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Improving Performance in Continuous Casting - Pyrotek

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<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

pyrotek<br />

supplement<br />

pyrotek<br />

supplement<br />

Page 2<br />

• Latest Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

Technology <strong>in</strong> the Modern Casthouse<br />

- <strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> for the<br />

Customer<br />

• Unique Melt Quality Practices for<br />

Sheet Cast<strong>in</strong>g<br />

Page 3<br />

• Transfer Launder from the Filtration<br />

Unit to the Headbox/Tundish<br />

• Thermollite Launders<br />

Page 4<br />

• Vacuum Formed Refractory Ceramic<br />

Fiber Launders<br />

• Headboxes/Tundishes<br />

• Steady Eddy<br />

Page 5<br />

• Metal Temperature Inside the Headbox<br />

or Tundish<br />

• SMT Furnace<br />

Page 6<br />

• Tips and Component Parts<br />

Page 7<br />

• Tip Baffle Designs<br />

Page 9<br />

• Graphite Release Agents<br />

• Technical Assistance <strong>in</strong> Cont<strong>in</strong>uous<br />

Sheet Cast<strong>in</strong>g<br />

Page 10<br />

• Conclusion<br />

Page 11<br />

• <strong>Pyrotek</strong> Locations<br />

Click for web<br />

<strong>in</strong>formation<br />

Click for current<br />

datasheet


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

Jonathan Prebble,<br />

Manager of<br />

Alum<strong>in</strong>ium Process<br />

Technology<br />

<strong>Pyrotek</strong> has<br />

the expertise,<br />

technology,<br />

experience<br />

and the<br />

global<br />

resources to<br />

maximize the<br />

performance<br />

of your<br />

cont<strong>in</strong>uous<br />

sheet cast<strong>in</strong>g<br />

systems.<br />

Page 2<br />

LATEST ConT<strong>in</strong>uouS<br />

CAST<strong>in</strong>g TECHnoLogY <strong>in</strong><br />

THE MoDERn CASTHouSE<br />

improv<strong>in</strong>g <strong>Performance</strong> For The<br />

Customer<br />

This is the fifth <strong>Pyrotek</strong> article <strong>in</strong> a series on<br />

improv<strong>in</strong>g casthouse performance written<br />

for Alum<strong>in</strong>ium <strong>in</strong>ternational Today (AiT).<br />

The previous <strong>Pyrotek</strong> articles have <strong>in</strong>cluded<br />

improv<strong>in</strong>g performance <strong>in</strong>: Furnace Melt<br />

Treatment; Casthouse Furnace Build<strong>in</strong>g and<br />

Repair; the Degass<strong>in</strong>g Process; the Filtration<br />

Process, and Slab Cast<strong>in</strong>g Processes.<br />

Please see the previous articles <strong>in</strong> the AiT<br />

Series at www.pyrotek.<strong>in</strong>fo/alum<strong>in</strong>ium.<br />

This article br<strong>in</strong>gs us to the cont<strong>in</strong>uous<br />

sheet cast<strong>in</strong>g operation. It is advisable to<br />

review <strong>Pyrotek</strong>’s previous AIT articles on the<br />

techniques and equipment needed to meet<br />

the melt quality specifications required<br />

for the end product, preferably before<br />

cont<strong>in</strong>u<strong>in</strong>g with this article.<br />

Cont<strong>in</strong>uous cast<strong>in</strong>g is the process of<br />

convert<strong>in</strong>g molten alum<strong>in</strong>ium directly from<br />

a furnace <strong>in</strong>to a solid wide sheet. This<br />

article will ma<strong>in</strong>ly address the process of<br />

tw<strong>in</strong> roll casters, as this is by far the most<br />

common type of cont<strong>in</strong>uous sheet cast<strong>in</strong>g<br />

employed worldwide and shows the largest<br />

amount of market growth. The other forms<br />

of cont<strong>in</strong>uous cast<strong>in</strong>g such as block casters,<br />

belt casters and wheel and belt casters,<br />

have their own unique niche <strong>in</strong> alum<strong>in</strong>ium<br />

production.<br />

Cont<strong>in</strong>uous sheet cast<strong>in</strong>g of alum<strong>in</strong>ium began<br />

<strong>in</strong> the 1950’s and has become <strong>in</strong>creas<strong>in</strong>gly<br />

important <strong>in</strong> the alum<strong>in</strong>ium <strong>in</strong>dustry. It has<br />

ga<strong>in</strong>ed the respect of alum<strong>in</strong>ium producers<br />

worldwide. This susta<strong>in</strong>ed growth is due to<br />

the economic advantages of the cont<strong>in</strong>uous<br />

cast<strong>in</strong>g process when compared to the<br />

conventional DC cast<strong>in</strong>g process. It is also<br />

due to the improved sheet quality and the<br />

wide range of alloys that can be produced.<br />

The economic advantages for cont<strong>in</strong>uous<br />

pyrotek<br />

supplement<br />

iMPRoV<strong>in</strong>g PERFoRMAnCE <strong>in</strong><br />

THE ConT<strong>in</strong>uouS SHEET CAST<strong>in</strong>g PRoCESS<br />

cast<strong>in</strong>g over conventional DC cast<strong>in</strong>g<br />

<strong>in</strong>clude the follow<strong>in</strong>g:<br />

• Lowers capital <strong>in</strong>vestment cost<br />

• Utilises less energy<br />

• Requires less labour<br />

• Works well <strong>in</strong> smaller cast<strong>in</strong>g facilities<br />

• Avoids the need for a Hot Mill<br />

• Provides a wide range of alloys and<br />

widths<br />

In addition to tw<strong>in</strong> roll casters, there are<br />

6 block cast<strong>in</strong>g mach<strong>in</strong>es <strong>in</strong> operation<br />

today, cast<strong>in</strong>g th<strong>in</strong> slab between 12-25<br />

mm thick up to 860 mm wide. There are<br />

also 12 belt cast<strong>in</strong>g mach<strong>in</strong>es currently <strong>in</strong><br />

operation. These normally cast th<strong>in</strong> slab<br />

between 14-19 mm and a maximum of<br />

1930 mm wide. Hazelett has a current<br />

design up to 2300 mm wide. Wheel and belt<br />

casters, known ma<strong>in</strong>ly as wire rod casters, can<br />

also cast narrow strips up to 400 mm wide<br />

and 12-30 mm thick. Cont<strong>in</strong>uus Properzi<br />

is a market leader with this type of process<br />

and has designs, which can produce up to<br />

21 mt/hour.<br />

Tw<strong>in</strong> roll cast<strong>in</strong>g <strong>in</strong>corporates two watercooled<br />

rolls and uses off-l<strong>in</strong>e roll<strong>in</strong>g.<br />

There are over 400 tw<strong>in</strong> roll casters <strong>in</strong><br />

operation today, cast<strong>in</strong>g gauges from<br />

3 mm up to 10 mm. The widest sheet width to<br />

date is 2450 mm.<br />

uniquE MELT quALiTY<br />

PRACTiCES FoR SHEET CAST<strong>in</strong>g<br />

There are a couple of po<strong>in</strong>ts to highlight<br />

<strong>in</strong> regard to sheet cast<strong>in</strong>g. Charges of solid<br />

remelt <strong>in</strong>got and good clean scrap will<br />

produce a cleaner melt than a charge of<br />

very oily light gauge scrap. Oily scrap and<br />

light gauge scrap can <strong>in</strong>crease the amount of<br />

oxides that are formed as well as hydrogen,<br />

which is also absorbed dur<strong>in</strong>g the melt<strong>in</strong>g<br />

process. Many producers of light gauge<br />

foil set an <strong>in</strong>ternal limit for the maximum<br />

percentage of scrap permitted <strong>in</strong> each<br />

melt<strong>in</strong>g furnace charge to optimise metal<br />

quality.


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

Figure 1 - Schematic draw<strong>in</strong>g of the typical cont<strong>in</strong>uous sheet cast<strong>in</strong>g layout<br />

Dwell or settl<strong>in</strong>g time <strong>in</strong> the hold<strong>in</strong>g furnace<br />

before start<strong>in</strong>g to cast is essential <strong>in</strong> help<strong>in</strong>g<br />

to remove <strong>in</strong>clusions. The metal should<br />

rema<strong>in</strong> still and quiet for several hours,<br />

allow<strong>in</strong>g <strong>in</strong>clusions to settle to the bottom<br />

of the furnace. Charg<strong>in</strong>g from the melter<br />

to the holder usually takes place about<br />

every 2-4 hours dur<strong>in</strong>g cont<strong>in</strong>uous cast<strong>in</strong>g.<br />

Although settl<strong>in</strong>g is very useful <strong>in</strong> remov<strong>in</strong>g<br />

<strong>in</strong>clusions, additional melt treatment such<br />

as <strong>in</strong>-l<strong>in</strong>e degass<strong>in</strong>g and filtration, is often<br />

required to remove <strong>in</strong>clusions caused by<br />

such turbulence.<br />

TRAnSFER LAunDER FRoM<br />

THE FiLTRATion uniT To THE<br />

HEADBox/TunDiSH<br />

When the metal leaves the filtration unit, it<br />

needs to be clean and ready for the caster.<br />

Any turbulence <strong>in</strong> the melt after leav<strong>in</strong>g the<br />

filtration unit will only cause more oxides and<br />

hydrogen bubble formations. The material<br />

used <strong>in</strong> this launder section should be cleaned<br />

properly after each use and should not conta<strong>in</strong><br />

any particulates that would support the<br />

formation of <strong>in</strong>clusions. This launder section<br />

should be light <strong>in</strong> weight so operators can<br />

easily move it <strong>in</strong> and out of place dur<strong>in</strong>g start<br />

up and shut down. It should also be <strong>in</strong>sulated<br />

to m<strong>in</strong>imize melt temperature loss just prior<br />

to cast<strong>in</strong>g. <strong>Pyrotek</strong> has several recommended<br />

options for the launder sections used <strong>in</strong><br />

cont<strong>in</strong>uous cast<strong>in</strong>g.<br />

THERMoLLiTE LAunDERS<br />

Thermollite is a pre-formed,<br />

<strong>in</strong>sulat<strong>in</strong>g, phosphate bonded wollastonite<br />

refractory available <strong>in</strong> a density range of<br />

30-45 lb/ft 3 (480-640 Kg/m 3 ). It has been<br />

specifically developed for direct contact<br />

with molten alum<strong>in</strong>ium and its various<br />

alloys. Thermollite provides the specific<br />

advantage of reduc<strong>in</strong>g heat loss <strong>in</strong> the<br />

melt transfer <strong>in</strong>volv<strong>in</strong>g a low metal flow<br />

rate. Thermollite can also serve as an<br />

alternative to certa<strong>in</strong> <strong>in</strong>sulat<strong>in</strong>g, vacuum<br />

formed refractory ceramic fiber launders.<br />

Although preheat<strong>in</strong>g is not necessary with<br />

Thermollite, storage <strong>in</strong> a dry heated area<br />

is recommended prior to use. Thermollite<br />

launders do not require a support<strong>in</strong>g steel<br />

shell <strong>in</strong> most applications. It is reusable<br />

and resistant to thermal shock. Thermollite<br />

can also be used <strong>in</strong> other applications<br />

<strong>in</strong>clud<strong>in</strong>g tundishes for horizontal casters.<br />

ZYP Boron Nitride Lubricoat ® Blue is used<br />

as the coat<strong>in</strong>g and can be reapplied after<br />

each use as necessary. Customers who<br />

have switched to Thermollite report that<br />

they are very pleased with the quality of<br />

the material and the life of the product.<br />

All the <strong>in</strong>side corners <strong>in</strong> the launder have<br />

a radius design allow<strong>in</strong>g them to be easily<br />

cleaned between casts.<br />

pyrotek<br />

supplement<br />

Cont<strong>in</strong>uous<br />

cast<strong>in</strong>g<br />

has several<br />

economic<br />

advantages<br />

over<br />

conventional<br />

DC cast<strong>in</strong>g<br />

<strong>in</strong>clud<strong>in</strong>g<br />

lower capital<br />

<strong>in</strong>vestment,<br />

less energy use,<br />

less labour, and<br />

functionality<br />

<strong>in</strong> smaller<br />

cast<strong>in</strong>g<br />

facilities.<br />

Luanne B. Short<br />

global Sales Manager -<br />

Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

Page 3


Page 4<br />

<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

Customers<br />

who have<br />

switched to<br />

Thermollite<br />

report they are<br />

very pleased<br />

with the<br />

quality of the<br />

material and<br />

the life of the<br />

product.<br />

Thermollite 37 Silica Bonded<br />

RCF<br />

Density 594 kg/m3 (37 lbs/ft3 514 kg/m<br />

)<br />

3<br />

(32 lbs/ft3 )<br />

M.o.R. 2.37 MPa<br />

345 lbs/<strong>in</strong> 2<br />

Temperature Rat<strong>in</strong>g:<br />

- Cont<strong>in</strong>uous use<br />

- Maximum Service<br />

850°C (1560°F)<br />

1000°C (1830°F)<br />

Figure 2 - Thermollite comparative eng<strong>in</strong>eer<strong>in</strong>g properties<br />

VACuuM FoRMED REFRACToRY<br />

CERAMiC FiBER LAunDERS<br />

Vacuum formed launders<br />

are pre-formed by <strong>Pyrotek</strong> to<br />

the customer’s specifications<br />

and are reusable. These vacuum formed<br />

shapes are manufactured from high purity<br />

alum<strong>in</strong>o-silicate fibers <strong>in</strong> a one-piece<br />

design that elim<strong>in</strong>ates metal leakage.<br />

These ceramic fibers are formed together<br />

with a special<br />

bond<strong>in</strong>g process to<br />

create a smooth,<br />

h o m o g e n e o u s ,<br />

f<strong>in</strong>ished surface<br />

that is resistant to<br />

thermal shock. They<br />

also have a low<br />

thermal conductivity<br />

that requires no<br />

pre-heat<strong>in</strong>g and<br />

Figure 3 - Vaccum formed launder are reusable with<br />

proper treatment for<br />

multiple cast<strong>in</strong>g campaigns.<br />

HEADBoxES/TunDiSHES<br />

Tilt casters, vertical casters<br />

and some horizontal casters utilise a<br />

headbox system. This simple design<br />

allows metal to be run-off <strong>in</strong>to a sow<br />

mold <strong>in</strong> order to obta<strong>in</strong> the proper melt<br />

1.83 MPa<br />

267 lbs/<strong>in</strong> 2<br />

L.o.i. 900°C (1650°F) 0.55% 0.74%<br />

Thermal Conductivity:<br />

- Btu-<strong>in</strong>/ft 2 /hr<br />

- W/(m*K)<br />

Shr<strong>in</strong>kage<br />

- at 400°C (750°F)<br />

- at 730°C (1350°F)<br />

1.12 @ 1000°F<br />

1.30 @ 1500°F<br />

0.16 @ 540°C<br />

0.19 @ 815°C<br />

0.11%<br />

0.80%<br />

1090°C (2000°F)<br />

1260°C (2300°F)<br />

1.08 @ 1000°F<br />

1.62 @ 1500°F<br />

0.16 @ 540°C<br />

0.24 @ 815°C<br />

0.33%<br />

0.33%<br />

Figure 4 - Typical headbox<br />

pyrotek<br />

supplement<br />

temperature and head<br />

level prior to releas<strong>in</strong>g<br />

metal <strong>in</strong>to the cast<strong>in</strong>g<br />

tip. <strong>Pyrotek</strong> vacuum<br />

formed headboxes are<br />

a one-piece design to<br />

prevent leakage.<br />

The material is the<br />

same as that used for<br />

the vacuum formed<br />

launders. There are two<br />

basic headbox designs,<br />

one for vertical casters<br />

and one for tilt casters.<br />

On both designs,<br />

variations <strong>in</strong> height<br />

and wall thickness<br />

are available to<br />

accommodate customer<br />

requirements. Feed holes<br />

and dra<strong>in</strong> holes can be<br />

precision drilled either<br />

at the <strong>Pyrotek</strong> factory or on-site at the<br />

customer. ZYP Boron Nitride Lubricoat ®<br />

Blue is aga<strong>in</strong> used as a protective<br />

coat<strong>in</strong>g and is applied by <strong>Pyrotek</strong> prior<br />

to shipp<strong>in</strong>g. Headboxes and tundishes<br />

should be recoated as necessary with<br />

the same product after each use.<br />

STEADY EDDY<br />

This level control unit <strong>in</strong> the<br />

headbox ma<strong>in</strong>ta<strong>in</strong>s the proper headlevel<br />

without caus<strong>in</strong>g turbulence <strong>in</strong> the metal.<br />

Any metal turbulence <strong>in</strong> the headbox will<br />

affect the cast sheet surface. <strong>Pyrotek</strong> supplies<br />

the complete unit with the float and plug.<br />

These units should typically last for years<br />

with proper handl<strong>in</strong>g and ma<strong>in</strong>tenance,<br />

but the float and graphite plug are generally


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

replaced after each use. The graphite plug<br />

should be coated with ZYP Boron Nitride<br />

Lubricoat ® Blue to prevent stick<strong>in</strong>g <strong>in</strong> the<br />

feed hole from the launder.<br />

Figure 7 - Steady Eddy<br />

METAL TEMPERATuRE <strong>in</strong>SiDE<br />

THE HEADBox oR TunDiSH<br />

The target start-up metal temperature<br />

<strong>in</strong>side the headbox ranges from<br />

710–730°C, depend<strong>in</strong>g on several<br />

conditions <strong>in</strong>clud<strong>in</strong>g the alloy and cast<br />

width. After the metal has reached the<br />

desired temperature and headlevel, the<br />

metal is released <strong>in</strong>to the tip to rapidly<br />

flood the tip. The temperature <strong>in</strong> the<br />

headbox is then slowly decreased to the<br />

lowest operat<strong>in</strong>g temperature consistent<br />

with good sheet surface f<strong>in</strong>ish and cast<strong>in</strong>g<br />

speed. In order to reach this desired<br />

temperature at start up, there are many<br />

controls that can be implemented <strong>in</strong> the<br />

transfer system. Launder covers, both<br />

heated and unheated, can be used to<br />

prevent excessive heat loss on the surface<br />

of the metal. Heated lids <strong>in</strong> the degass<strong>in</strong>g<br />

chamber and filter box can also help<br />

to reduce heat loss. Proper designs and<br />

correct materials used <strong>in</strong> the transfer<br />

system can further reduce heat loss.<br />

SMT FuRnACE<br />

<strong>Pyrotek</strong> has recently <strong>in</strong>troduced the Stable<br />

Metal Temperature (SMT) furnace. This<br />

molten metal stabilization system accepts<br />

the <strong>in</strong>evitable temperature variations<br />

aris<strong>in</strong>g from long cast<strong>in</strong>g campaigns<br />

from the hold<strong>in</strong>g furnaces. The system<br />

is designed to modify the fluctuat<strong>in</strong>g<br />

<strong>in</strong>com<strong>in</strong>g molten alum<strong>in</strong>ium and deliver<br />

to the head box a flow of precisely<br />

controlled molten alum<strong>in</strong>ium temperature<br />

ranges.<br />

Figure 5 - Typical Tilt Caster Headbox<br />

Figure 6 - Typical Vertical Caster Headbox<br />

Benefits of the SMT Furnace <strong>in</strong>clude:<br />

• Reduction <strong>in</strong> premature cast<strong>in</strong>g<br />

aborts due to tip failure generated by<br />

temperature fluctuations with<strong>in</strong> the<br />

tip<br />

• More consistent cast product<br />

thickness<br />

• Less critical furnace control<br />

• Lower furnace temperatures result<strong>in</strong>g<br />

<strong>in</strong> a reduction of oxide formation,<br />

hydrogen absorption, and energy costs<br />

• Reduced refractory wear<br />

• Furnace temperature fluctuation<br />

security<br />

• Faster cold-roll<strong>in</strong>g due to more<br />

consistent sheet thickness<br />

The SMT Furnace is positioned after the filter<br />

box and before the f<strong>in</strong>al launder lead<strong>in</strong>g<br />

to the headbox/tundish. It is constructed<br />

utilis<strong>in</strong>g state of the art cast<strong>in</strong>g materials and<br />

techniques to produce a monolithic body<br />

pyrotek<br />

supplement<br />

Wayne Bost<br />

Technical Service<br />

Manager, Cont<strong>in</strong>uous<br />

Cast<strong>in</strong>g<br />

Page 5


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

Mark V<strong>in</strong>cent,<br />

European Development<br />

and Project Manager<br />

Page 6<br />

capable of up to 4 years service life. The<br />

system boasts many technical and safety<br />

features and complies to CE regulations.<br />

High performance <strong>in</strong>sulation technology<br />

ensures heat loss is kept to an absolute<br />

m<strong>in</strong>imum and therefore temperature<br />

stability is improved.<br />

A pneumatically operated lid gives<br />

access to the molten metal chamber<br />

while an electrically actuated security<br />

p<strong>in</strong> ensures security of the lid and<br />

operators. Air lock refractory sections<br />

at the <strong>in</strong>let and outlet ensures heat loss<br />

is aga<strong>in</strong> kept to an absolute m<strong>in</strong>imum<br />

through the surface layers.<br />

Two heater protection tubes<br />

manufactured from Sialon are mounted<br />

horizontally and provide efficient<br />

heat dissipation for the heat<strong>in</strong>g<br />

elements with<strong>in</strong>. Because the Sialon<br />

heater protection tubes are mounted<br />

Figure 8 - Schematic of the SMT Furnace PiD & SCR operation<br />

horizontally and not vertically, hot spots<br />

and cold spots are elim<strong>in</strong>ated. The Sialon<br />

tubes are constantly submerged under<br />

the molten alum<strong>in</strong>ium even when the<br />

system is not <strong>in</strong> cast<strong>in</strong>g mode. This gives<br />

a tremendous technical advantage <strong>in</strong> that<br />

oxide generation is omitted and metal<br />

quality is assured. Indeed, the capacity<br />

of the system is generally around 240<br />

kg <strong>in</strong> the static condition, the molten<br />

alum<strong>in</strong>ium be<strong>in</strong>g ma<strong>in</strong>ta<strong>in</strong>ed <strong>in</strong> the<br />

pyrotek<br />

supplement<br />

liquid state dur<strong>in</strong>g breaks <strong>in</strong> cast<strong>in</strong>g. There<br />

is no need to dra<strong>in</strong> the system other than<br />

to carry out specific l<strong>in</strong>e ma<strong>in</strong>tenance.<br />

Energy is provided by two SiC electric<br />

resistant heaters, one be<strong>in</strong>g <strong>in</strong>serted<br />

<strong>in</strong>to each of the Sialon heater protection<br />

tubes. Temperature measurement of<br />

the molten alum<strong>in</strong>ium is provided<br />

through a thermocouple placed <strong>in</strong>side a<br />

Sialon thermocouple protection sheath<br />

strategically placed with<strong>in</strong> the molten<br />

metal chamber. The output from the<br />

thermocouple provides the necessary data<br />

for the manipulation of the energy required<br />

to ma<strong>in</strong>ta<strong>in</strong> a tight molten metal output<br />

temperature range. The energy control is<br />

manipulated by the use of two SCR units<br />

and PID control algorithms.<br />

A pilot unit has been <strong>in</strong> use for over 2<br />

years. The metal temperature deviations <strong>in</strong><br />

various locations along the transfer system<br />

were greatly reduced by<br />

the implementation of the<br />

SMT furnace, provid<strong>in</strong>g a<br />

stable metal temperature <strong>in</strong><br />

the headbox. The pilot SMT<br />

Furnace is perform<strong>in</strong>g as<br />

designed and is successfully<br />

hold<strong>in</strong>g the metal<br />

temperature <strong>in</strong> the headbox<br />

at ± 1°C.<br />

TiPS AnD<br />

CoMPonEnT PARTS<br />

The tip is the most critical<br />

component <strong>in</strong> the cast<strong>in</strong>g<br />

process. NECO, now part<br />

of the <strong>Pyrotek</strong> family, began<br />

produc<strong>in</strong>g ceramic fiber tips<br />

<strong>in</strong> 1982. NECO material is<br />

produced with practically<br />

“shot free” alum<strong>in</strong>o-silicate<br />

fibers bonded with a colloidal silica<br />

b<strong>in</strong>der. The NECO material is soft on the<br />

<strong>in</strong>side for the proper <strong>in</strong>sulat<strong>in</strong>g properties<br />

and hard on the outside for dimensional<br />

stability. The NECO tip material quickly<br />

replaced maranite tips, which were the<br />

<strong>in</strong>dustry norm at the time. The <strong>in</strong>itial NECO<br />

tips were made by jo<strong>in</strong><strong>in</strong>g tip sections<br />

together to obta<strong>in</strong> the proper width. As<br />

the <strong>in</strong>dustry changed to wider widths<br />

and th<strong>in</strong>ner gauges, the NECO material<br />

has been designed to be wider and more


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

dimensionally stable along the orifice<br />

end. The widest tip currently produced<br />

is 2400 mm. There are also three tip radii<br />

currently available for the different roll<br />

diameters (see figure 10).<br />

Each NECO tip is custom designed for<br />

each cast<strong>in</strong>g operation. The tip width is<br />

determ<strong>in</strong>ed by the sheet width, tak<strong>in</strong>g<br />

<strong>in</strong>to consideration the lateral spread of<br />

the metal as it exits the tip and flows<br />

out on the angle of the end dam. The<br />

lateral spread will depend on the caster<br />

set up, headlevel <strong>in</strong> the head box, and<br />

alloy. The tip height is determ<strong>in</strong>ed by the<br />

tip base, the distance from the feed tube<br />

and the <strong>in</strong>itial set back from the roll gap.<br />

Us<strong>in</strong>g the start up sett<strong>in</strong>g of the roll gap,<br />

the overall orifice end thickness of the<br />

assembled tip is calculated to be as close<br />

to the rolls as possible, without touch<strong>in</strong>g<br />

them at all. The roll gap determ<strong>in</strong>es the<br />

sheet gauge, not the orifice open<strong>in</strong>g of<br />

the tip. The thickness of the <strong>in</strong>side parts<br />

<strong>in</strong>side the tip determ<strong>in</strong>es<br />

the orifice open<strong>in</strong>g.<br />

S<strong>in</strong>ce the NECO tip<br />

has a silica b<strong>in</strong>der, it is<br />

important to prevent the<br />

alum<strong>in</strong>ium from attack<strong>in</strong>g<br />

the silica on the surface.<br />

Protection is <strong>in</strong> the form<br />

of a Fiberfrax paper l<strong>in</strong><strong>in</strong>g<br />

or a protective coat<strong>in</strong>g.<br />

<strong>Pyrotek</strong> recommends the<br />

use of a Fiberfrax paper<br />

l<strong>in</strong><strong>in</strong>g for tips that feed<br />

through a feed tube, and<br />

of a ZYP Boron Nitride<br />

Lubricoat ® coat<strong>in</strong>g for tips<br />

that feed metal <strong>in</strong>to the tip<br />

us<strong>in</strong>g a tundish.<br />

TiP BAFFLE DESignS<br />

<strong>Pyrotek</strong> can design a tip custom-made for<br />

the end user. This design depends on many<br />

factors <strong>in</strong>clud<strong>in</strong>g:<br />

•<br />

•<br />

•<br />

•<br />

•<br />

•<br />

•<br />

Type of caster<br />

Roll diameter<br />

Width of cast sheet<br />

Gauge of cast sheet<br />

Tip table dimensions<br />

Feed open<strong>in</strong>g dimensions<br />

Alloy<br />

The vertical caster tips are designed<br />

as a “T-Type” shape with a round<br />

counter-sunk feed tube hole on<br />

one side of the assembled tip for<br />

metal entry. The feed tube hole<br />

matches the dimensions of the<br />

end user’s round feed tube. The<br />

<strong>in</strong>terior baffle design distributes<br />

the molten metal across the width<br />

of the tip for uniform temperature<br />

distribution. The tip sections are<br />

l<strong>in</strong>ed with Fiberfrax paper, not<br />

only to prevent the alum<strong>in</strong>ium<br />

from attack<strong>in</strong>g the silica <strong>in</strong> the<br />

tip material, but also for thermal<br />

properties and sheet surface<br />

quality. The tip section radius is<br />

matched to the roll diameter.<br />

The tilt caster tips are designed<br />

with a baffle that is “dog house”<br />

shaped. The center baffle is placed<br />

38.1-50.8 mm above the metal entry<br />

Figure 10 - Cont<strong>in</strong>uous cast<strong>in</strong>g tip diagram<br />

po<strong>in</strong>t. The distance or spac<strong>in</strong>g between<br />

the center baffle and the next baffle is<br />

critical. Each space between the baffles<br />

thereafter <strong>in</strong>creases <strong>in</strong> width. The spac<strong>in</strong>g<br />

forces the hot alum<strong>in</strong>ium to flow out to<br />

the edges of the tip for more uniform<br />

temperature distribution <strong>in</strong>side the tip.<br />

The width of the baffle is dependent<br />

on the tip width and metal spac<strong>in</strong>g.<br />

<strong>Pyrotek</strong> can also produce completely<br />

assembled tips accord<strong>in</strong>g to the end<br />

user’s confidential design.<br />

Figure 9 - nECo Tip for<br />

cont<strong>in</strong>uous cast<strong>in</strong>g<br />

pyrotek<br />

supplement<br />

NECO TM<br />

Cast<strong>in</strong>g Tips<br />

Page 7


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

The tip is the<br />

most critical<br />

component<br />

<strong>in</strong> the cast<strong>in</strong>g<br />

process.<br />

nECo, the<br />

<strong>in</strong>dustry<br />

standard for<br />

cast<strong>in</strong>g tips,<br />

now part of<br />

the <strong>Pyrotek</strong><br />

family, began<br />

produc<strong>in</strong>g<br />

ceramic fiber<br />

tips <strong>in</strong> 1982.<br />

Page 8<br />

The horizontal tips use various designs<br />

and radii, but should be coated with ZYP<br />

Boron Nitride Lubricoat ® Blue. If the<br />

caster tip is fed by a wide tundish, the<br />

metal distribution takes place outside of<br />

the tip. In this case, the spacers <strong>in</strong>side<br />

the tip are required only to ma<strong>in</strong>ta<strong>in</strong><br />

the precise and uniform orifice open<strong>in</strong>g<br />

across the width of the tip, as well as<br />

prevent leakage on the edges of the tip.<br />

The fewer spacers used <strong>in</strong>side the tip<br />

will result <strong>in</strong> better heat distribution and<br />

metal flow. <strong>Pyrotek</strong> provides the NECO<br />

tip material for the tip sections and the<br />

mach<strong>in</strong>ed calcium silicate boards for the<br />

<strong>in</strong>side parts. The end risers are mach<strong>in</strong>ed<br />

to conform to the <strong>in</strong>side profile of the tip<br />

sections to prevent leakage and to give<br />

the precise orifice open<strong>in</strong>g required by<br />

the end user. The mach<strong>in</strong>ed boards are<br />

also used for the spacers to ma<strong>in</strong>ta<strong>in</strong> the<br />

ZYP Boron Nitride Lubricoat ® is a registered trademark of ZYP Coat<strong>in</strong>gs Inc.<br />

pyrotek<br />

supplement<br />

precise orifice open<strong>in</strong>g of the tip across<br />

the full width of the tip.<br />

At this po<strong>in</strong>t, it is appropriate to mention<br />

that tip assembly is a learned art. Careful<br />

calculations and attention to details are<br />

necessary. If the tip is not assembled<br />

properly, restricted metal flow will<br />

result <strong>in</strong> a forced shut down. This is<br />

wasted time and lost profit for end users.<br />

Cont<strong>in</strong>uous casters are more profitable<br />

when they run cont<strong>in</strong>uously.<br />

Some end users, such as Norandal <strong>in</strong><br />

Salisbury, North Carol<strong>in</strong>a, USA, have<br />

an up-to-date tip shop, a controlled<br />

environment for tip storage, and welltra<strong>in</strong>ed<br />

personnel <strong>in</strong> tip assembly. This<br />

end user purchases tip sections and<br />

components parts from <strong>Pyrotek</strong> and they<br />

assemble their tips <strong>in</strong>-house.


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

Figure 11 - Tip component parts<br />

gRAPHiTE RELEASE AgEnTS<br />

<strong>Pyrotek</strong> offers three different<br />

Nekote products to prevent the<br />

alum<strong>in</strong>ium sheet from stick<strong>in</strong>g<br />

to the roll shell. All three products are<br />

exceptionally well dispersed with ultra<br />

f<strong>in</strong>e graphite particles suspended <strong>in</strong> water.<br />

Figure 13 shows the typical technical data<br />

for the three types of Nekote products.<br />

<strong>Pyrotek</strong> has a recommended dilution<br />

ratio of 1 part Nekote to 220 parts water.<br />

The concentration of graphite depends on<br />

many different factors of caster operation.<br />

If stick<strong>in</strong>g occurs us<strong>in</strong>g the recommended<br />

ratio, the operator should first try open<strong>in</strong>g<br />

the spray nozzles before decreas<strong>in</strong>g the<br />

dilution ratio.<br />

It is important to vigorously shake the<br />

conta<strong>in</strong>er of concentrate prior to mix<strong>in</strong>g<br />

it with water. It is recommended to beg<strong>in</strong><br />

Figure 13 - Typical properties of nekote products<br />

the mixer or agitator <strong>in</strong> the tank of water<br />

and slowly pour<strong>in</strong>g the concentrated<br />

Nekote <strong>in</strong>to the vortex of the mixer to<br />

ga<strong>in</strong> a good dispersion. The mix<strong>in</strong>g tank<br />

and delivery tank should be agitated at<br />

all times dur<strong>in</strong>g use. Due to the<br />

casthouse environment, it is<br />

important to keep the diluted<br />

tanks covered to prevent debris<br />

from enter<strong>in</strong>g the tank, which could clog<br />

the spray nozzles.<br />

N e k o t e - 3 5 T<br />

concentrate may<br />

become thixotropic<br />

over a period of<br />

time. A thixotropic<br />

solution holds the<br />

solid particles <strong>in</strong> a<br />

gel form to prevent<br />

settl<strong>in</strong>g. The operator<br />

should shake the jug<br />

to release the gel<br />

and the product will<br />

return to the orig<strong>in</strong>al<br />

liquid and pourable<br />

form.<br />

Figure 12 - nekote-35<br />

Nekote-35XL is the newest generation of<br />

graphite release agents because the graphite<br />

particles stay <strong>in</strong> suspension much longer<br />

than Nekote-35 and without becom<strong>in</strong>g<br />

thixotropic like Nekote-35T.<br />

TECHniCAL ASSiSTAnCE <strong>in</strong><br />

ConT<strong>in</strong>uouS SHEET CAST<strong>in</strong>g<br />

<strong>Pyrotek</strong> has well tra<strong>in</strong>ed sales eng<strong>in</strong>eers<br />

world-wide <strong>in</strong> cont<strong>in</strong>uous sheet cast<strong>in</strong>g.<br />

nekote-35 nekote-35xL nekote-35T iSo Procedure<br />

Solids, wt% 22.0 ± 0.5 22.0 ± 0.5 24.0 ± 0.5 CW 8224<br />

pH 9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5 CW 8216<br />

Viscosity, cPs1 25 75 200 CW 8220<br />

Particle Size, Median2 ,µm 1.40 ± 0.25 1.40 ± 0.15 1.40 ± 0.15 CW 8226<br />

Particle Size, Max2 , µm 15 10 10 CW 8226<br />

1 Brookfield Model LVT II - Average calculated on batches prepared s<strong>in</strong>ce 2004<br />

Viscosity measured on samples that brought directly from production then stored for one hour at 77ºF<br />

#2 Sp<strong>in</strong>dle at 60 RPM at 77°F<br />

2 Horiba LA 500 Particle Size Analyzer<br />

<strong>Pyrotek</strong> also has designated product<br />

specialists <strong>in</strong> all areas of sheet cast<strong>in</strong>g, as<br />

well as a professional technical services<br />

consult<strong>in</strong>g team. On-site technical assistance<br />

is available for casthouse operations.<br />

pyrotek<br />

supplement<br />

NEKOTE TM<br />

RELEASE AGENTS<br />

PYRoTEK’S<br />

MiSSion<br />

“Provid<strong>in</strong>g<br />

<strong>in</strong>novative<br />

solutions<br />

to customer<br />

needs<br />

utiliz<strong>in</strong>g<br />

our global<br />

resources.”<br />

Page 9


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

<strong>Pyrotek</strong><br />

has well<br />

tra<strong>in</strong>ed sales<br />

eng<strong>in</strong>eers <strong>in</strong><br />

cont<strong>in</strong>uous<br />

sheet<br />

cast<strong>in</strong>g <strong>in</strong><br />

world-wide<br />

locations<br />

as well as<br />

designated<br />

product<br />

specialists.<br />

Burtay Çalli,<br />

European Cont<strong>in</strong>uous<br />

Cast<strong>in</strong>g Consultant<br />

Page 10<br />

ConCLuSion<br />

Cont<strong>in</strong>uous sheet cast<strong>in</strong>g is a grow<strong>in</strong>g<br />

and important segment of the alum<strong>in</strong>ium<br />

<strong>in</strong>dustry. Metal quality is dictated by the<br />

end product. Excellent th<strong>in</strong> gauge foil<br />

quality is achievable by us<strong>in</strong>g the correct<br />

products and equipment and by follow<strong>in</strong>g<br />

predeterm<strong>in</strong>ed production procedures.<br />

<strong>Pyrotek</strong> is aware of the growth <strong>in</strong> cont<strong>in</strong>uous<br />

sheet cast<strong>in</strong>g and is respond<strong>in</strong>g to the<br />

needs of this <strong>in</strong>dustry segment. Innovative<br />

and improved products and materials<br />

have been developed, while other new<br />

potential materials are be<strong>in</strong>g tested by<br />

the <strong>Pyrotek</strong> Research and Development<br />

pyrotek<br />

supplement<br />

group. Unique new equipment has been<br />

designed and developed for the specific<br />

needs for cont<strong>in</strong>uous sheet cast<strong>in</strong>g.<br />

Cont<strong>in</strong>uous sheet cast<strong>in</strong>g<br />

is a grow<strong>in</strong>g and important<br />

segment of the alum<strong>in</strong>ium<br />

<strong>in</strong>dustry.<br />

These new developments evolve not<br />

only from <strong>Pyrotek</strong>’s R&D group, but from<br />

partnerships with customers - provid<strong>in</strong>g<br />

<strong>in</strong>novative solutions and cont<strong>in</strong>uously<br />

improv<strong>in</strong>g materials, products, equipment<br />

and global expertise.


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

PYRoTEK’S MAJoR LoCATionS<br />

ASiA<br />

CHINA, Shenzhen<br />

Phone: (86) 755-26632324<br />

e-mail: shenzhen@pyrotek.<strong>in</strong>fo<br />

INDIA, Pune<br />

Phone: (91) 21-375-6800<br />

e-mail: pune@pyrotek.<strong>in</strong>fo<br />

INDONESIA, Jakarta<br />

Phone: (62) 21-563-8507<br />

e-mail: jakarta@pyrotek.<strong>in</strong>fo<br />

JAPAN, Kobe<br />

Phone: (81) (0)78-265-5590<br />

e-mail: kobe@pyrotek.<strong>in</strong>fo<br />

KOREA, Daegu<br />

Phone: 82 (0)53-523-5202<br />

e-mail: korea@pyrotek.<strong>in</strong>fo<br />

MALAYSIA, Kuala-Lumpur<br />

Phone: (603) 5631-3096<br />

e-mail: kualalumpur@pyrotek.<strong>in</strong>fo<br />

TAIWAN, Kaohsiung City<br />

Phone: (886) 7-224-8222<br />

e-mail: taiwan@pyrotek.<strong>in</strong>fo<br />

THAILAND, Bangkok<br />

Phone: (66) (0) 2 361-4870<br />

e-mail: bangkok@pyrotek.<strong>in</strong>fo<br />

AuSTRALiA<br />

AUSTRALIA (ANZ HEADQUARTERS)<br />

Phone: (61) (0)2 9631-1333<br />

e-mail: sydney@pyrotek.<strong>in</strong>fo<br />

CAnADA<br />

QUEBEC, Drummondville<br />

Phone: (819) 477-0734<br />

e-mail: drummondville@pyrotek.<strong>in</strong>fo<br />

EuRoPE<br />

CZECH REPUBLIC, Blansko<br />

Phone: (420) (0) 516-527-111<br />

e-mail: blansko@pyrotek.<strong>in</strong>fo<br />

GERMANY, Grevenbroich<br />

Phone: (49) (0)2182-8-10-20<br />

e-mail: grevenbroich@pyrotek.<strong>in</strong>fo<br />

SWEDEN, Ed<br />

Phone: (46) (0) 534-62000<br />

e-mail: ed@pyrotek.<strong>in</strong>fo<br />

SWITZERLAND, Sierre<br />

Phone: (41) (0)27-455-82-64<br />

e-mail: sierre@pyrotek.<strong>in</strong>fo<br />

UNITED KINGDOM, Milton<br />

Keynes<br />

Phone: (44) (0)1 908-561155<br />

e-mail: miltonkeynes@pyrotek.<strong>in</strong>fo<br />

MExiCo<br />

MEXICO, Santa Catar<strong>in</strong>a<br />

Phone: (52) 81-8336-9117<br />

e-mail: mexico@pyrotek.<strong>in</strong>fo<br />

MiDDLE EAST<br />

UNITED ARAB EMIRATES, Dubai<br />

Phone: (971) (0)4-883-77-00<br />

e-mail: dubai@pyrotek.<strong>in</strong>fo<br />

nEW ZEALAnD<br />

NEW ZEALAND, Auckland<br />

Phone: (64) (0)9 272-2056<br />

e-mail: auckland@pyrotek.<strong>in</strong>fo<br />

RuSSiA/CiS<br />

RUSSIA/CIS, Moscow<br />

Phone: (7) 095-230-71-63<br />

e-mail: moscow@pyrotek.<strong>in</strong>fo<br />

SouTH AFRiCA<br />

REPUBLIC OF SOUTH AFRICA,<br />

Richards Bay<br />

Phone: (27) (0)35 7974039<br />

e-mail: richardsbay@pyrotek.<strong>in</strong>fo<br />

This supplement can also be viewed at www.pyrotek.<strong>in</strong>fo/cont<strong>in</strong>uous_cast<strong>in</strong>g<br />

Read other supplements <strong>in</strong> this series:<br />

SouTH AMERiCA<br />

BRASIL, São Paulo<br />

Phone: (55) (0)11-4786-5233<br />

e-mail: saopaulo@pyrotek.<strong>in</strong>fo<br />

VENEZUELA, Puerto Ordaz<br />

Phone: (58) 286-994 1894<br />

e-mail: puertoordaz@pyrotek.<strong>in</strong>fo<br />

u.S.A.<br />

CALIFORNIA, Cerritos<br />

Phone: (562) 623-0085<br />

e-mail: cerritos@pyrotek.<strong>in</strong>fo<br />

INDIANA, Columbia City<br />

Phone: (260) 248-4141<br />

e-mail: columbiacity@pyrotek.<strong>in</strong>fo<br />

INDIANA, Evansville<br />

Phone: (812) 867-6343<br />

e-mail: evansville@pyrotek.<strong>in</strong>fo<br />

NEW YORK, Canastota<br />

Phone: (315) 697-8410<br />

e-mail: canastota@pyrotek.<strong>in</strong>fo<br />

NEW YORK, Elmsford<br />

Phone: (914) 345-4740<br />

e-mail: elmsford@pyrotek.<strong>in</strong>fo<br />

NORTH CAROLINA, Salisbury<br />

Phone: (704) 642-1993<br />

e-mail: salisbury@pyrotek.<strong>in</strong>fo<br />

OHIO, Solon<br />

Phone: (440) 349-8800<br />

e-mail: solon@pyrotek.<strong>in</strong>fo<br />

PENNSYLVANIA, Carlisle<br />

Phone: (717) 249-2075<br />

e-mail: carlisle@pyrotek.<strong>in</strong>fo<br />

WASHINGTON, Spokane Valley<br />

Phone: (509) 926-6211<br />

e-mail: spokane@pyrotek.<strong>in</strong>fo<br />

WISCONSIN, Waukesha<br />

Phone: (262) 524-9095<br />

e-mail: waukesha@pyrotek.<strong>in</strong>fo<br />

Explore the many filtration solutions to improve your melt quality at www.pyrotek.<strong>in</strong>fo/filtration<br />

Learn more about improv<strong>in</strong>g performance <strong>in</strong> your furnace operations at www.pyrotek.<strong>in</strong>fo/furnace_operations<br />

Improve your furnace melt treatment process with <strong>in</strong>formation at www.pyrotek.<strong>in</strong>fo/melt_treatment<br />

F<strong>in</strong>d out about solutions for the degass<strong>in</strong>g process at www.pyrotek.<strong>in</strong>fo/degass<strong>in</strong>g<br />

Investigate how to improve your slab cast<strong>in</strong>g processes at www.pyrotek.<strong>in</strong>fo/slab_cast<strong>in</strong>g<br />

pyrotek<br />

supplement<br />

<strong>Pyrotek</strong> is<br />

unique <strong>in</strong><br />

its ability to<br />

provide the<br />

<strong>in</strong>tegration<br />

of <strong>in</strong>novative<br />

technologies,<br />

process<br />

expertise<br />

and a global<br />

perspective.<br />

CORPORATE<br />

OFFICE<br />

9503 East Montgomery Avenue<br />

Spokane Valley, WA 99206<br />

Phone: (509) 926-6212<br />

Fax: (509) 927-2408<br />

e-mail: <strong>in</strong>fo@pyrotek.<strong>in</strong>fo<br />

Visit<br />

<strong>Pyrotek</strong><br />

onl<strong>in</strong>e<br />

at<br />

www.pyrotek.<strong>in</strong>fo<br />

Page 11


<strong>Improv<strong>in</strong>g</strong> <strong>Performance</strong> - Cont<strong>in</strong>uous Cast<strong>in</strong>g<br />

pyrotek<br />

supplement

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