Abstract
Mold fluxes play pivotal roles during the continuous casting process, and it is important to choose a correct flux for the steel grade being cast. In the present work, interactions between various steel grades and CaO-SiO2-based flux is captured through plant measurements. Mold slag pool depth and composition were measured at different durations during the casting process. Further, a kinetic model has been developed to validate the change in mold flux composition with time. The model is based on the effective equilibrium reaction zone concept, and is dynamically linked to the ChemApp thermodynamic library, which provides access to thermodynamic databases of the FactSage software. Casting parameters such as casting speed variation (1–1.35 m/s), slag pool depth (10–30 mm), and temperature (1500°C, 1400°C, and 1300°C) across each flux layer have been used as inputs to the model. Three plant cases were validated using the model, namely low-C steel (C ~ 0.05%, Mn ~ 0.5%, Al ~ 0.05%), medium-C steel (C ~ 0.15%, Mn ~ 1.1%, Al ~ 0.05%), and high-Si steel (C ~ 0.005%, Mn ~ 0.2%, Al ~ 1%, Si ~ 3.2%). The model predicted the change in slag composition in real time, which showed a significant SiO2 reduction from the mold slag and at the same time an Al2O3 pick-up into it.
Similar content being viewed by others
References
B. Sauerhammer, Metall. Mater. Trans. B 36, 503 https://doi.org/10.1007/s11663-005-0042-z (2005).
N. Sridhar and D. Dunn, Corrosion 50, 66 (1994).
K.C. Mills and A.B. Fox, ISIJ Int. 43, 1479 https://doi.org/10.2355/isijinternational.43.1479 (2003).
M. Wang, Y.-P. Bao, H. Cui, H.-J. Wu, and W.-S. Wu, ISIJ Int. 50, 1606 https://doi.org/10.2355/isijinternational.50.1606 (2010).
J. Yang, H. Cui, J. Zhang, O. Ostrovski, C. Zhang, and D. Cai, Metall. Mater. Trans. B 50, 2636 https://doi.org/10.1007/s11663-019-01667-0 (2019).
J. Yang, J. Zhang, O. Ostrovski, Y. Sasaki, C. Zhang, and D. Cai, Metall. Mater. Trans. B 50, 2175 https://doi.org/10.1007/s11663-019-01643-8 (2019).
J. Zhang, B. Zhao, and B. Yan, Metall. Mater. Trans. B 54, 981 https://doi.org/10.1007/s11663-023-02749-w (2023).
M.-S. Kim, M.-S. Park, and Y.-B. Kang, Metall. Mater. Trans. B 50, 2077 https://doi.org/10.1007/s11663-019-01658-1 (2019).
G.H. Kim and I. Sohn, Metall. Mater. Trans. B 47, 1773 https://doi.org/10.1007/s11663-016-0650-9 (2016).
J. Yang, L. Wang, Y. Li, T. Wang, L. Kong, and X. Zang, Metall. Mater. Trans. B 53, 1516 https://doi.org/10.1007/s11663-022-02461-1 (2022).
G.-L. Ou, Y.-C. Liu, S.-Y. Yen, H.-Y. Wang, Y.-H. Su, M.-J. Lu, and S.-K. Lin, J. Mater. Res. Technol. 9, 12091 https://doi.org/10.1016/j.jmrt.2020.08.111 (2020).
P. Ni, T. Tanaka, M. Suzuki, M. Nakamoto, M. Ersson, and P.G. Jönsson, ISIJ Int. 59, 2024 https://doi.org/10.2355/isijinternational.ISIJINT-2019-007 (2019).
M.-S. Kim and Y.-B. Kang, Calphad 61, 105 https://doi.org/10.1016/j.calphad.2018.02.010 (2018).
J. Park, S. Sridhar, and R.J. Fruehan, Metall. Mater. Trans. B 45, 1380 https://doi.org/10.1007/s11663-014-0076-1 (2014).
Q. Wang, S. Qiu, and P. Zhao, Metall. Mater. Trans. B 43, 424 https://doi.org/10.1007/s11663-011-9600-8 (2012).
W. Ju-jin, Z. Li-feng, C. Wei, W. Sheng-dong, Z. Yue-xin, and R. Ying, J. Eng. Sci. 43, 786 (2021).
M.-A. Van Ende and I.-H. Jung, ISIJ Int. 54, 489 https://doi.org/10.2355/isijinternational.54.489 (2014).
N. Pradhan, M. Ghosh, D.S. Bhor, and S. Mazumdar, ISIJ Int. 39, 804 https://doi.org/10.2355/isijinternational.39.804 (1999).
J.L. Klug, M.M. d. S.M. Pereira, E.L. Nohara, S.L. d. Freitas, G.T. Ferreira, and D. Jung, Ironmak. Steelmak. 43, 559 (2016). https://doi.org/10.1080/03019233.2016.1213026
L. Kaufman and H. Bernstein, Computer Calculation of Phase Diagrams with Special Reference to Refractory Metals (Academic Press, New York, 1970), pp74–91.
C.W. Bale, E. Bélisle, P. Chartrand, S. Decterov, G. Eriksson, A.E. Gheribi, K. Hack, I.-H. Jung, Y.-B. Kang, and J. Melançon, Calphad 55, 1 https://doi.org/10.1016/j.calphad.2016.07.004 (2016).
A.D. Pelton and P. Chartrand, Metall. Mater. Trans. A 32, 1355 https://doi.org/10.1007/s11661-001-0226-3 (2001).
T. Schulz, B. Lychatz, N. Haustein, and D. Janke, Metall. Mater. Trans. B 44, 317 https://doi.org/10.1007/s11663-013-9796-x (2013).
I.-H. Jung and M.-A. Van Ende, Metall. Mater. Trans. B 51, 1851 https://doi.org/10.1007/s11663-020-01908-7 (2020).
M.-A. Van Ende and I.-H. Jung, Metall. Mater. Trans. B 48, 28 https://doi.org/10.1007/s11663-016-0698-6 (2017).
M.-A. Van Ende and I.-H. Jung, Comput. Mater. Syst. Des. 47, 66 (2018).
M.-A. Van Ende, Y.-M. Kim, M.-K. Cho, J. Choi, and I.-H. Jung, Metall. Mater. Trans. B 42, 477 https://doi.org/10.1007/s11663-011-9495-4 (2011).
S. Petersen and K. Hack, Int. J. Mater. Res. 10, 98 https://doi.org/10.3139/146.101551 (2007).
M. Dapiaggi, G. Artioli, C. Righi, R. Carli, and J. Non-Cryst, Solids 353, 2852 https://doi.org/10.1016/j.jnoncrysol.2007.05.019 (2007).
R. Carli, C. Righi, and M. Dapiaggi, in Proceedings of the 8th Conference on Molten Slags, Fluxes and Salts. Editor M. Sanches (Santiago, Chile: GECAMIN), 1121 (2009).
T. Watanabe, H. Fukuyama, and K. Nagata, ISIJ Int. 42, 489 https://doi.org/10.2355/isijinternational.42.489 (2002).
M.-D. Seo, C.-B. Shi, H. Wang, J.-W. Cho, S.-H. Kim, and J. Non-Cryst, Solids 412, 58 https://doi.org/10.1016/j.jnoncrysol.2015.01.008 (2015).
H.G. Ryu, Z.T. Zhang, J.W. Cho, G.H. Wen, and S. Sridhar, ISIJ Int. 50, 1142 https://doi.org/10.2355/isijinternational.50.1142 (2010).
Z. Zhang, G. Wen, J. Liao, and S. Sridhar, Steel Res. Int. 81, 3264 https://doi.org/10.1002/srin.201000058 (2010).
Acknowledgements
The authors would like to thank the Management of Tata Steel, India, for all the financial assistance given to carry out the research and giving permission to publish the work.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Supplementary Information
Below is the link to the electronic supplementary material.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Sahoo, P.P., Ranjan, M., Srivastava, K. et al. Capturing the Interaction Between Mold Flux and Different Steel Compositions During Industrial-Scale Continuous Casting Trials. JOM (2024). https://doi.org/10.1007/s11837-024-06570-x
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s11837-024-06570-x