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Analysis and Application of Soft Reduction Amount for Bloom Continuous

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DOI: 10.2355/isijinternational.54.504

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 ISIJ International, Vol. 54 (2014), No. 3, pp. 504–510

Analysis and Application of Soft Reduction Amount for Bloom

Continuous Casting Process

Cheng JI,* Sen LUO and Miaoyong ZHU

School of Materials and Metallurgy, Northeastern University, 3-11, Wenhua Road, Shenyang, Liaoning, 110819 China.
(Received on November 24, 2013; accepted on January 7, 2014)

Based on the principle of solidification shrinkage compensation, a soft reduction amount calculation
method was derived for bloom continuous casting process, and the bearing steel GCr15 was chosen as
specific research steel to describe calculation process in detail. A two-dimensional heat transfer model
was built to predict the solidification process of bloom, and the material properties of GCr15 were derived
by weighted averaging of the phase fractions. The predicted temperature and shell thickness were verified
by a thermal infrared camera and nail shooting results, respectively. The soft reduction amount of typical
high carbon alloy steel blooms were calculated and discussed. The plant results showed that after the
application of soft reduction to the bloom, centerline segregation and “V” type segregation were improved
significantly. The carbon and sulfur ratios of the bloom centerline were reduced from 1.39 to 1.09 and
2.14 to 1.29, respectively.

KEY WORDS: bloom continuous casting; soft reduction; reduction amount; solidification shrinkage; high
carbon alloy steel; macro-segregation.

factors and variable industrial process, it is still difficult to

1. Introduction
Soft Reduction (SR) technology has proved to be an
effective method to reduce slab and bloom centerline segre-
gation and porosity in many industrial practices.1–10) The
principle of SR is to impose a reasonable reduction rate/
amount on the solidification end of the strand for compen-
sating liquid core shrinkage and preventing the solute-
enriched liquid flowing toward the center of the strand without
creating internal cracks.1,2,4) In bloom SR process, the reduc-
tion is usually executed by 6–10 withdrawal units which are
arranged in the air cooling zone with intervals of 1.0–3.5 m.
Therefore the reduction interface is discontinuous, and the
SR amount is generally selected as the primary control
parameter during the bloom SR process.
Since Miyazawa and Schwerdtfeger simulated the macro-
segregation caused by bulging on slab continuous casting
process in 1981,11) some researchers studied the flow fluid
and macro-segregation induced by deformation of the solid
skeleton in mushy zone.12–16) Recently, Menghuai Wu and et
al.15,16) developed a two-phase columnar solidification mod-
el to describe the effect of shell deformation, melt flow, den-
drite growth on the macro-segregation behavior, and
revealed more detailed mechanism and principles of SR.
However, due to the complicated coupled macro and micro
This article is one which was originally scheduled for publication in the
special issue (Vol. 54, No. 2) on “Cutting Edge of Computer Simulation of
Solidification, Casting and Refining” and instead was specially published in
this regular issue.
* Corresponding author: E-mail: jic@smm.neu.edu.cn
DOI: http://dx.doi.org/10.2355/isijinternational.54.504
precisely quantify the SR amount, and more studies were
carried out with industrial trial method. At the same time,
because of the different trial conditions, the empirical SR
amount was significantly different, for example the 7.5±1.5
mm for bloom thickness of 350 mm,2) 1.54–6.41 mm for
bloom thickness of 380 mm,6) and 20–30 mm for bloom
thickness of 400 mm.9) Therefore, it is difficult to form com-
mon criteria from these industrial trail results only.
In this paper, based on the solidification shrinkage com-
pensation principle, a calculation method for SR amount is
derived, and bearing steel GCr15 was chosen as specific
research steel to illustrate calculation process in detail. A
heat transfer model was developed to predict the bloom tem-
perature distribution based on the specific parameters of
bloom continuous casting machine. In order to improve the
accuracy of the calculation results, the material properties of
GCr15 were derived by weighted averaging of the phase
fractions, and the predicted temperature and shell thickness
were verified by thermal infrared camera and nail shooting
results, respectively. According to the temperature distribu-
tion and shell deformation of GCr15 bloom, the SR amounts
under different casting speeds were calculated. The SR
amount of two other typical high carbon alloy steel, 82B and
72A, were presented and applied to industrial practice as
well. Finally, the plant results without and with SR were
compared and discussed.
2. SR Amount Calculation Model
Figure 1 shows the schematic of the bloom SR process,

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 ISIJ International, Vol. 54 (2014), No. 3

Fig. 1. The schematic of the bloom SR process.

Fig. 3. Schematic of the shell deformation during SR process.

strand points, m2.

In order to reduce centerline segregation and porosity of
strand, the liquid core should be compensated with ΔAi as
shown in Fig. 3. Combining the Eqs. (2)–(4), ΔAi could be
Fig. 2. The temperature distributions on the bloom transverse sec- derived by the following equation:
tion.
dMi dMi −1
−
and the temperature distribution of transverse section on SR ΔAi = dz dz
ρl
start point, SR point under Unit 3 and SR end point corre-
∫ ∫ ρ ( x, y, zi ) dxdy − ∫0 ∫0 ρ ( x, y, zi −1 ) dxdy ...... (5)
Yi Xi Yi −1 Xi −1
spond to the Figs. 2(a) to 2(c), respectively. It is obvious that
the liquid core shrinks continuously due to the temperature = 0 0
ρl
decrease along the casting direction.
The mass flow rate of strand transverse section along the The deformation behavior as shown in Fig. 3 is another
casting direction at strand point zi could be calculated as: important factor which influences the SR effect, because
most of SR amount is consumed on the bloom deformation
dMi
= ∫ ∫ ρ ( x, y, zi ) dxdy .................. (1)
Yi Xi
process.15,18,19) The SR efficiency η i is defined to characterize
dz 0 0
the relationship between SR amount on the strand surface and
Where x, y and z are width, thickness, and length of the the required SR amount of the shrinkage volume.18,20)
bloom, respectively, and ρ (x, y, z) is steel density function According to the authors’ previous work,19,21) the SR effi-
which is related to temperature. ciency η i could be expressed as:
In ideal conditions, the liquid core shrinkage, as shown in
ΔAi
Fig. 2, would be supplied by free flowing liquid steel, and ηi = .................................. (6)
dM/dz is constant for the whole strand due to the mass con- ΔSi
servation along the casting direction. However, according to Where, the ΔSi is the surface shrinkage area on i th strand
the research by Takahashi et al.,17) the dendrites begin to point shown in Fig. 3, m2, and it could be calculated as:
form network and block liquid flow when the solid fraction,
ΔSi = Ri ⋅ Xi ............................... (7)
fs, becomes equal to 0.31, and the liquid steel could not be
supplied deep into the mushy zone completely. In the non- Where, Ri is the surface SR amount in i th SR point shown
free flowing zone, the mass difference between the i th and in Fig. 3, m; Xi is the bloom width in i th strand point shown
i-1th SR points can be calculated as follow: in Fig. 3, m.
Combining the Eqs. (5)–(7), the Ri could be expressed as:
⎛ dMi dMi −1 ⎞
ΔMi = ⎜ − ⎟ ⋅ ΔLi ................... (2) ΔAi
⎝ dz dz ⎠ Ri =
Where, ΔLi is the length between the i th and i-1th strand ηi ⋅ X i
points, m. The volume of required liquid steel, which is
assumed to be supplied for the mass difference between the =
(∫ 0
Yi
∫0 ρ ( x, y, zi ) dxdy − ∫0 ∫0
Xi Yi −1 Xi −1
ρ ( x, y, zi −1 ) dxdy ) .... (8)
i th and i-1th strand points, could be calculated as: ρ l ⋅η i ⋅ X i
ΔMi
ΔVi = ................................ (3)
ρl 3. Heat Transfer Model Description
Where, ρ l is steel density at liquidus temperature, kg/m3. In the present work, a 4-strand arc bloom continuous cast-
On the other hand, because the ΔVi is caused by solidifica- ing machine is chosen as specific research objective, and its
tion shrinkage between the i th and i-1th strand points, it also schematic is shown in Fig. 4. The SR is executed by with-
could be calculated as: drawal units, which are located between 16.187 m and
24.649 m of the distance from the meniscus as shown in Fig.
ΔVi = ΔAi ⋅ ΔLi ............................. (4)
4, and the bloom section was 325 mm × 280 mm at room
Where, ΔAi is the shrinkage area between the i th and i-1th temperature. In order to obtain the shrinkage compensation

505 © 2014 ISIJ

 ISIJ International, Vol. 54 (2014), No. 3
of liquid core, ΔAi, a heat transfer model of quarter bloom
transverse section was developed to predict the temperature
distribution of whole strand under steady casting conditions.
Based on some simplified assumptions,22) a two-dimensional
transient heat conduction equation was employed to
describe the heat transfer behavior as follow:
∂T ∂ ⎛ ∂T ⎞ ∂ ⎛ ∂T ⎞
ρ (T ) c (T ) = ⎜ λ (T ) ⎟ + ∂y ⎜ λ ( T ) ∂y ⎟ ........... (9)
∂t ∂x ⎝ ∂x ⎠ ⎝ ⎠ ute redistribution on the basis of the assumption of Ueshima
Where, T and t are temperature, °C and calculation time,
s, respectively. ρ (T ), c(T ), and λ (T) are the density, kg/m3,
specific heat, J/(kg·°C), and heat conductivity, W/(m·°C),
respectively.
In the present work, a kind of bearing steel, GCr15, was
chosen as specific research steel grade, and its main compo-
Fig. 4. The schematic of the bloom continuous casting machine.
Fig. 5. Phase fraction, solute segregation and material properties of GCr15: (a) phase fraction and solute segregation, (b)
density, (c) enthalpy, and (d) conductivity.
© 2014 ISIJ
sition was 1.00 Wt Pct C, 0.25 Wt Pct Si, 0.30 Wt Pct Mn,
0.01 Wt Pct P, 0.01 Wt Pct S, and 1.45 Wt Pct Cr.
3.1. Material Properties
In order to obtain more accurate material properties of
GCr15 between the solidus and liquidus temperatures range,
a one-dimensional direct finite-difference model was devel-
oped to calculate the evolution of phase fraction and the sol-
et al.23) Furthermore, the MnS inclusion precipitation during
the solidification process was considered for the accuracy of
the calculation results, and the rates of diffusion into solid
and liquid phases were determined by diffusion coefficients
and equilibrium distribution coefficients of the ele-
ments.23,24) The specific parameters and calculation process
are described in detail by the present authors’ previous
work.25)
Figure 5(a) shows the evolution of phase fraction, inter-
dendritic solute segregation ratio during the solidification
process of GCr15 with cooling rate of 0.25°C/s. It can be
seen that the γ phase generated directly from liquid steel
without forming δ phase in the solidification process. The
element segregation ratio increases gradually at the initial
stage of solidification and then increase rapidly at the end
of solidification.
Figures 5(b), 5(c), and 5(d) show the density, enthalpy,
and conductivity of GCr15, respectively, which were calcu-
lated by weighted phase fraction equations which are
described in detail by Li and Thomas.26)
3.2. Boundary Conditions
The finite element method was adopted to calculate Eq.
(1), and the initial temperature of all nodes was set as the
506
 ISIJ International, Vol. 54 (2014), No. 3
casting temperature, 1 479°C, which is the most common
temperature in the industrial practice. The heat flux at the
symmetrical sides of the model is assumed to be zero.
3.2.1. In the Mold
A simplified boundary condition equation of the form
proposed by Savage and Pritchard was used to calculate the
heat flux of the surface center along the casting direction.27)
qcenter = A − B t .......................... (10)
where, qcenter is the heat flux on the bloom surface center,
MW/m2; t is time in the mold, s; A and B are coefficients
which depend on the mold cooling conditions. In the present
work, A varied between 1.25–1.45 × 106, and B varied
between 5.5–6.5 × 104.
The heat flux decreases along bloom transverse surface
from surface center to corner due to the shell shrinkage, and
therefore the heat flux of bloom surface, qmold, should be cal-
culated as:
qmold = qcenter ⋅ (1 − exp( a1 x − a2 )) .............. (11)
Where, a1 and a2 are parameters according to different
height in mold, for example a1=68.5 and a2=11.7 on the
bloom wide surface at the mold exit; x is the position from
surface center to corner, m.
3.2.2. In the Secondary Cooling Zones
The equivalent convection coefficients are usually
applied to calculate heat transfer in secondary cooling
zones. According to the experimental results of Nozaki et
al.,22) the equivalent convection coefficient of cooling water
and radiation, hiec, is expressed by:
heci = α i ⋅ Wi ( x )0.55 ⋅ (1 − 0.0075Tw )
hci ⋅ N Ri ⋅ RLi
+σ ⋅ ε ⋅ (Tsurf + Tamb ) ⋅ (Tsurf 2 + Tamb 2 ) + i ...... (12)
Z L
The right of the Eq. (12) is composed of three parts for
calculating heat extraction of spray water, radiation, and
roller contact.
In the first part, αi is a modified parameter of i th cooling
zone; Tw is cooling water temperature, °C; Wi(x) is the water
flux distribution in i th cooling zone, l/(m2·min), where x is the
distance from bloom surface center to corner, and Wi(x) was
measured by the nozzle characteristics of the testing stand.28)
In the second part, σ is Stefan-Boltzmann constant,
5.67 × 10–8 W/(m2·K4); ε is steel emissivity; Tsurf and Tamb are
the surface temperature of the strand and the ambient tem-
perature, respectively, K.
In the third part, hci is the heat transfer coefficient
between rollers and bloom in i th cooling zone, W/(m2·K); NRi
is the roller number of i th cooling zone; R iL is the contact
length between rollers and bloom in i th cooling zone, m; Z iL
is the total length of the i th cooling zone, m. According to
the previous research,29,30) hci is set as 0.3–3.6 kW(m2· K),
and R iL is equal to 0.02 m.
3.2.3. In the Air Cooling Zones
In the air cooling zones, the equivalent heat transfer coef-
ficient h iair is composed by radiation and rollers contact, and
it is calculated as follows:
507
Fig. 6. Comparison between the predicted and measured surface
temperature and shell thickness.
hci ⋅ N Ri ⋅ RLi
heci = σ ⋅ ε ⋅ (Tsurf + Tamb ) ⋅ (Tsurf 2 + Tamb 2 ) + ... (13)
Z Li
3.3. Model Validation
The model was verified by plant measured surface tem-
perature and shell thickness. The surface temperature was
measured by a thermal infrared camera (A40, FLIR), and
the shell thickness was measured by nail shooting method.
Figure 6 shows the comparison between the predicted and
the measured results when the casting speed is 0.8 m/min.
The relative error between the predicted and the measured
temperature is less than ±0.84%, while the relative error
between the predicated shell thickness and nail shooting
results is less than 1.86%.
4. SR Amount Calculation and Application Results
4.1. SR Amount Calculation
The SR should act on the area where the liquid steel could
not flow freely. So based on the research of Takahashi17) the
SR start point was chosen as fs=0.31 at strand centerline. On
the other hand, the SR should be applied at the proper posi-
tion to squeeze solute-enriched liquid out of the strand cen-
ter, and so the SR end point was chosen as fs=0.92 at strand
centerline based on the present authors’ previous work.25)
Figure 7 compares the isolines of solid fraction 0.00,
0.31, 0.92 and 1.00 in the bloom thickness direction with
different casting speed. It can be seen that the mushy zone
and SR zone are both prolonged and move towards the end
of the strand with increase of the casting speed, because the
time for heat release decreases while the heat release speed
in the air cooling zone remains almost unchanged. When the
casting speed increases every 0.05 m/min, the SR zone is
prolonged by about 0.35 m, while the SR start point moves
towards cast end with about 1.18 m.
The shrinkage area, ΔAi, between the SR point (fs=0.31–
0.92) and SR start point (fs=0.31) could be calculated by Eq.
(5) and the predicted temperature distribution. The calculat-
ed results with different casting speeds are shown in Fig. 8.
It can be seen that ΔAi increased almost linearly in the cast-
ing direction with increasing distance from the SR start
point. When the casting speed increases, the maximum of
ΔAi (at the position of fs=0.92) also increases.
According to the present authors’ previous work,19) a
© 2014 ISIJ
 ISIJ International, Vol. 54 (2014), No. 3

Fig. 9. The SR efficiency with different SR amounts and non-

solidification ratios.

Fig. 7. The isolines of different solid fractions on bloom thickness

direction with different casting speed.

Fig. 10. The non-solidification ratio of bloom transverse section

with different casting speed.

Table 1. The calculation results of SR amount with typical casting

speeds.

Steel Casting speed SR amount of withdrawal units (mm)

grade (m/min) Unit 1 Unit 2 Unit 3 Unit4 Unit 5 Unit 6 Total
0.70 1.06 3.40 5.22 9.68
0.75 1.42 3.08 4.08 8.58
GCr15
0.80 2.12 2.69 3.41 8.22
Fig. 8. The shrinkage area between SR point and SR start point
with different casting speed. 0.85 1.79 2.43 3.08 7.30
0.75 2.64 4.36 7.00

three-dimensional thermal mechanical coupled model was 0.80 3.13 3.71 6.84
82B
built to describe the deformation behavior of continuous 0.85 0.53 2.68 3.32 6.53
casting bloom during SR process, and the relationship 0.90 0.69 2.46 3.03 6.18
between the SR efficiency and non-solidification ratio is
0.75 1.91 4.94 6.85
shown in Fig. 9. It can be seen that the SR efficiency
increases with the increase of non-solidification ratio when 0.80 2.32 4.24 6.56
72A
the SR amount is same. When the non-solidification is 0.85 2.62 3.80 6.42
same, the SR efficiency increases rapidly with the increase 0.90 2.78 3.50 6.28
of SR amount at the beginning, then decrease slowly, and
finally tended to relative stability.
Based on the predicted results of temperature distribution, Table 1 shows that the total SR amount of 280 mm × 325
the non-solidification ratio of bloom transverse section with mm section GCr15 bloom is 7.3–9.68 mm depending on the
different casting speed was calculated and is shown in Fig. casting speeds, while the SR amount of single withdrawal
10. It can be seen that the non-solidification ratio decreases unit is 1.06–5.22 mm. The SR amount of units is decided by
almost linearly along with strand position. both the shrinkage area and the deformation behavior. With
According to above mentioned calculation results of ΔAi, increasing casting speed, more withdrawal units participate
the SR efficiency and the non-solidification ratio, the SR in SR process due to the prolonged mushy zone, but the total
amount of the GCr15 strand surface were calculated from SR amount decreases due to less shell deformation needed.
Eq. (8), and the results are listed in Table 1. Besides of GCr15, the calculation method also had been

© 2014 ISIJ 508

 ISIJ International, Vol. 54 (2014), No. 3

used to calculate SR amount of other high carbon alloy

blooms, 72A (tire cord steel) and 82B (prestressed strand
steel), which main composition are listed in Table 2, and
their calculation results of SR amount are listed in Table 1
as well. With the typical casting speed of 0.75–0.90 m/min,
the total SR amount of 280 mm × 325 mm section 82B and
72A blooms are 6.18–7.00 mm and 6.28–6.85 mm, respec-
tively. The 82B and 72A blooms need less SR amount than
that of GCr15 to compensate solidification shrinkage for
their lower carbon and alloy content.

4.2. Application Results

The SR amounts listed in Table 1 were applied to the
above mentioned bloom continuous casting machine. With
the similar casting conditions listed in Table 3, the macro-
graphs of the blooms longitudinal and transverse section
before and after the SR application were compared in Figs.
11 and 12.
The left column of Fig. 11 is the macrographs of the
blooms longitudinal section without SR, and it is clear that
the centerline segregation and “V” type segregation are
more and more serious with the increase of carbon and alloy
content. As shown in the right column of Fig. 11, the blooms
center quality improved significantly after the SR applica-
tion. There are some internal cracks which are perpendicular
Fig. 11. Macrographs of longitudinal bloom section without SR:
to the blooms centerline on the 1/4 location of bloom height (a), (c) and (e); and with SR: (b), (d) and (f).
after the SR application, and these cracks may be caused by
the amplified straightening stress, when the SR was execut-
ed by units 1 to 3 which have straightening function besides
of withdrawal. Additionally, Fig. 12 shows the huge center
porosity with radius greater than 8 mm in the transverse sec-
tion of GCr15 bloom was eliminated while the macrostruc-
ture of whole section became homogeneous after the SR
application.
The carbon and sulfur segregation ratios on the GCr15
bloom centerline were measured quantitatively by the chem-
Fig. 12. Macrographs of transverse bloom section with (a) and
ical analysis of drillings. The sampling positions are shown
without (b) SR for GCr15.
in Fig. 13.
Figures 14(a) and 14(b) show the carbon and sulfur seg-
regation ratios at the GCr15 bloom centerline, respectively.
It is clear that the sulfur segregation is more serious com-
pared to the carbon segregation. Figure 14(a) shows that the
maximum of the carbon segregation ratio decreased from

Table 2. The Ts, Tl and main composition of steel (in mass%).

Steel grade Ts (°C) Tl (°C) C Si Mn P S Cr

GCr15 1 292.7 1 453.9 1.00 0.25 0.30 0.010 0.010 1.45
82B 1 317.3 1 464.5 0.83 0.23 0.80 0.008 0.015 0.28
72A 1 333.6 1 476.8 0.70 0.19 0.50 0.010 0.008 0.02 Fig. 13. Schematic illustration of sampling method.

Table 3. Parameters of the casting conditions.

Water flowrate of secondary cooling zones (l/min)

Casting Casting
Steel
speed temperature Zone 1 Zone 2 Zone 3 Zone 4 Zone 5
grade
(m/min) (°C)
I/O L/R I/O L/R I O L/R I O L/R I O L/R
GCr15 0.75 1 476–1 480 23.9 23.9 18.1 15.6 5.9 6.5 10.2 3.3 4.0 5.7 2.1 2.7 3.6
82B 0.80 1 480–1 488 26.3 23.9 29.0 25.0 9.6 10.5 16.5 5.4 6.4 9.2 3.4 4.4 5.9
72A 0.75 1 490–1 496 25.1 23.9 27.1 23.4 8.9 9.8 15.3 5.0 5.9 8.5 3.1 4.0 5.4

509 © 2014 ISIJ

 ISIJ International, Vol. 54 (2014), No. 3
Fig. 14. The carbon (a) and sulfur (b) segregation ratios at the bloom centerline.
1.39 to 1.09 after the SR application, and the proportion of
the carbon segregation ratio greater than 1.05 decreases
from 76.7% to 6.7%. As shown in Fig. 14(b), the sulfur ratio
at the bloom centerline fluctuates abruptly with the maxi-
mum of 2.14 before the SR application, and this uneven dis-
tribution decreased significantly while the peak ratio
became 1.29 after the SR application.
5. Conclusions
The SR amount is usually chosen as a control parameter
in bloom continuous casting process due to its feature of dis-
continues reduction, and in this paper the SR amount calcu-
lation method is derived which is based on the principle of
solidification shrinkage compensation.
In order to obtain the shrinkage compensation of liquid
core, a heat transfer model was developed to predict the
temperature distribution with specific equipment parame-
ters, and bearing steel GCr15 was chosen as specific
research steel. In order to improve the accuracy of calcula-
tion results, the material properties of GC15 were calculated
by weighted averaging of the phase fractions. The predicted
temperature and shell thickness were verified by thermal
infrared camera and nail shooting result with the relative
error of less than ±0.84% and 1.86%, respectively.
From the temperature predicted results and the deforma-
tion behavior of continuous casting bloom, the calculation
process of the SR amount under different casting speed was
presented and discussed. The total SR amount increases
with the increase of carbon and alloy content for different
steel grade, and with typical casting speeds the total SR
amount of 280 mm × 325 mm section GCr15, 82B and 72A
blooms were 7.3–9.68, 6.18–7.00 mm and 6.28–6.85 mm,
respectively.
The plant results showed that the centerline segregation
and “V” type segregation of high carbon alloy blooms
improved significantly after the SR application, and the car-
bon and sulfur ratios on the GCr15 bloom centerline were
reduced from 1.39 to 1.09 and 2.14 to 1.29, respectively.
© 2014 ISIJ
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Acknowledgments
The present work is financially supported by the National
Natural Science Foundation of China No. 50925415 and No.
51004030. The authors sincerely acknowledge helpful com-
ments and suggestions of Prof. Yogeshwar Sahai of the Ohio
State University. The special thanks are due to the Xingtai
Iron & Steel Corporation for industrial trials and application.
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