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Optimization of continuous casting process in steel manufacturing industry

Conference Paper · August 2014

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 Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
Optimization of continuous casting process in steel
manufacturing industry
Muhammad Iqbal Hussain
School of Manufacturing Engineering.
Universiti Malaysia,Perlis
Kangar Perlis Malaysia
miqbal@unimap.edu.my
NG. Hooi. Xian
School of Manufacturing Engineering.
Universiti Malaysia,Perlis
Kangar Perlis Malaysia
hooi_xian@yahoo.com
Abstract— The continuous casting process is used for
solidifying molten steel into semi-finished steel. The
technology for Secondary Cooling Zone (SCZ) is extremely
important for output of casting machine and billet quality.
Occurrences of internal defects e.g. edge cracks commonly
known as diagonal cracks in the continuous cast product of
steel Grade H is commonly related to the uniformity of the
water flow rate control in SCZ. Design of Experiment, DOE is
used in analyzing the parameters that influences the quality of
the billet production; Secondary Zone 1st sector water flow
nd
rate, Secondary Zone 2 sector water flow rate and Secondary
rd
Zone 3 sector water flow rate. The optimum results are
attained to achieve the best combination of parameters value
to be used in continuous casting process.
st
Keywords: diagonal cracks, DOE, secondary zone 1 sector water
flow rate, secondary zone 2nd sector water flow rate, secondary zone
3rd sector water flow rate.
1. Introduction
Billet is a semi-finished steel product produced out from
different types of scrap metals for the used in construction site
as well as to fulfil needs in other secondary processes, e.g.
rolling or forging into finished product, e.g. round bar,
deformed bar or wire rod in coil forms. Today in the
modernized world, the demand for billets continues to rise.
305
Zuraidah Mohd Zain
School of Manufacturing Engineering.
Universiti Malaysia,Perlis
Kangar Perlis Malaysia
zuraidah@unimap.edu.my
Hence there is a growing need to understand the causes of
defects occurring in the continuous casting process to improve
casting conditions for production of high quality billets, thus
increasing yield production, reducing wastages and energy
consumption in return for higher profit to the company [1].
The research improvement concentrates on the finding out the
causes of diagonal cracks which commonly occurs during the
casting process in the Continuous Casting Machine (CCM).
The casting process is the most important and critical process
whereby the molten steel will be cast out through a copper
mould while passing through a series of cooling sections to
maintain the shape and size of the billets. The crack of the
continuous casting billet is a fatal defect which may be cause
by various different reasons. In this study, series of
experiments are carried out with the aid of Design Expert,
Design of Experiment (DOE) software to determine the
processing parameters in reducing and avoiding the formation
of such cracks.
1.2. Problem Statement
Diagonal cracks are defects which are regularly occurring
through strands the 6-strand after being cast out from the
casting machines. The occurrence of such defect tends to
lower the yield production thus leading to loss in profit and
material wastage. The presumed parameters influencing such
 Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY

defect maybe due to the secondary 1st, 2nd and 3rd sector water
flow rate. For that reason, investigation is carried out to attain
and achieve the actual and ideal process requirement in the
CCM.

1.3. Research Objective

Among the objectives for this study:-
(1) To study and identify the effects of secondary zone 1st, 2nd
and 3rd sector water flow rate during casting process.
(2) To ascertain and discover the optimum settings for the
Fig.1.1, The continuous casting process.
secondary zone 1st, 2nd and 3rd sector water flow rate
during casting process. 1.5. Diagonal Crack
Diagonal crack is a main concern as it occurs frequently
1.4. The Basic Principles of Continuous during production of Grade H billets. Diagonal cracks arise as
Casting Machine (CCM) a result of bulging of the narrow and broad faces due to lack of
The CCM facility in company M is a 6-strand caster used to support, and also where the strand shell case undergoes
produce “semi-finished” billets. The objective of this section rhombic distortion (rhomboidity). Even in cases where there is
is primarily to cast the molten steel into billet. Figure 1.1 [2] a perfect mould taper and properly aligned foot rolls, uneven
shows an example of the bow type caster found in most steel strand cooling in secondary cooling zone of billet caster can
mills. Once the required metallurgical composition or grade of cause rhomboidity. Although several studies suggested that
steel is achieved at a certain temperature of 1590oC-1600oC, cracks are related to rhomboid condition of the billet [3-7],
the molten steel is then transferred via nozzle into a ladle. this crack can also occur due to absence of rhomboid, due to
When the ladle filled with molten steel is in the casting improper corner radius [3, 8], or mould distortion and wear [4,
position, the slide gate is opened and the molten steel is 5].
transferred to the tundish via a long nozzle. A stopper rod is
located at the bottom of the tundish which controls the flow
rate of the molten steel into the mould. The tundish acts as a
pool containing the liquid steel which feeds liquid steel to the
mould at a regulated rate. The tundish allows continuous
feeding of molten steel to the mould during ladle exchanges.

Fig. 1.2, Sample of cross-sectional area of a billet which

shows diagonal crack.

306
 Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY

Table 1.1, Summary of the analysis for diagonal crack. The experiment conducted using Design-Expert software, is
Defect  Easily detectable rhomboidity by thoroughly analysed to investigate the three factors
identification measuring the diagonal.
Possible Causes  Non-uniform PCZ or at the mould influencing the experiment response. Optimization is carried
exit area or at SCZ. out after analysis to obtain the most optimum parameter using
 Guide rolls not aligned
numerical, graphical or point prediction tools offered by the
Other Associated  Deformed mould tube or with
Causes deposits on the outer surface. Design-Expert software.
 Too high steel tapping temperature.
 Incorrect mould geometry.
Suggested  Check alignment between mould and Based on the optimum settings generated by Design-Expert
Remedies guide rolls. software for minimum goal of diagonal crack at moderate high
 Check position and efficiency of
spraying nozzles. level of importance is water flow rate (1st sector) =
 Replace mould tube 407.39l/min, water flow rate (2nd sector) = 326.12l/min and
Solution by  To conduct preventive maintenance
conditioning water flow rate (3rd sector) = 68.02l/min. The optimum
frequently according to production
schedule. condition represents the combinations/setting of factor levels
Possible Effects  Cracks in the sub skin area up to that is expected to produce the best performance. The 3D
on Rolled product 5mm can create defects on hot rolled
products. surface graph result produced by Design-Expert software is
 Rhomboidity higher than 5% can shown in Figure 1.3.
create problems on hot rolling.

1.6. Statistical Design of Experiment (DOE)

Once DOE method has been chosen as the primary method for
research study, the data collected is analyzed accordingly.
The three factors are set with its high and low values to build
and determine the range of each level.
Table 1.2, Levels for Design Factors.
Design Factors Levels
Low High
st
Secondary 1 Sector Water 400 432
Flow Rate, l/min
Fig. 1.3, 3D Surface Graph based on the model’s desirability
Secondary 2nd Sector Water 326 350 on diagonal crack.
Flow Rate, l/min
Figure 1.3 shows 3D Surface Graph for the factors A and B in
Secondary 3rd Sector Water 68 80
the model. It estimates the performance at optimum condition.
Flow Rate, l/min
Notice how it flattens as the desirability is achieved. This is a
region of stability for minimum diagonal crack response.
In this research study, a Full Two-Level Factorial Design, 2k is
chosen toward the consideration of the criterion of the
research study. A full factorial design considers all plausible
combinations of the design factors and levels.

1.7. Result

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 Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY

[5] H. Mori, “Causes and Prevention of Defects in

Continuous Casting. Pt.1” Tetsu-to-Hagane (J. Iron
Steel Inst. Jpn.) Vol.58 (10), 1972, 1511-1525.
[6] W.P. Young and W.T. Whitfield, “Casting of Quality
Steel at Wisconsin Steel”, 51ST National Open Hearth
and Basic Oxygen Steel Conference, AIME, New
York, Vol. 51, 1968, 127-132.
[7] K. Matsunaga, Y. Ohkita, S. Hirayama, S. Kimiya,
S. Kojima, ”Progress in the Continuous-Strand
Casting of Billets at Kokura Steel Works of Sumitomo
Metals (Retroactive Coverage)”, 59th National Open
Hearth and Basic Oxygen Steel Conference, (St.
Louis Mo.), Metallurgical Society AIME, New York,
N.Y., 1976, 228-249.
[8] Y. Aketa and K. Ushijima, Tetsu-to-Hagane (J. Iron
Fig. 1.4, Overlay plot produced by Graphical Optimization. Steel Inst. Jpn.) Vol. 45 1959, 1314-1345.

Graphical Optimization presents the area of feasible response

values in the factor space. Through the graph, a visual search
is carry out in search for the best compromise. Yellow region
is the area that satisfies the constraint evaluated; on the other
hand, gray region is the area which does not meet the required
criteria. The flag ‘pointed’ in Figure 1.4 depicts the area of
feasible response for the model in accordance to the optimum
settings evaluated in Figure 1.3.

1.8. Conclusion
With the aid of Design Expert Software, optimization is
carried to discover a range of optimum setting for secondary
zone 1st, 2nd and 3rd sector water flow rate. By using the range
of optimum settings generated by Design Expert Software, it
is known that there’s a slight decrease in the numbers of billets
rejected from 359 to 321 billets (reduction of 8.5%) and from
321 to 311 billets (reduction of 3.1%).
1.9. References
[1] Hans F. Schrewe, Continuous Casting of Steel-
Fundamentals Principles and Practice, 1987,
Stahleisen.
[2] F.R. Camisani-Calzohari, I.K. Craig, P.C. Pistorius,
“Control strategies for the secondary cooling zone in
continuous casting”, IEEE, 1999.
[3] I.V Samarasekera and J.K. Brimcombe, “The
influence of Mold Behaviour on the production of
Continuously Cast Steel Billets,” Metallurgical
Transaction B, Vol. 13B (1), 1982, 105-116.
[4] V.P. Perminov, N.M. Lapotyshkin, V.E. Girskii, A.I.
Chizhikov, “Prevention of Distortion in A
Continuously-Cast Square Alloy Steel Billet”, Stal. In
English, Vol.7, 1968, 560-563.

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