12/06/2018

PROJECT PRESENTATION

ON

STUDY OF EMBR MOLD IN LD#2 SLAB CASTER NO#1

GUIDED BY :
Manas Ranjan Mohapatra
Manager Mechanical Maintenance

SUBMITTED BY :
Kamod Ranjan (VT 20181553)
B.E
Mechanical Engineering
BIT MESRA

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ACKNOWLEDGEMENT

Any accomplishment, big or small, has a number of persons behind the scene
and I must acknowledge that this project was no expectation.

First of all I would like to convey my gratitude to my guide Mr. Manas Ranjan
Mohapatra (Manager Mechanical Maintenance) for his continuous support
during my project. He has been a constant source of encouragement during
the entire project. He provided me valuable information as well as knowledge
regarding my project.

Finally, I would like to convey a word of thanks to “ TATA STEEL”administration

for providing me this great opportunity to undergo my summer internship under
its esteemed banner.

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TATA STEEL
An introduction

 Tata Steel Limited (formerly Tata Iron and Steel Company Limited (TISCO)) is an Indian
multinational steel-making company.

 It’s headquartered in Mumbai, Maharashtra, India, and a subsidiary of the Tata Group.

 Established in 1907 , Tata Steel is the world ‘s 6th largest company with an existing annual
crude steel capacity of 27.5mtpa.

 Asia’s 1st integrated private sector steel company is now the world’s second most
geographically diversified steel producer ,with operations in 24 countries.

 The first private sector found by JAMSETJI NUSSERWANJI TATA which started with a
production capacity of 1,00,000 tones has transformed into a global giant.
Vision : “benchmark in “value creation” and “Corporate Citizenship” through the excellence


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SNTI (Shavak Nanavati Technical Institute)

 Shavak Nanavati Technical Institute (SNTI), established in 1921 as the technical training
department of Tata Steel, now develops skilled employees for other companies as well.

 Its 400,000 volume library is one of the most popular in the city.

 It was the inspiration of the founder of TISCO, “Let the Indians learn to do things by
themselves” , which came into reality by the establishment of the institute.

 Today SNTI form an integral part of the HR management division of TATA STEEL.

 It has rendered commendable service in nation development of technical manpower not only
for Tata Steel, but also for the steel plants in the public sector and other manufacturing
industries.

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What Is Steel ?

 Steel is a compound of iron and carbon(less then 1.5%). Modern steels also use
traces of magnesium, chromium, tungsten, molybdenum, manganese, nickel and
cobalt. All of these can be used to varying degrees to help make the steel harder,
lighter, more or less resistant to heat and electrical current, more ductile and corrosion
resistant. Steels are a large family of metals.

 Steel is an alloy of iron and other elements, including carbon . When carbon is the
primary alloying element, its content in the steel is between 0.002% and 2.1% by weight.
The following elements are always present in steel: carbon, manganese, phosphorus,
sulfur, silicon, and traces of oxygen, nitrogen and aluminum. Alloying elements intentionally
added to modify the characteristics of steel include: manganese, nickel, chromium,
molybdenum, boron, titanium, vana dium and niobium.

 Carbon and other elements act as a hardening agent, preventing dislocations in the iron
atom crystal lattice from sliding past one another. Varying the amount of alloying elements
and the form of their presence in the stee l (solute elements, precipitated phase) controls
qualities such as the hardness, ductility, and tensile strength of the resulting steel. Steel
with increased carbon content can be made harder and stronger than iron, but such steel is
also less ductile than iron.

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How a steel plant work ?

Steel is an alloy of iron and carbon. It is produced in a two-stage process.

 First, iron ore is reduced or smelted with coke and limestone in a blast furnace, producing molten iron
which is either cast into pig iron or carried to the next stage as molten iron.

 In the second stage known as steelmaking, impurities such as sulfur, phosphorus, and excess carbon
are removed and alloying elements as manganese, nickel, chromium and vanadium are added to
produce the exact steel required. Steel mills then turn molten steel into blooms, ingots, slabs and sheet
through casting, hot rolling and cold rolling.

Process involved in manufacturing

 Carbonization of COKE
 Blast furnace
 Basic Oxygen Steel making [BOS]

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Carbonization of COKE
 Well graded coal is selected
 Heated or carbonized to COKE
 Heated coal is cooled
 Proper COKE are fed into the Blast furnace for the farther process
Blast furnace
 Iron ore, coke and limestone are put into the top, and preheated air is blown into the bottom.
 Several reactions take place before the iron is finally produced...
C(s) + O 2(g) CO2(g)
CaCO3(s) CO2 (g) + CaO(s)
CO2(g) + C(s) 2CO(g)
CaO(s) + SiO(s) CaSiO3(l)
3CO(g) + Fe2O3(s) 2Fe(l) + 3CO2(g)
Basic Oxygen Steel making [BOS]
 Hot metal from the blast furnace and steel scrap are used in Basic Oxygen Steel making (BOS).
 A water-cooled oxygen lance is lowered into the converter and high-purity oxygen is blown on to the metal at very
high pressure.
 The oxygen combines with carbon and other unwanted elements, eliminating them from the molten charge.
 the temperature of the metal is controlled by the quantity of added scrap.
 lime is added as a flux to help carry off the other oxidized impurities.
 The carbon leaves the converter as a gas, carbon monoxide, which can, after cleaning, be collected for re-use as
a fuel.
 lime is added as a flux to help carry off the other oxidized impurities.
 the converter is tilted and the steel is tapped into a ladle.

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Process Flow At Tata Steel

Raw Steel Marketing &

Materials
Iron Making materials Rolling sales

Ore Merchant Mill

mines Llong
sinter
&
plant New Bar Mill product C
Qurries
Division
Ld-1 Marcketing
U
Wire Rod Mill &
Blast sales S
West furnaces
Bokaro
T
Division O
Coke
Ld-2 Hot Strip Mill Flat product
M
Marcketing
plant & E
Jharia sales
Division Cold Rolling Mill R
S
Raw
Materials Coke, Sinter & Division Flat Products Division
Devision

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LD SHOP DESCRIPTION
 The LD shop takes in Hot metal from the blast furnace and refine them so that it can be
turned into refined steel before being cast into billets and slabs depending on the
requirements.

 In Tata Steel there are presently LD# 1, LD# 2, LD# 3 and TSCR departments for the
above mentioned process.

LD# 2 Shop
The main units of LD# 2 Shop are:-
1). Hot metal receiving and Handling
2). Desulphurization
3). Basic oxygen furnace
4). Online purging
5). Ladle furnace
6). RH degasser
7). Gas cleaning plant
8). Secondary emission plant

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LD#2 Shop Process

 The hot metal is received in the torpedo pits of the LD shop via torpedo (capacity is 200T to
320T) from the blast furnace.

 The metal received is crude in terms of the composition and needed to be further refined.

 The first step in LD# 2 shop is DESULPHURIZATION process, the Sulphur content is
controlled in this process.

 The desulphurization process takes place in the D.S unit where calcium carbide and
magnesium are used to and the sulphur is brought down to the target level depending on
the grade requirements.

 The next step is the BOF process. This is the most widely used steel refining process and
this was first introduced in the towns of Linz and Donowitz and hence the name LD.

 In the LD converter Oxygen is blown from the top of the converter to reduce the carbon
content also various additives like fluxes, Ferro alloys and scrap is added to stabilize the
process and to produce the required grade of Steel. The metal obtained is called “Primary
Refined Steel”

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 The steel after refining in the BOF is tapped and is sent to the Ladle furnace
where the trimming
additions takes place to fine tune the steel compositions.

 In the ladle furnace the molten steel is heated by means of electrode to

maintain temperature wire
feeding system for Ferro alloy.

 From the ladle furnace the steel is sent to the caster for casting into billets or
slabs.

 In certain cases where high quality and cleanliness is required the steel is sent t
the RH(Ruhrstahl -Heraeus) facility which is a vacuum degassing unit to further
reducecarbon, oxygen, nitrogen and hydrogen content.

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Overview of LD2 & Slab Caster

LD-2
Supplied by S.N. Portugal of Portugal LD 2 was commissioned in 1993. With two BOF vessels from VAI, the plant has a rated
capacity of 1.10 million tonnes. Hot metal is supplied in 200 t nominal capacity torpedo ladles from the blast furnaces. The metal
is poured into 150 t transfer ladles at the hot metal pouring pit .The hot metal in the transfer ladle is desulphuriser at the
desulphurization unit after removing the slags and thereafter, taken to the converters.
The details of hot metal handling system are:
 Hot Metal Receiving: The input Hot Metal comes from Furnaces A, B, C, D, F, G, H & I in torpedo ladles of 220tons.

 Torpedo Area : Hot Metal from Torpedo is transferred to ordinary Transfer Ladle of 150tons capacity by tilting the Torpedo.
From 2 torpedoes we get metal for three heats.

 Hot Metal Desulphurization: Initially BF Slag is raked of with the help of raking machine. Then desulphurisation starts with
the injection of CaC2 & Mg injection through refractory lance with Nitrogen as the carrier gas. The lance dips inside the metal
and injection starts. Sulphur of the hot metal removes in the form of CaS & MgS and floats up. This is raked off. The time of
DS depends on the initial ‘S’ content of the hot metal & the final product specification required.

 Converter: The 3 BOF vessels have been supplied by SMS Demag. Pig iron in the transfer ladle is taken inside the BOF
vessels for controlled oxidation using lance heater. At this stage additives are added to prepare the required blend of steel.
Inert gas, Argon is blown in order to maintain the uniformity of the hot metal. Lance heater used for oxidation contains 3
concentric flow paths.
The centre flow path is used for blowing oxygen into the vessel and the other 2 flow paths are used to water cooling of lance.
At the time of oxidation, the lance goes deep into the vessel so that uniform oxidation can take place. Slag formation takes
place in the upper part of the vessel whereas molten steel in produced in the lower part. Slag is removed by tilting the vessel
from the top of the vessel into a ladletransfer car below and the steel is poured into another ladle below it from the neck
opening of the vessel by tilting it in opposite direction.

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 Steel in the ladle now is taken for further secondary metallurgical processing in SMLP (Secondary
Metallurgical Ladle Processing) shop mentioned below.
 Different Routes : Different routes of steel making are mentioned below:
Converter-Caster(30-35% Heats)
Converter-RH-Caster(18-20% Heats)
Converter-LF-Caster(50-55% Heats)
Converter-LF-RH-Caster(6-8% Heats)
 RH Degasser: The process was developed by Rheinstahl Heinrich in 1957. The process in named after
him. In order to produce steel for high - end applications, liquid steel is routed through. This
degassing unit in which treatment takes place under vacuum.The degassing chamber is a cylindrical
steel shell with two legs called snorkels and the openings at the top side are provided for exhaust, alloy
additions, observations and control. During degassing metal enters the cylindrical vacuum chamber
through one snorkel and flows back under gravity through other. The chamber is lifted and lowered to an
appropriate level in the ladle containing molten steel. The chamber is evacuated and the molten steel
just rises in the chamber. The atmospheric pressure causes the molten steel to rise above the, still bulk
level, in the snorkel, under deep vacuum. Lift gas like argon is then introduced in the inlet snorkel which
expands and rises up thereby raising the velocity of steel in the inlet snorkel. The net result of this is
that degassing takes place very efficiently. Gravity causes steel to flow back in the ladle via the other
snorkel. Degassed steel is slightly cooler and denser than in the ladle and hence it forces the lighter
undegassed steel upwards thereby ensuring adequate mixing and homogeneity. At the end of the
process alloy additions may be made depending upon the superheat available in the steel.
 Ladle Furnace: Liquid steel from the converter is tapped into preheated ladles and then treated at the
ladle furnace for homogenization, increase of temperature and for trimming additions are done. It is a
simple ladle like furnace provided with bottom plug for argonpurging and lid with electrodes to become

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an arc furnace for heating the bath. Another lid may be provided to connect it to vacuum line, if required.
Chutes are provided for additions and an opening even for injection. It is capable of carrying out stirring,
vacuum treatment, synthetic slag refining, plunging, injection etc. all in one unit without restraint of
temperature loss, since it is capable of being heated independently.

Slab Caster
There are three single strands continuous casting machine
which have been specifically designed to cast high quality
Slabs suitable for hot charging to the Hot Strip. The main
machine at LD# 2 and Slab Caster was modified to include
A new vertical mould and Bender/Straightener
Segments, up gradation of ladle turret, modification of the
Tundish Car and existing segments, augmentation of hydraulic
systems including pipe work, instrumentation & automation
System and numerous attendant changes for the Company
to manufacture more demanding grades of steel.

 The machine is equipped to cast 215mm thick and

800-1550mm wide slabs. No.1 caster is vertical mould caster
and other two are curved mould caster. Each bender strand
has mould and a radius of 10m with a support length of 29.75m.

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 The vertical caster has a radius of 7.5m over this length this slab is initially supported by mould followed by
cooling grids and then top and bottom rollers during solidification. The partly or fully solidified curved slab
is removed by continuous straightening method prior to withdrawal and final solidification. Hot metal for
casting is supplied from converters via secondary steel making facilities. The charged ladle with steel in its
optimum state is transported to position. As the turret is rotated, the Tundish is driven over the mould from
its pre-heat station by a Tundish car. Ladle shroud is then fixed for shrouding of ladle to Tundish stream.
Once all “ready to cast” interlocks are healthy, casting is started.
 The mould is mounted on pivot arms supported from mould table support frame and is water-cooled. This
mould support frame also locates and supports the top-zone. This is an important of machine as it ensures
correct relationship between mould, top-zone and strand guides. The pivot arms carrying the mould are
oscillated to improve surface finish of slabs by means of oscillation.
 As the slab emerges from mould, it is cooled by a mist-spray cooling system. The cooling strand is guided
down by various roller segments following the caster radius along a curved path. The upper sections of
segments can be raised hydraulically and are held by means of hydraulic cylinders against packers, which
are pre-set to give required slab thickness. Immediately following the strand guide segments is the
straightener segment. This segment is designed to continuously remove the curvature of the strand as it
passes through the segment.
 From the straightener, slab passes into withdrawal unit which has 7segments arranged horizontally to
support the slab as it progresses towards cut-off machine. As strand emerges from cast withdrawal rollers,
the dummy bar disconnect mechanism is activated. The slabs are cut into lengths by oxygen/gas machine
which is supported on rails. As the predetermined length is sensed, the machine lowers on to the slabs and
travels with the slabs at casting speed. The twin burners mounted on cross carriages, cut the slab from
either end. The discharge roller table then transports the slabs to the cross transfer area. The slabs are
marked online by an Al-spray marking machine on their way to the cross transfer.

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Continuous Casting
 Continuous Casting is the process whereby molten steel is solidified into a "semi-finished" billet, bloom, or
slab for subsequent rolling in the finishing mills.
 It allows lower-cost production of metal sections with better quality, due to the inherently lower costs of
continuous, standardized production of a product, as well as providing increased control over the process
through automation.
 In Continuous Casting molten metal is tapped into the ladle from furnaces. the ladle is transported to the
top of the casting machine. Usually, the ladle sits in a slot on a rotating turret at the casting machine; one
ladle is 'on cast' while the other is made ready, and is switched to the casting position once the first ladle is
empty.
 From the ladle, the hot metal is transferred via a refractory shroud to a holding bath called a Tundish. The
Tundish allows a reservoir of metal to feed the casting machine thus acting as a feed metal feed to the
mould and metal is drained from the Tundish through another shroud into the top of an open-base copper
mould.
 A lubricant can also be added to the metal in the mould to prevent sticking, and to trap any slag particles —
including oxide particles.
 the shroud is set so the hot metal exits it below surface of the slag layer in the mould and is thus called a
submerged entry nozzle (SEN).
 the bulk of metal within the walls of the strand is still molten. The strand is immediately supported by
closely-spaced, water cooled rollers ; these act to support the walls of the strand against the Ferro static
pressure of the still-solidifying liquid within the strand. To increase the rate of solidification, the strand is
also sprayed with large amounts of water as it passes through the spray-chamber.

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Important Components of Continuous Casting:

 Ladle: Steel from the electric or basic oxygen furnace is tapped into a ladle and taken to the continuous
casting machine. The ladle is raised onto a turret that rotates the ladle into the casting position
above the Tundish. Liquid steel flows out of the ladle into the Tundish. Ladle slide gate valves
are used for greater pouring accuracy, increased ladle hold time, and safer and easier ladle
preparation.

 Tundish: The shape of the Tundish is typically rectangular, but delta and "T" shapes are also common.
Nozzles are located along its bottom to distribute liquid steel to the moulds.

The Tundish also serves several other key functions:

* Enhances oxide inclusion separation

* Provides a continuous flow of liquid steel to the mould during ladle Exchanges

* Maintains a steady metal height above the nozzles to the moulds,

* Provides more stable stream patterns to the mould.

* Ladle shrouds are used for stream protection and reduction of steel re- oxidation between ladle and
Tundish .

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Continuous Casting Process

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 Submerged Entry Nozzle : From the Tundish the molten metal enters the mould through a shroud.
Often, the shroud is set so the hot metal exits it below surface of the slag layer in the mould and is thus
called a submerged entry nozzle (SEN).Submerged Entry Nozzles are used in the steelmaking process to
prevent re-oxidation of the molten steel directly from stream contact with the surrounding environment
and from air

 Mould: The main function of the mould is to establish a solid shell sufficient in strength to contain its
liquid core upon entry into the secondary spray cooling zone. The mould is basically an open-ended box
structure, containing a water-cooled inner lining fabricated from a high purity copper alloy. Mould water
transfers heat from the solidifying shell. The working surface of the copper face is often plated with
chromium or nickel to provide a harder working surface, and to avoid copper pickup on the surface of the
cast strand, which can facilitate surface cracks on the product.
Mould oscillation is necessary to minimize friction and sticking of the solidifying shell, and avoid shell
tearing, and liquid steel breakouts Friction between the shell and mould is reduced through the use of
mould lubricants such as oils or powdered fluxes. Oscillation is achieved either hydraulically or via
motor-driven cams or levers which support and reciprocate (or oscillate) the mould.

 Segments : Segments are the set of rollers which helps the semi solidified slabs to move from the mould
to the torch cutting machine through the guide rollers. Generally the rollers of the segments are in taper
form so that compression of the slab up to 3 meters is possible.

 Torch Cutting Machine : Torch cutting machine is used to cut the solidified slabs into desired length
according to the demand. The torch cutting machine in Tata Steel is supplied by GEGA.

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EMBR (Electro Magnetic Breaking)

Introduction :
 It is a special kind of a mold quite similar to the conventional mechanical (gear) mold in
terms of physical appearance but hugely different from it in the working aspect.

 A mold is a hollow container used to give shape to molten or hot liquid material when it cools
and hardens.

 In order to continuously cast high quality steels for demanding purposes electromagnetic
stirring are a must for billets and blooms. Stirring will improve strand quality, reproducibility,
yield, production flexibility and productivity.

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Description Of Equipment
 The smart mold is centered on the fork of the mold table and fixed onto the mold table by
means of four folding eve bolts .

 The smart mold is aligned to the mold table on the mold alignment stand (mold frame).

 It is located outside the plant ,by turning the ecentric of the mold frame and by means of
description of mold and bending zone.

Components of EMBR Mold

 INSERT

 The insert consists of the following components :

 wide side copper plate
 Narrow side copper plate
 Wide side beckup plates
 Narrow side backup plates
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structure &function of insert

 The isert consists of backup plates with bolted copper plates and is located in the mold
frame.
 The insert wide side are fixed bolted to the supporting walls.
 The wide side can be shifted , as it is adjusted upon changing of the casting thickness.
 The symmetry expansion of the wide side copper plates is forced by a fitted key resting
centrically against the copper plate and backup plate.

Wide and Narrow Plates

 The distance between the wide plates implies the thickness of the slab to be cast which is
normally about 215 in
 The distance between the narrow plates implies the width of the slab.
 The plates are coated with pure copper of thickness 40 mm on oneside which are further
coated with nickel and cobalt for improving the wear resistance of pure copper as pure
copper is costly and degrades every 450-600 heats (1 heat=160 tonnes). The thickness of
this nickel and cobalt coating increases from 0.5 mm at the top to 2 mm at the bottom of
the plates.
 The junction of the copper coating and the plates is connected to thermocouples which
indicates the temperature of that point in a screen..
 There are 4 rows and 11 columns in each of the wide plates while the narrow plates have
4 rows and 2 columns each with a total of 104 thermocouples.
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 The narrow plates are kept inclined at an angle of 1.1-1.28 degrees towards the
lower portion so that the molten steel ,which goes on solidifying and hence
consequently decreasing in dimension upon solidifying, does not just slip from in
between the plates.

 The movement of the narrow plates are very slow which is 0.8 m/min. Each narrow
plate is connected to two servos, one at the top and the other at the bottom, which
facilitates its movement in or out. In every round of command given to the servos the
narrow plates move by 12.5 mm.

 There are two methods of movement of the narrow plates so that the molten steel
which is solidifying remains in a healthy position. These are:- S type & H type,

 The plates contain cut lines (as shown in the figure) to facilitate the free circulation of
water in the plates to keep the temperature moderate and the plates cool as well as
prevent the copper coating from getting degraded.

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 Electromagnets

 When molten steel is poured into the mold there is a lot of turbulence in it which greatly
tend to hamper the properties of the steel which is being casted. Hence to obtain higher
grade and better quality steel the EMBR mold has electromagnets which greatly tend to
nullify this turbulence by developing a high current electromagnetic field.

 The electromagnets are attached to the wide plates and are totally 4 in number.

 There are two sets of coil on each of the wide plate or strand (visible in the figure). There
are two strands, namely: Strand 1 upper coil & Strand 1 lower coil.

 Each of the strands now further has two coils as we discussed above.
Strand 1 upper coil has: Coil 11A &Coil 11B.
Strand 1 lower coil has: Coil 12A &Coil 12B

 Each of the coils is water cooled continuously to maintain and regulate the temperature.
The water used here is a special kind of water called “de mineralized water”.

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The EMBR electromagnet will trip under the following conditions:

 When the inlet temperature is 48 °C or more than that, and
 When the conductivity>2 µs/cm. (it has to be less than 2 at all times).
 The current and voltage required to produce the electromagnetic field is 560 Ampere
and 180 volts respectively.

 Foot rollers
 The foot rollers are fixed to the bottom side of the wide side supporting walls by
means of hex. Head screws.
 The axles support three rollers and the chocks are guided through a parallel key.
 The rollers are supported in needle bearings.
 The foot rollers are aligned to the copper plates in the mold alignment stand.

 Lateral roll
 These are the rolls attached to the bottom of the mold just below the plates to direct
the solidifying steel towards the bender and from where it proceeds on to the
segments.
 three rollers are arranged at three levels vertically spaced at 180mm.
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 Clamping and expending device

 This component clamps the wide side supporting wall loose side to the wide side
supporting wall fixed side.
 The clamping force (hydraulic pressure) is applied by pre – stressed disc spring.
 It is also used to increase the casting gap to avoid damage and cracking.

 Narrow Side Adjusting Device

 Two hydraulic cylinders are provided for each narrow side.
 These cylinders are bolted to the supporting wall right and left.
 The piston of the hydraulic cylinder is hinged with the holding plate of the narrow side.

 Mold Cover
 The frame are deposited on the casting floor.
 The inner cover is placed onto the supporting wall fixed and loose side of the mold
frame.
 A channel for steam exhaust is installed at the cover and the frame fixed side.

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 Primary cooling system

 Primary cooling system implies the cooling of the plates.
 The wide and narrow plates bear an intense amount of heat from the molten steel so the
need to be cooled down.
 This is also done to ensure the safety of the copper plates.
 The water used in this system is soft water.
Soft water circulates in
Wide plate at 4000 Lpm.
Narrow plate at 550 Lpm.

 Secondary cooling system

 This refers to the cooling of the molten steel to form a slab.
 The slab of steel that comes out of the mold is molten from inside and solid from outside
due to cooling.
 The water used in this system is normal tap water and is sprayed on the slab directly
perpendicular it from a pipe whose ends are made flat in order to make sure that they
come out with force and cover the maximum surface area.
 If this is not present then the heat from the molten steel inside the solidified shell will
cause the shell to melt and ultimately leading to breakout or bleeding.

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Some Technical Data Of The EMBR Mold

Length , width , Height 4930mm, 2230mm, 1651mm
Dead weight smart mold with ABB FC mold G2 25050 kg
Dead weight smart mold cover 5400kg
Width adjusting range 950 – 1600 mm
Equipped with casting thickness 215 mm
Casting thickness range (cold) 210 – 230 mm
Length of copper plate 900 mm
Thickness of copper plate wide side 40mm
Thickness of copper plate narrow side 40 mm
Maximum remachining of copper plate 15mm
Cooling direction in the copper plate From bottom to top
Foot roller diameter 100mm
Width adjustment Hydraulic
Smart mold level measuring equipment VUHZ
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Process & Function Of EMBR mold

 The EMBR mold cools the liquid steel coming from the tundish by means of water
cooled copper plates.
 The length of the EMBR mold is determined in such a way that the strand shell formed
by cooling will have sufficient strength to withstand the ferrostatic pressure in the roller
strand guide connected downstream as well as withdraw force.
 The EMBR mold determines the strand cross section . When liquid steel starts
solidifying ,the thickness of strand shell varies at the EMBR mold exit according to the
casting speed.
 The EMBR mold is centered automatically and fixed by four folding eye bolts . By
placing of it on mold table , the cooling water connections for primary and secondary
water are established.
 The primary cooling water is fed via the mold table, mold frame , backup plate and
copper plate bottom side.
 The cooling water is recycled via the copper plate top side, backup plates, mold frame
and mold table.
 Sealing between mold frame and mold table is effected by a rubber seal.

 Cooling water is supplied to and from the wide and narrow side via plug type pipes or
telescopic tubes.

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Advantages of EMBR Mold

 Reduced Mold Powder Entrapments
• Inclusions remain small and relatively harmless because of the calcium treatment of the
steel.
• Because of this and the high casting speed normally used for thin slabs, mold powder
entrapments constitutesthe major source of detrimental non-metallic inclusions.
• With EMBR, the lower meniscus flow speed and the turbulence results in that mold
powder entrapment will be nearly eliminated.
• More than 90% of the non-metallic inclusions are eliminated.

 Improved Core Quality

• Higher speed of casting means low quality. When using an optimized EMBR, the quality
level at higher throughputs is improved.
• The quality becomes equal or better to the quality level to that for significantly lower
casting speeds without EMBR.

 Reduced Meniscus Swelling

• The braking reduces the meniscus swelling close to the narrow mold sides.
• The resulting flatter meniscus allows for a more even layer of molten mold powder, thus
improving lubrication and reducing therisks of surface cracks.
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EMBR increases mold lifetime

• EMBR lowers the mold level fluctuation. Temperature cycling and thermal fatigue of
the copper plates are dramatically reduced.

• Twice as more mold lifetime from casters using EMBR.

Increases Steel Temperature at Meniscus

• Heat transfer from the middle of the mold to the solidification front is reduced.

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THANK YOU

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