameter (D ≥ Q/3.75). This parameter constraint ensures that the diameter is sufficiently large to maintain stable liquid metal flow and prevent clogging, while still being small enough to provide effective heat extraction, thus balancing both requirements through quantitative optimization.
4Stability of the object's composition
If the copper tube diameter is too large, then the flow stability improves, but the heat extraction efficiency decreases
Solution Approach 1:
The patent resolves this contradiction by establishing an upper bound for the copper tube diameter (D ≤ Q/1.25). This parameter constraint ensures that the diameter does not exceed the optimal value, thereby maintaining high heat extraction efficiency while still providing sufficient flow stability, thus balancing both requirements through quantitative optimization.
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
This configuration ensures a regular and stable casting process by maintaining a thin, homogeneous steel layer on the copper tube, maximizing heat extraction, and preventing clogging, while allowing for symmetrical and efficient powder injection, thereby enhancing the overall casting process stability.
Implementation Method 1
The water-cooled copper tube 3 forms a heat exchanger that extracts heat from the liquid steel
Implementation Method 2
the water-cooled copper tube 3 forms a heat exchanger that extracts heat from the liquid steel
Implementation Method 3
the shape of this dome 2 causes the metal to flow towards its periphery, the flow being deflected towards the internal wall of the nozzle
Implementation Method 4
maintaining a thin, homogeneous steel layer on the copper tube, maximizing heat extraction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a continuous casting equipment for a flow of liquid metal from a tundish (1) into a mould (9), said equipment comprising: a vertical duct disposed upstream of the mould (9) with respect to the direction of travel of the liquid metal; said duct comprising from upstream to downstream a refractory ring (5), a copper tube (3) with an internal diameter D and a submerged entry nozzle (8), a dome (2) disposed inside the refractory ring (5) and comprising a sloped upper part (16), said upper part (16) being defined so as to deflect the liquid metal coming from the tundish (1) towards the inner walls of the vertical duct; characterized in that the diameter D of the copper tube (3) ranges between a minimum diameter equals to Q/3.75 and a maximum diameter equals to Q/1.25, where Q is the nominal liquid metal flow rate of the equipment and is comprised between 200 and 800 kg/min and D the diameter expressed in mm.