Description:TECHNICAL FIELD
Present disclosure, in general, relates to the field of metallurgy. Particularly, but not exclusively, the present disclosure relates to a cooling system of a continuous casting process for producing billets. Further, embodiments of the present disclosure disclose a header for cooling the billet at an exit of a mold in the continuous cooling process.

BACKGROUND OF THE DISCLOSURE

A billet is a solid metal having square or rectangular profile that has been cast into shape by continuous casting process. The continuous casting process involves casting a molten metal in a mold. Further, to form the billet with the required properties, the molten metal in the mold is cooled at multiple stages. At a first stage of cooling, a coolant may be circulated along an outer surface of the mold. In the first stage of cooling a portion of outer layer of the molten metal in the mold is solidified and the inner portion remains in the semi- molten state. Further, when the outer layer of the billet is formed, the billet in a semi solidified state is drawn out of the mold. However, for further process of the billet in the semi solidified state, a second stage of cooling is employed, where the coolant is directly impinged on the surface of the billet extending from an outlet of the mold. The second stage of cooling involves spraying the coolant to the semi solidified billet as the billet exits the mold. The second stage of cooling is employed to immediately cool the billet in the semi solidified state to continue solidification.

Conventionally, the second stage of cooling is achieved by a coolant header. The coolant header may be positioned at each face of the semi solidified billet such that each face of the billed is sprayed with the coolant. The conventionally employed header consists of nozzles which are employed to spray the coolant onto the billet. The nozzles are positioned at predefined length of the coolant header and are configured to spray the coolant either intermittently or continuously, based on nature of properties to be imparted to the billet. Further, number of nozzles to be employed may also vary based on a myriad of factors including, but not limited to, material of billet being cast and specific heat of the coolant. However, as requirement for maintaining faster casting speed and larger dimensioned billet persists, the conventional headers are insufficient to provide the necessary cooling.

The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the conventional mechanisms.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the prior art are overcome by a device as claimed and additional advantages are provided through the device as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the present disclosure a header for cooling a continuously casted metal billet at an exit of a mold is disclosed. The header includes a conduit which is extending from the exit of the mold and in a direction along movement of the continuously casted metal billet. The conduit is configured to channelize a coolant for cooling the continuously casted metal billet. Further, at least four sets of nozzles are disposed at predefined locations on the conduit, where each of the at least four sets of nozzles is disposed at a predefined angle relative to the conduit to dispense the coolant on the continuously casted metal billet for solidification.

In an embodiment, the conduit extends from a collar, located proximal to the exit of the mold, and the collar is configured to mount the conduit adjacent to the exit of the mold.

In an embodiment, the conduit extends at a predefined angle from the collar, along the direction movement of the continuously casted metal billet from the exit of the mold.

In an embodiment, the conduit includes a first section and a second section connected at an offset axis to longitudinal axis of the first section.

In an embodiment, each of the at least four sets of nozzles includes at least two nozzles, oriented at a predefined angle to the conduit.

In an embodiment, a first set of nozzles of the at least four nozzles is angled with respect to a longitudinal axis of the conduit, such that the first set of nozzles is oriented towards the exit of the mold when installed.

In an embodiment, a second set of nozzles, a third set of nozzles and a fourth set of nozzles are disposed normal to the longitudinal axis of the conduit.

In an embodiment, the fourth set of nozzles is positioned closer to the third set of nozzles, for increasing rate of solidification of the continuously casted metal billet.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiments when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Figures 1a and 1b illustrate a front view and a side view of a header for cooling a continuously casted metal billet respectively, in accordance with an embodiment of the present disclosure.

Figures 2a and 2b illustrate a front view and a side view of the header defined with a first section and a second section connected at an offset axis to the first section, in accordance with an embodiment of the present disclosure.

Figures 3a and 3b illustrate a front view and a side view of a conduit extending at a predefined angle from a collar of the header of Figure 2.

Figures 4a and 4b illustrate a front view and a side view of the conduit extending at a predefined angle from the collar of the header of Figure 2.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the system and method illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that, the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other devices, mechanisms, systems, assemblies, methods, and processes for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that, such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusions, such that a mechanism, an assembly, or a device that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

In accordance with various embodiments of the present disclosure, a header for cooling a continuously casted metal billet at an exit of a mold is disclosed. The header includes a conduit which is extending from the exit of the mold and in a direction along movement of the continuously casted metal billet. The conduit is configured to channelize a coolant for cooling the continuously casted metal billet. Further, at least four sets of nozzles are disposed at predefined locations on the conduit, where each of the at least four sets of nozzles is disposed at a predefined angle relative to the conduit to dispense the coolant on the continuously casted metal billet for solidification.

Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals will be used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to Figures 1 to 4.

A billet may be manufactured by a continuous casting process, which involves solidifying a molten metal into a continuously casted metal billet [hereafter referred to as billet]. In the steel industry, an alloy of steel may be continuously casted to form the billet. The billet may be manufactured by tapping the molten metal into a ladle from furnaces. The ladle transports the molten metal from the furnace to a casting machine. From the ladle, the molten metal may be transferred into the casting machine where the molten metal enters a mold. The dimensions of the mold may be defined based on the required billet size and on the casting speed. Further, the mold may be cooled in multiple stages to solidify the molten metal. The primary cooling stage involves supplying a coolant along an outer surface of the mold to solidify a portion of the metal being directly in contact with the mold. The primary cooling stage forms a thin shell by cooling the molten metal which is contact with the inner surface of the mold. Upon formation of the thin shell, partially solidified billet may be drawn out of the mold, where the partially solidified billet may be subjected to a secondary cooling stage. The secondary cooling stage includes directly impinging the coolant onto the billet. The secondary cooling stage involves plurality of cooling zones where at a first cooling zone the coolant may be sprayed onto the billet as soon as the billet exits the mold. Further, remaining cooling zones may be achieved by passing the billet through coolant-cooled rollers. The secondary cooling stage enables complete solidification of the billet for further processing.

With advancements in the filed casting, dimensions of the molds are continuously increased to improve the productivity of steel manufacturing. Such increase in the size of the mould, a cooling rate required to cool the billet is also required to be increased. For such increased requirement of cooling rate, a header with 8-nozzles have been developed, where nozzles are positioned at predefined locations and predefined angles along the header.

Figures 1a and 1b is an exemplary embodiment of the present disclosure which illustrates a header (100) for cooling a billet in the first cooling zone of the secondary cooling stage. The header (100) may be configured to cool the billet as the billet exits a mold. The header (100) may include a conduit (10) which is configured to channelize a coolant for cooling the billet. The conduit (10) may extend from a collar (11) which is located proximal to an exit of the mold. The conduit (10) may be connected to the collar (11) such that, the conduit (10) extends from the exit of the mold and in a direction along movement of the billet. Further, the collar (11) may be defined with provisions to mount the header (100) adjacent to the exit of the mold.

In an embodiment, the header (100) may be defined with an inlet [not shown in Figures] to channelize the coolant into the conduit (10). Further, the header (100) may include an outlet (12) defined at an end of the conduit (10) and away from the collar (11), to dispense excess coolant from the conduit (10) which is not dispensed onto the billet. In an embodiment, at least one header (100) may be provided to cool each face of the billet. Considering the billet is of polygonal shape i.e., of square or rectangular shape, four number of headers may be provided to cool the billet.

Further, at least four sets of nozzles (1, 2, 3, 4) may be disposed at predefined locations of the conduit (10). The at least four sets of nozzles (1, 2, 3, 4) may be configured to dispense the coolant channelized through the conduit (10), onto the billet. Each of the at least four sets of nozzles (1, 2, 3, 4) is disposed at a predefined angle relative to the conduit (10) to dispense the coolant on the billet for solidification. Furthermore, each of the at least four sets of nozzles (1, 2, 3, 4) includes at least two nozzles, where each nozzle may be oriented at a predefined angle relative to the conduit (10). In an embodiment, each nozzle of the at least two nozzles may be oriented based on the location on the billet at which the cooling may be required.

In an exemplary embodiment, as seen in Figure 1b, a first set of nozzles (1) of the at least four sets of nozzles (1, 2, 3, 4) may be positioned proximal to the collar (11). The first set of nozzles (1) may be disposed at an angle with respect to a longitudinal axis of the conduit (10) such that, the first set of nozzles (1) are oriented towards the exit of the mold. The first set of nozzles (1) may be configured to dispense the coolant onto to the exit of the mold to cool the billet as the billet is drawn out of the mold. In an embodiment, each nozzle of the first set of nozzles (1) may be oriented with different angles to cover a larger area of the billet such that the billet at the exit of the mold may be effectively cooled.

In an exemplary embodiment, as seen in Figures 1a and 1b, the at least four sets of nozzles (1, 2, 3, 4) may further include a second set of nozzles (2), a third set of nozzles (3) and a fourth set of nozzles (4) disposed downstream of the first set of nozzles (1). The second set of nozzles (2), the third set of nozzles (3) and the fourth set of nozzles (4) may be disposed normal to the longitudinal axis of the conduit (10) to dispense the coolant on the billet. By disposing the second set of nozzles (2), the third set of nozzles (3) and the fourth set of nozzles (4) normal to the longitudinal axis of the conduit a larger area of the billed may be impinged the coolant. Each of the at least four sets of nozzles (1, 2, 3, 4) may be provisioned at predefined distance from the other nozzle. The predefined distance may be based on the cooling required at the corresponding area of the billet. In an embodiment, the first set of nozzles (1) may be positioned proximal to the collar (11) and the second set of nozzles (2) may be positioned proximal to the midpoint of the conduit (10). Further, the third set of nozzles (3) may be positioned at any point between the second set of nozzles (2) and the end of the conduit (10) and the fourth set of nozzles (4) may be positioned proximal to the end of the conduit (10). In an embodiment, the fourth set of nozzles (4) may be positioned closer to the third set of nozzles (3), for increasing rate of solidification of the continuously casted metal billet.

In an embodiment, each of the at least four sets of nozzles (1, 2, 3, 4) may be positioned equidistant to each other.

In an embodiment, length of the first set of nozzles (1) may be lesser than the length of the second set of nozzles (2). Further, the length of the second set of nozzles (2) may be lesser than the length of the third set of nozzles (3) and the fourth set of nozzles (4). Additionally, the length of the third set of nozzles (3) and the fourth set of nozzles (4) may be equal. The length of the nozzles may be based on the area of the billet to be dispensed with the coolant. For example, the first set of nozzles (1) may be located on the conduit (10) at a distance of about 1:8 length ratio of a total length of the conduit from the collar (11), the second set of nozzles (2) may be located on the conduit (10) at a distance of about 1:4 length ratio of the total length of the conduit from the first set of nozzles (1), the third set of nozzles (3) may be located on the conduit (10) at a distance of about 1:5 length ratio of the total length of the conduit from the second set of nozzles (2) and fourth set of nozzles (4) may be located on the conduit (10) at a distance of about 1:5 length ratio of the total length of the conduit from the third set of nozzles (3). Further, the length of the first set of nozzles (1) may be about 4:5 length ratio of the length of the second set of nozzles (2). Further, the second set of nozzles (2) may be about 5:6 length ratio of the length of the third set of nozzles (3) and the fourth set of nozzles (4).

In an embodiment, the nozzle may be configured to dispense the coolant in an umbrella profile on the required area of the billet.

In an embodiment, the conduit (10) may be structured with arms extending laterally from the conduit (10) and configured to receive the nozzle. Further, each nozzle may have a L-shape to connect to the conduit (10). In an embodiment, the nozzles may be integrally formed with the conduit (10) or the nozzles may be connectable to the conduit (10).

In an embodiment, each nozzle of the at least four sets of nozzles (1, 2, 3, 4) may be oriented with an angle normal to the conduit (10), tipped towards other the other nozzle or tipped away from the other nozzle.

Figures 2a and 2b illustrate the conduit (10) defined with a first section (13) and a second section (14). The first section (13) of the conduit (10) may be connected to the collar (11). Further, the second section (14) may be connected at an offset axis to the longitudinal axis of the first section (13) to increase or decrease the area of cooling on the billet. The first section (13) may be connected to the second section (14) through a connection portion. The connection portion may be defined with an angle to connect the first section (13) with the second section (14) in an offset plane to that of the first section (13). In an embodiment, the second section (14) may be positioned such that the conduit (10) may be positioned closer to or away from the billet such that the rate of cooling and the area cooled on the billet may be varied. Furthermore, the first set of nozzles (1) may be disposed on the first section (13) of the conduit (10) and the second set of nozzles (2), the third set of nozzles (3) and the fourth set of nozzles (4) may be disposed on the second section (14) of the conduit (10). In an embodiment, any number of sets of nozzles may be disposed on each of the at least one first section (13) and the second section (14) of the conduit (10).

In an embodiment, the conduit (10) may be defined with at least two section and each of the sets of nozzles may be disposed on corresponding section of the conduit (10) based on requirement.

Referring now to Figures 3a, 3b, 4a and 4b the conduit (10) may be structured to extend at a predefined angle from the collar (11) along the direction movement of the billet from the exit of the mold [not shown]. The conduit (10) may be structured to extend at an angle towards or away from the billet for selectively dispensing the coolant on the billet.

In an embodiment, the first section (13) may be configured to extend at the predefined angle from the collar (11) along the direction movement of the billet from the exit of the mold and the second section (14) may be normal to the collar (11). Further, the first section (13) may be normal to the collar (11) and the second section (14) may be configured to extend at the predefined angle from the collar (11) along the direction movement of the billet from the exit of the mold.

In an embodiment, at least one header (100) may be provisioned for cooling each face of the billet.

In an embodiment, the conduit (10) may be defined with a circular profile, a rectangular profile, a square profile, and any other profile suitable for channelizing fluids.

In an embodiment, the nozzle may be defined with a circular profile, a rectangular profile, a square profile, and any other profile suitable for dispensing and spraying fluids in the required shape and rate.

In an embodiment, the conduit (10) and the nozzles may be made of a metallic material.

In an embodiment, the coolant may be one of but not limited to water, oils, oil emulsion and any other type of fluid capable of cooling metals.

In an embodiment, the header (100) may be configured to increase a cooling efficiency of the continuous casted process by increasing the rate of billet cooling.

In an embodiment, the header (100) may be employed to cool the billets having larger dimensions without any compromise in solidification pattern.

In an embodiment, the header (100) may increase solidification of the billet at the first zone of the secondary cooling stage.

Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals:

Reference Number Description
100 Header
1 First set of nozzles
2 Second set of nozzles
3 Third set of nozzles
4 Fourth set of nozzles
(1, 2, 3, 4) At least four sets of nozzles
10 Conduit
11 Collar
12 Outlet
13 First section
14 Second section

Claims:We Claim:

1. A header (100) for cooling a continuously casted metal billet at an exit of a mold, the header (100) comprising:
a conduit (10), extending from the exit of the mold and in a direction along movement of the continuously casted metal billet, the conduit (10) is configured to channelize a coolant for cooling the continuously casted metal billet; and
at least four sets of nozzles (1, 2, 3, 4) disposed at predefined locations on the conduit (10), wherein each of the at least four sets of nozzles (1, 2, 3, 4) is disposed at a predefined angle relative to the conduit (10) to dispense the coolant on the continuously casted metal billet for solidification.

2. The header (100) as claimed in claim 1, wherein the conduit (10) extends from a collar (11), located proximal to the exit of the mold, and the collar (11) is configured to mount the conduit (10) adjacent to the exit of the mold.

3. The header (100) as claimed in claim 1, wherein the conduit (10) extends at a predefined angle from the collar (11), along the direction movement of the continuously casted metal billet from the exit of the mold.

4. The header (100) as claimed in claim 1, wherein the conduit (10) comprises of a first section (13) and a second section (14) connected at an offset axis to longitudinal axis of the first section (13).

5. The header (100) as claimed in claim 1, wherein each of the at least four sets of nozzles (1, 2, 3, 4) includes at least two nozzles, oriented at a predefined angle to the conduit (10).

6. The header (100) as claimed in claim 1, wherein a first set of nozzles (1) of the at least four sets of nozzles (1, 2, 3, 4) is angled with respect to a longitudinal axis of the conduit (10), such that the first set of nozzles (1) is oriented towards the exit of the mold when installed.

7. The header (100) as claimed in claim 1, wherein a second set of nozzles (2), a third set of nozzles (3) and a fourth set of nozzles (4) are disposed normal to the longitudinal axis of the conduit (10).

8. The header (100) as claimed in claim 1, wherein the fourth set of nozzles (4) is positioned closer to the third set of nozzles (3), for increasing rate of solidification of the continuously casted metal billet.

9. A cooling system for a continuous caster comprising a header as claimed in claim 1.