Prediction of Slag Pool Thickness in Continuous Casting Mould

Physical properties of mould powder control the surface equality of the continuously cast products. Formation of mould slag of specific quality in caster mould requires correct formulation of melting rate property so that molten slag of adequate thickness is continuously generated. The melting of the casting powder, apart from mineralogical composition, is influenced by caster application conditions such as casting speed, oscillation parameters etc. The known melting rate tests are not amenable for quantitative prediction of slag pool thickness since they do not consider all the application conditions together. Present work describes a methodology predicting slag pool thickness based on melting rate measurements using various known experimental techniques. The measured melting rate data has been combined to generate acceleration coefficients incorporating effect of slag consumption and mould oscillation on powder melting. An effective melting rate parameter (EMR) has been formulated using these coefficients. Measured slag pool thickness (d ) during actual casting correlates well with the defined EMR in the speed range of 0.55 to 1.5 m/min.d=35.70·EMR·V/(a·b)+2.1, R2=0.94 The high confidence level of this correlation indicates applicability of effective melting rate parameter (EMR) concept for prediction of slag pool thickness.