Liquid-Cooled Mold Cooling for Continuous Casting
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Solution Overview
Problem
Existing cooling methods for liquid-cooled molds in continuous casting and remelting plants result in premature solidification of metals due to high temperature gradients, leading to surface defects like 'hooks' and 'tears' in the cast products, as water-based cooling systems have limited temperature control and efficiency.
Innovation Solution
The method involves using higher temperature cooling media such as pressurized water, liquid metals, or molten salts (ionic liquids) to reduce heat dissipation, with controlled temperature differences and a heat exchanger to manage and recover waste heat, ensuring delayed primary solidification of metals below the meniscus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water-based cooling systems are used with conventional temperature control, then cooling efficiency is maintained, but premature solidification occurs leading to surface defects
Solution Approach 1:
The patent changes the temperature parameter of the cooling medium from conventional water temperature (20-50°C) to elevated temperature (50-200°C) to reduce the temperature gradient between the liquid metal and cooling medium, thereby preventing premature solidification at the meniscus while maintaining effective heat removal from the mold
Solution Approach 2:
The patent converts the typically harmful effect of heat into a beneficial control mechanism by using heated cooling media. The thermal energy that would normally cause premature solidification is instead used to maintain optimal temperature gradients, delaying solidification to the desired location below the meniscus and improving surface quality
2Reliability
If high flow rate cooling water is used, then vapor bubble formation is prevented, but strong cooling effect causes solidification front to run ahead of meniscus
Solution Approach 1:
The patent changes multiple parameters of the cooling system: elevating the temperature of the cooling medium (reducing temperature gradient), increasing pressure (preventing vaporization), and adjusting flow rate. These combined parameter changes allow effective heat removal while controlling the solidification front to form below the meniscus rather than ahead of it
3Device complexity
If conventional water cooling circuits are used, then system simplicity is maintained, but temperature control range is limited
Solution Approach 1:
The patent changes the operating parameters of the cooling circuit by using pressurized systems that allow water or alternative fluids to operate at elevated temperatures (50-200°C) without vaporization. This extends the temperature control range while maintaining a relatively simple circuit structure based on conventional pump-and-pipe systems with added pressure control
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 approach effectively reduces the cooling effect, delaying initial solidification of metals and improving the surface quality of cast products by maintaining a controlled temperature gradient, allowing for smoother solidification and reducing defects.
Implementation Method 1
the heat dissipation being effected by the cooling water running through the gap between the mold insert and the water jacket
Implementation Method 2
the liquid metal solidifies in contact with the inner wall and the heat is dissipated from the outer wall of the mold insert, which is in contact with the coolant
Implementation Method 3
a heat exchanger to manage and recover waste heat
Data Source
Figure 1
AI summary
In order to avoid solidification which proceeds over the meniscus of the metal mirror during the continuous casting or remelting of steels and alloys, the cooling conditions are set in such a way that, in the case of inlet temperatures of the coolant at room temperature or else considerably thereabove, outlet temperatures of the coolant of at least 80°C are achieved. Suitable coolants are pressurized water, metals which are liquid below 100°C and also ionic liquids (salt melts) which are liquid above room temperature and up to at least 200°C, it being possible for the differences in temperature between the coolant inlet and the coolant outlet in the mould to be between 5°C and 150°C.