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STEEL
What is Steel ?
What are the applications of steel?
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Type of Steel - By Composition Type of steel By Shape

What are the process route for producing steel?

CONTINUOUS CASTING

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STEEL - Applications

CONTINUOUS CASTING

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STEEL - Applications

CONTINUOUS CASTING

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STEEL - Process Route : Flat Products

CONTINUOUS CASTING

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STEEL - Process Route : Flat Products

CSP plant

Hot rolling mill Cold rolling mill Pickling

Reversing cold rolling mill Annealing and surface Shears and galvanizing and improving finishing equipment

CONTINUOUS CASTING

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STEEL - Process Route : Long Products

CONTINUOUS CASTING

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STEEL - Process Route : Long Products

CONTINUOUS CASTING

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STEEL - Process Route : Past & Present

SOAKING PIT SLABBING / BLOOMING MILL

ReHeating Furnace
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CONTINUOUS CASTING

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STEEL - Process Route : Past & Present

Advantages of Continuous Casting :
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Energy Efficient Process Yield is much higher Mass production of Semi-Finished product Lower Operating Cost Consistent Quality

Dis-Advantage
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High Capital Cost

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CONTINUOUS CASTING

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Basics of Continuous Casting

What is Continuous Casting
Transforms Liquid metal into Solid on Continuous basis. Water Cooled open ended copper mould Mould oscillates along axis of strand Dummy bar closes the mould from one end while start casting and continuously withdrawn through segments. Along with D/bar, Partially Solidified Strand continuously withdrawn. Core with liquid gradually solidifies as strand moves

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CONTINUOUS CASTING

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Basics of Continuous Casting

PRODUCT RANGE
Slabs
Slab Casting thickness 150 - 400 mm width 400 - 3,200 mm

Blooms and beam blanks

Rectangular min. 200 x 240 mm max. 400 x 600 mm Square min. 220 x 220 mm max. 345 x 345 mm Round dia. min. 100 mm dia. max. 600 mm Beam Blank max. 1,119 x 500 x 132 mm min. 243 x 170 x 73 mm

Twin Casting thickness 100 - 350 mm width 300 - 1,575 mm

Medium Slab Casting thickness 90 - 150 mm width 300 - 3,050 mm

Thin Slab Casting thickness 40 70(90) mm width 790 - 1,680 mm

Billets
Square 76 - 215 mm

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CONTINUOUS CASTING

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Basics of Continuous Casting

Types of Continuous Casting Machines

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CONTINUOUS CASTING

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Basics of Continuous Casting

Type of Caster Advantages Dis-advantages

Vertical Casters

No deformation through bending and unbending Good floatation of inclusions and oxides

Large overall heights High Ferro static pressure Casting speed limited by lack of available length.
Early and considerable deformation of the shell Higher ferro static pressure than curved mould Large degree of straightening deformation.

Curved type Caster with Minimal hindrance of straight oxide float-out mould provided the vertical section is sufficiently long.

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Basics of Continuous Casting

Type of Caster Advantages Dis-advantages

Curved type Strand straightened Oxide or inclusion Caster with only when shell is Floatation Is poor and curved already relatively thick. defect related to sliver mould in the product is high. Low overall height, low ferro-static pressure, simple withdrawal and straightening

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Basics of Continuous Casting

Design aspects of Continuous Casting Type of Product Tonnage Machine Length and Casting Speed Vertical Height of Mould Radius of Machine Roller Pitch Metallurgical Length
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Square Root Law

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Continuous Casting Metallurgy

Solidification Process

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CONTINUOUS CASTING

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Continuous Casting Metallurgy

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CONTINUOUS CASTING

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Continuous Casting Metallurgy

Hot Ductility

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CONTINUOUS CASTING

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Continuous Casting Metallurgy

Hot Ductility

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CONTINUOUS CASTING

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Continuous Casting Metallurgy

Hot Ductility

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Continuous Casting Metallurgy

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CONTINUOUS CASTING

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Continuous Casting Metallurgy

Cleanness in Continuous Casting Non-Metallic Inclusions Entrapment or Dissolve of Non desirable gases

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CONTINUOUS CASTING

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Continuous Casting Metallurgy

Secondary Metallurgy :

Inclusion formation begins during precipitation de-oxidation with the formation of endogeneous oxides. Control on Carry over Slag from EAF Removal of dissolve gases
Oxygen Using De-oxidiser Hydrogen VD Nitrogen VD

Removal of Oxides by floatation

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Continuous Casting Metallurgy

Caster :

Re-Oxidation and Gases pick-up During Teeming from Ladle to Tundish During Pouring from Tundish to Mould

Non-Metallic Inclusion Clogging

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CONTINUOUS CASTING