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Meltshop Process Automation
Carboox develops and implements technological solutions for operational tasks in steelmaking, especially for processes of addition of mould fluxes in Continuous Casting Machines and addition of nozzle filler in ladle sliding gates.
Each case it is analyzed in particular, so that the best solution is developed in accordance with the expectations of the user.
Spherical granular mould flux or powder for billets blooms and slabs.
Description: Mould Fluxes are a mixture of several minerals synthetic materials and Carbon components used in continuous casting of steel. They can be supplied in powder or spherical granules. The spherical shape shows many benefits concerning flowability and insulation of mould surface.
The manufacturing of those products follows a strict control of raw materials, process and product quality control in order to give the best performance required by users.
Application: The mould flux is applied over the liquid steel surface inside the mold forming a melting pool of liquid slag with defined properties. The formulations of the mold flux are normally done in function of the steel grade and casting speed that usually goes from 11-196 inches/min (0.3 - 5.0 m/min). Note: These materials can be applied manually or automatically. Carboox can also help the choice or even supply equipments for automatic flux feeders.
Starting Powder
Carboox also manufactures exothermic fluxes used to start continuous casting sequence.
Those fluxes reduce the common problems that can occur during the beginning of casting avoiding breakouts and improving the product quality.
Consumption: The consumption of mold flux ranges from 0.88 - 1.98 pound/ton depending on steel grade and casting condition.
Functions:
Provides a lubricating film of molten slag between the solidified shell and the copper mold wall to prevent adhesion and make easy the strand withdraw;
Modifies the heat transfer rate from steel to the mold;
Ensures thermal insulation of the mold steel surface to avoid early solidification;
Protects the liquid steel from reaction with atmospheric gases;
Promotes absorption of non-metallic inclusions;
Benefits:
High performance in all continuous casting conditions reducing breakouts and providing high surface and internal qualities of cast product;
Mold flux for ultra low carbon with very low carbon content and high interfacial tension in order to avoid carbon pick up and slag entrainment;
Mold flux for peritectic grades with high basicity to smooth heat transfer and reductions of longitudinal cracks occurrence;
Mold flux for high carbon grades with excellent lubricating properties. This flux can be also supplied with exothermic components to reduce pinholes;
CARBOOX develops a specific product for each user in order to optimize all mould flux properties such as viscosity, melting temperature, fusion rate, and compatible with casting parameter of each machine.
Ladle and Tundish cover materials with insulation and/or refining properties.
Description: The covers materials are powders or spherical granulated mixtures designed to insulate, prevent of oxidation and absorb non metallics inclusions from liquid steel in tundish or ladle. The active tundish cover will form a liquid pool that is highly efficient to avoid nitrogen pick up and re-oxidation. This liquid pool is thermodynamically favorable to absorb oxide inclusions that flow during the process.
Application: These materials are applied direct to liquid surface steel.
Tundish: after teeming starts at tundish metal level is 20% of tundish capacity, the tundish cover material is applied in order to cover all the entire liquid surface. Each new heat or when the operator sees a “red area” a new amount of material must be added, normally one or two bags. The adding is made trough the tundish lid hole.
Ladle: After pouring steel from BOF or EAF to the ladle the cover material is added. The addition must cover the entire liquid steel surface in the ladle with a layer of 1.5 – 2.5 inches. During secondary refining activities such as temperature measurements and sampling the “red areas” must be covered to ensure the liquid steel protection.
Functions:
Avoid heat loss of liquid steel surface in tundish or ladle;
Protection from reaction with atmosphere gases;
Absorption of non-metallics inclusions;
Benefits:
Providing high surface and internal quality of the cast products;
Reduction of heat loss during casting keeping the superheat of steel in the tundish as specified;
CARBOOX supplies several kinds of cover material with many chemical composition in order to cast several steel grades. The purpose of cover material is taking into account and also others parameters in order to supply a tailor made material to match the needs of users and reaching the mentioned benefits.
ZIRCAL SRL, supplies slot type and segment type purging plugs in order to clean liquid steel from inclusions and gases and achieve homogenous heat distribution in ladles.
For special alloyed steel grades, ZIRCAL SRL produces purging systems in order to clean liquid steel from inclusions & gases and achieve homogenous heat distribution in tundishes.
Wonjin Europe BV supplies magnesia-carbon bricks for ladles, EAF’s and converters.
MgO-C Brick is made by compounding the Magnesia material and Graphite. It was firstly developed for the electric furnace in 1970s. Since then, it has been applied as one of major interior materials for the electric furnace and second refining ladle facility.
The major causes of MgO-C Brick damages are the chemical reaction by slag, thermal impact and abrasion. We have been supplying the optimum products through the complicated survey on operating conditions by application. We have affluent application performances for large longitudinal bricks(over 1M) for converters as well as electric furnaces and second refining ladles.
Honeycomb ceramics are a core business of Rauschert. Our aim is to supply your applications individually, flexibly and economically according to your requirements.
We offer the following products & services:
Catalyst Carriers
Honeycombs for heat exchange
Flow rectifier
Capacity for large quantities
Broad range of various materials & geometries
Products according to customers drawings
With more than 100 years experience in supplying industrial customers, 1500 employees in 13 countries and 17 manufacturing plants Rauschert is meeting today's international challenges.
