Stabilized Lubricant Composition for Continuous Casting
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Solution Overview
Problem
Existing lubricant compositions for continuous steel casting face challenges with manageability, sedimentation stability, and pumpability, particularly in open casting processes, where powders are difficult to use due to poor manageability and limited rheological stability, leading to issues like excessive flake formation and cracking.
Innovation Solution
A stabilized lubricant composition for ingot molds, comprising a dispersion of lubricant powder in an oily liquid with a stabilization additive, which is rheologically stable for storage and pumpable during use, featuring a non-Newtonian pseudo-plastic fluid behavior, preventing sedimentation and ensuring effective lubrication in both close and open casting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lubricant powder is used in open casting, then steel quality is improved, but manageability deteriorates making it difficult to use
Solution Approach 1:
The patent transforms the physical state of the lubricant from solid powder to liquid suspension form, changing parameters such as viscosity, flowability, and particle distribution. This allows the lubricant to be delivered through pumping systems while maintaining the quality benefits of powder-based lubrication.
Solution Approach 2:
The patent introduces a liquid carrier medium as an intermediary to transport solid lubricant particles. This liquid suspension acts as a mediator between the pumping system and the casting process, enabling easy delivery while maintaining lubrication effectiveness.
2Ease of operation
If liquid lubricant composition is used to improve manageability, then ease of operation is improved, but rheological stability deteriorates causing sedimentation
Solution Approach 1:
The patent creates a dynamic suspension system where particles remain dispersed through controlled viscosity and flow characteristics. The liquid composition maintains stability during storage and pumping by balancing particle density, liquid viscosity, and flow dynamics to prevent sedimentation.
Solution Approach 2:
The patent forms a composite liquid suspension combining solid lubricant particles with a liquid carrier medium. This composite structure integrates the benefits of both solid powder (lubrication quality) and liquid (manageability), with particles uniformly distributed throughout the liquid matrix.
3Reliability
If powder lubricant is used, then steel quality is improved, but pumpability deteriorates
Solution Approach 1:
The patent changes the physical parameters of the lubricant delivery system by converting from solid powder to liquid suspension. This enables the lubricant to flow through pumping systems and delivery lines while maintaining the quality characteristics of powder-based lubrication at the application point.
Solution Approach 2:
The patent employs hydraulic principles by using a liquid suspension that can be pumped and delivered through fluid delivery systems. The liquid carrier medium allows the lubricant to be transported hydraulically to the casting mold, combining ease of delivery with effective lubrication.
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
The composition provides prolonged shelf-life, improved manageability, reduced sedimentation, and enhanced pumpability, resulting in better steel quality with reduced flake and crack formation, and increased casting speed, while maintaining the quality standards of ingot mold powders.
Implementation Method 1
a stabilization additive, which ensures rheological stability in static conditions and sufficient fluidity for pumping in dynamic conditions
Implementation Method 2
preventing sedimentation and ensuring effective lubrication
Implementation Method 3
featuring a non-Newtonian pseudo-plastic fluid behavior, preventing sedimentation and ensuring effective lubrication
Implementation Method 4
rheologically stable for storage and pumpable during use
Implementation Method 5
thermal insulation of the liquid steel in the ingot mold to prevent the solidification thereof
Implementation Method 6
absorption of non-metallic inclusions from the steel
Implementation Method 7
the liquid layer acts as a lubricant
Data Source
AI summary
Described herein is a stabilized lubricant composition for use in steel casting, in particular in continuous casting processes. In particular, the lubricant composition for processes for producing steel by continuous casting includes a dispersion of a lubricant powder, for an ingot mold, in continuous casting, in an oily liquid means, and a stabilization additive, characterized in that it has the following shear thinning index values:RVT0.1/11/1010/100100/1000STI3.0-7.52.0-6.51.0-3.00.5-2.0wherein RVT is the ratio between two different shear speeds and STI is the shear thinning index corresponding to the RVT values.