Patent Grant
11745257
The present invention relates to a continuous casting nozzle (specifically, an immersion nozzle, a tundish nozzle or the like) configured to be fittingly engageable with a stopper mainly for controlling flow rate during discharge of molten steel from a tundish to a casting mold, and a continuous casting nozzle and stopper combination.
As used in this specification, the term “continuous casting nozzle” will hereinafter be referred to simply as “nozzle”.
In continuous casting of molten steel, inclusions such as alumina is likely to adhere to a fitting engagement region including a contact area between a stopper and a nozzle, causing difficulty in flow rate control.
As a measure to prevent inclusions from adhering to the fitting engagement region, for example, the below-mentioned Patent Document 1 discloses a stopper-receiving nozzle provided in the bottom of a tundish, wherein the nozzle comprises two porous refractory members provided to define, respectively, upper and lower molten steel contact surfaces bordered by a contact area with a stopper, so as to allow argon gas to be blown through the porous refractory members, independently.
However, in the case where argon gas is blown through the porous refractory members, problems can arise that: a gas bubble diameter in molten steel becomes excessively large; the flow rate is excessively increased to cause difficulty in flow rate control; and, due to a large area of a gas blowing surface, a blowing amount of gas becomes uneven depending on position of the gas blowing surface and thereby adhesion of inclusions is more likely to occur in a part of the gas blowing surface.
There has also been known a nozzle configured to blow argon gas from a gas outlet other than such a porous refractory member.
For example, with a view to allowing blowing of inert gas to perform from a position close to a pouring hole (nozzle inner bore) while suppressing flow of the inert gas into molten steel in a casting mold, thereby further reducing re-contamination of molten steel after removal of inclusions by inert gas, the below-mentioned Patent Document 2 discloses a continuous casing upper nozzle in which a plurality of gas blowing holes are provided on the circumference of an upper end face of the upper nozzle centered at the center of the pouring hole, wherein a relationship between a total cross-sectional area A (m2) of the gas blowing holes, and a volume Vg (m3) of a flow passage (slit) through which inert gas flows inside the upper nozzle is set in a specific range.
Such a through-hole type nozzle is composed of a refractory material having a denser microstructure than that of a porous refractory material. Thus, as compared with a porous type nozzle, the through-hole type nozzle is superior in terms of corrosion resistance and abrasion resistance, but inferior in terms of thermal shock resistance. Moreover, in some aspects, such a through-hole portion is a “defect” in a structural body, and has the disadvantage that a thermal or mechanical stress is apt to concentrate thereon to trigger breaking of the structural body. Particularly, in a case where start or stop of discharge of molten steel, or flow rate control of molten steel, is performed by operation of fittingly engaging a stopper with an upper end of the inner bore of the nozzle, the stopper operation itself can apply a mechanical external force, such as shock or compressive force, directly to the nozzle, thereby increasing a risk of breaking of the through-hole type nozzle.
With a view to providing a hard-to-break through-hole type nozzle, the below-mentioned Patent Document 3 discloses a nozzle provided with a through-hole penetrating through a nozzle body and communicated with a gas pool, wherein the through-hole is formed in a three-dimensional non-linear shape.
On the other hand, with a view to preventing clogging around an upper nozzle due to inclusions in molten steel, the below-mentioned Patent Document 4 discloses an upper nozzle in which a refractory material having a significant clogging suppression effect is provided at each of an upper end of the upper nozzle contactable with a region where molten steel flows in a contracted manner, and a portion of a stopper head contactable with the upper nozzle, wherein the refractory material is free of C element, and has a high Al2O3 or MgO content.
Patent Document 1: JP-A H06-297118
Patent Document 2: JP-A 2017-064778
Patent Document 3: JP-A 2013-184199
Patent Document 4: JP-A H09-314292
A gas outlet formed as a through-hole or slit is deemed to be a defect in an integrated microstructure of a refractory material, and can trigger breaking of the refractory material due to concentration of a mechanical stress or thermal stress on the defect, or the like, as mentioned above. Further, such breaking will occur in an irregular (random) direction and at an irregular position. If the breaking occurs in a fitting engagement region between a nozzle and a stopper, it is likely to cause a serious problem, e.g., that it becomes unable to control the flow rate or distribution of blowing gas, and further molten steel flow rate control and stopping functions are impaired, thereby becoming unable to maintain normal casting.
Even if the through-hole as a gas outlet or a gas distribution path is formed in a structure which makes it less likely for a stress to concentrate thereon, as in the Patent Document 3, there still remains a risk of causing breaking of the nozzle.
On the other hand, in the case where a peculiar refractory material excellent in corrosion resistance and anti-adhesion property is disposed in a part of the fitting engagement region, as in the Patent Document 4, this refractory material generally has a higher thermal expansibility and a higher elastic modulus than those of the main body refractory material composing a nozzle body improved in terms of thermal shock resistance. If such a peculiar refractory material is installed in contact with the main body refractory material, a risk is increased that it presses and breaks the main body refractory material.
A problem to be solved by the present invention is to provide a nozzle or a stopper having a gas blowing function, which is capable of preventing irregular breaking to be triggered by a gas outlet or a gas passage path communicated with the gas outlet, or, even in the event of breaking, preventing expansion of the breaking, and a combination of the nozzle and the stopper.
Further, another problem to be solved by the present invention is to provide a nozzle capable of, in a case where a refractory material having a higher thermal expansibility than that of a main body refractory material composing a nozzle body of the nozzle is installed in a fitting engagement sub-region with a stopper, preventing irregular breaking of the nozzle body, and a combination of the nozzle and the stopper.
The present invention provides a nozzle and a nozzle and stopper combination having features as described in the following sections 1 to 11.
1. A nozzle located beneath a stopper for controlling a flow rate of molten steel in continuous casting of molten steel, and fittingly engageable with the stopper in a fitting engagement region. The nozzle comprises: a fitting engagement sub-region including a contact area with the stopper, the fitting engagement sub-region comprising a layer composed of a refractory material for the fitting engagement region (the layer will hereinafter be referred to as “fitting engagement region refractory material layer”);
a nozzle body composed of a refractory material different from the refractory material for the fitting engagement region (hereinafter referred to as “main body refractory material”); and
a gas outlet provided in at least one boundary area between the fitting engagement region refractory material layer and the main body refractory material in a surface of the nozzle contactable with molten steel.
2. The nozzle as described in the section 1, wherein the gas outlet is composed of a plurality of through-holes or a slit.
3. The nozzle as described in the section 2, wherein each of the through-holes has a diameter of 2 mm or less, or the slit has a width of 1 mm or less.
4. The nozzle as described in the sections 1 to 3, wherein the refractory material for the fitting engagement region is a refractory material having a carbon content of 5 mass % or less (including zero) (this refractory material will hereinafter be refereed to as “carbonless refractory material”).
5. The nozzle as described in the section 4, wherein the carbonless refractory material has a ZrO2 content of 75 mass % or more, and a carbon content of 5 mass % or less (including zero), a remainder mainly consisting of an oxide.
6. The nozzle as described in the section 4, wherein the carbonless refractory material has a spinel (Al2O3·MgO) content of 75 mass % or more, and a carbon content of 5 mass % or less (including zero), a remainder mainly consisting of an oxide.
7. The nozzle as described in any one of the sections 1 to 6, wherein the main body refractory material is a refractory material primarily comprising a refractory raw material selected from the group consisting of an alumina-based refractory raw material, an alumina-silica based refractory raw material, a spinel-based refractory raw material, a zircon-based refractory raw material, and a magnesia-based refractory raw material.
8. A nozzle and stopper combination comprising the nozzle as described in any one of the sections 1 to 7, and a stopper, wherein the stopper comprises a gas outlet below a contact area thereof with the nozzle, wherein the gas outlet of the stopper is composed of one or more through-holes or a slit.
9. The nozzle and stopper combination as described in the section 8, wherein each of the through-holes of the stopper has a diameter of 2 mm or less, or the slit of the stopper has a width of 1 mm or less.
10. The nozzle and stopper combination as described in the section 8 or 9, wherein the stopper comprises a fitting engagement sub-region including the contact area with the nozzle, wherein at least a part of the fitting engagement sub-region comprises the fitting engagement region refractory material layer.
11. A nozzle and stopper combination comprising the nozzle as described in any one of the sections 1 to 7, and a stopper, wherein the stopper comprises a fitting engagement sub-region including a contact area with the nozzle, wherein at least a part of the fitting engagement sub-region comprises the fitting engagement region refractory material layer.
Here, “a nozzle located beneath a stopper for controlling a flow rate of molten steel in continuous casting of molten steel, and fittingly engageable with the stopper” typically means a nozzle, called “tundish nozzle” or “upper nozzle” configured such that it is installed in the bottom of a tundish and coupled to another pouring nozzle located therebelow, or an immersion nozzle mounted inside a tundish as with the tundish nozzle or the upper nozzle but typically extending downwardly farther than the tundish nozzle or the upper nozzle and immersed inside a casting mold.
The present invention provides a nozzle or a stopper having a gas blowing function, which is capable of preventing irregular breaking to be triggered by a gas outlet or a gas passage path communicated with the gas outlet, or, preventing expansion of the breaking.
The present invention also provides a nozzle capable of, in a case where a refractory material having a higher thermal expansibility than that of the main body refractory material is installed as the fitting engagement region refractory material layer, preventing irregular breaking of the nozzle body.
Further, the carbonless refractory material may be applied as the fitting engagement region refractory material layer. This makes it possible to prevent adhesion of in-molten steel inclusions to the fitting engagement region, and maintain the molten steel flow rate control function for a long period of time.
Embodiment for implementing the present invention will now be described.
In a fitting engagement region (see, for example,
Further, the fitting engagement region undergoes a large thermal change during pre-heating or start of pouring of molten steel, or due to gas blowing (cooling by blowing gas), so that a thermal stress arises inside the nozzle and/or stopper.
On the other hand, in an area having a boundary which interrupts the continuity of a refractory material composing the nozzle or the stopper (boundary area), a stress is likely to concentrate thereon to trigger breaking of the refractory material.
However, such a boundary area has a stress relaxation function although it is not at a high level.
Heretofore, such a boundary area has been generally formed in the following configurations.
(1) A configuration comprising two discontinuous layers made of the same material. For example, a configuration obtained by: preliminarily producing a shaped body composing a first layer; and charging a mixture for forming a second layer to be in contact relation with the shaped body, thereby producing integrated shaped bodied, or a configuration obtained by integrally fixing two shaped bodies in a state in which they are simply placed in contact with each other.
(2) A configuration obtained by combining two different materials. For example, a configuration obtained by: preliminarily producing a shaped body using one of the materials; and charging a mixture of the other material to be in contact relation with the shaped body, thereby producing integrated shaped bodied, or a configuration obtained by integrally fixing two shaped bodies made of different materials, in a state in which they are simply placed in contact with each other.
(3) A configuration comprising two layers obtained by using the same material or combining different materials, and a layer formed therebetween by using a material different from the two layers, such as mortar.
Here, the two refractory components (shaped bodies) structurally having a boundary area therebetween may be composed of the same or different refractory materials
Further, a gas outlet or a gas passage path communicated with the gas outlet is a void, i.e., a defect, in the microstructure of a refractory material, and a stress is likely to concentrate on the defect to trigger braking of the refractory material.
However, such a void has a function of absorbing or relaxing stresses in the microstructure of the refractory material.
Based on the above considerations, in the present invention, the gas outlet triggering further breaking is disposed in the aforementioned boundary area, instead of being disposed in the fitting engagement region between the nozzle and the stopper or a region having a microstructure integral/continuous with the fitting engagement region, which is important in molten steel flow rate control. That is, in the present invention, the boundary area having a stress relaxation function although it is at a low level is overlappingly provided with the gas outlet as a void having a further stress relaxation function. Thus, it becomes possible to further suppress or prevent the occurrence of the breaking or the expansion of the breaking.
Further, a cooling effect by gas blowing from the gas outlet can be expected to provide a secondary effect of suppressing a temperature rise of the refractory material to reduce a stress due to thermal expansion of the refractory material (particularly, an inner bore region or an upper end of the nozzle).
In the present invention, for example, in a case where a nozzle 2 as shown in
Then, one or each of the two boundary areas 9 may have a gas outlet 8A opened in a surface of the nozzle contactable with molten steel.
Further, for example, in a case where an upper end of a nozzle 2 is formed as a fitting engagement region refractory material layer 5A, as shown in
In each of the nozzles 2 illustrated in
In the present invention, the gas outlet may be composed of a plurality of through-holes or a slit. Although the stress relaxation function slightly varies depending on the number of the through-holes, the size of the through-hole, the size (width) of the slit, or the like, it may be determined according to individual casting conditions, such as balance with the amount of gas.
In the case where the gas outlet is composed of a plurality of through-holes, from a viewpoint of obtaining the stress relaxation function over the entire circumference of the boundary area as uniform as possible, the number of through-holes is preferably set to about eight or more, although it depends on the size of the boundary area.
According to knowledge of the present inventors, the diameter of the through-hole is preferably set to 2 mm or less, and the width of the slit is preferably set to 1 mm or less, from a viewpoint of optimizing a gas bubble diameter of gas in molten steel, which exerts an influence on an inclusion floating effect in a molten steel container or in a casting mold. The reason is that the setting makes it possible to control the amount of blowing of gas with a high degree of accuracy, and to increase the rate of small-diameter gas bubbles (about 3 mm or less) which are likely to facilitate floating of in-molten steel inclusions and less likely to cause steel defect.
Meanwhile, even when gas is blown into molten steel, in-molten steel inclusions (non-metal inclusions) mainly consisting of alumina adhere to the nozzle or the stopper, in some cases. A region in which such non-metal inclusions exert the largest influence on molten steel flow rate control is the aforementioned fitting engagement region.
Therefore, in the present invention, a refractory material having a carbon content of 5 mass % or less (including zero) (carbonless refractory material) and exhibiting anti-adhesion property against the non-metal inclusions may be installed in the fitting engagement region.
Adhesion of the non-metal inclusions is a phenomenon appearing as a result of a combination of various behaviors arising depending on compositions of a refractory material, and is also dependent on a carbon content in a refractory material contactable with molten steel. The major reason is that carbon is eluted into molten steel at a high speed to coarsen the microstructure of the refractory material.
The present inventors have found that, in a test room and an actual casting operation, an anti-adhesion property of a nozzle is significantly improved by setting a carbon content of a refractory material to be installed in the fitting engagement region, to 5 mass % or less (including zero), i.e., employing a carbonless refractory material as a refractory material to be installed in the fitting engagement region.
The carbonless refractory material may be an alumina-based or alumina-silica based refractory material. However, the present inventors have found that, in a test room and an actual casting operation, a material having: a ZrO2 content of 75 mass % or more, or a spinel (Al2O3·MgO) content of 75 mass % or more, and a carbon content of 5 mass % or less (including zero), a remainder mainly consisting of an oxide is more preferably used as the carbonless refractory material.
On the other hand, a main body refractory material composing a nozzle body of the nozzle may be a refractory material primarily comprising a refractory raw material selected from the group consisting of an alumina-based refractory raw material, an alumina-silica based refractory raw material, a spinel-based refractory raw material, a zircon-based refractory raw material, and a magnesia-based refractory raw material. A nozzle, particularly an elongated immersion nozzle, requires high thermal shock resistance. Thus, in the present invention, a material containing a carbon component in an amount of about 12 to 30 mass % may be used as the main body refractory material, as with a commonly-used main body refractory material.
Here, the thermal expansion (about 1.0 to 1.4% at 1500° C.) of the carbonless refractory material is greater than the thermal expansion (in an alumina-based refractory material having a carbon content of 25 mass %, about 0.5 to 0.6% at 1500° C.) of the above main body refractory material. Thus, when the carbonless refractory material is installed on the inner side of or in an upper part of the main body refractory material, and particularly when they are formed in an integral or continuous structure, it is often the case that the carbonless refractory material presses and breaks the main body refractory material.
Therefore, in the case where the carbonless refractory material is applied as the “fitting engagement region refractory material layer”, it is preferable to apply the present invention.
The carbonless refractory material (fitting engagement region refractory material layer) may also be provided in at least a part of a fitting engagement sub-region of the stopper to enhance the anti-adhesion function against the non-metal inclusions, or the in-casting mold inclusions floating effect, in the fitting engagement region.
It should be noted that the carbonless refractory material (fitting engagement region refractory material layer) to be applied to the fitting engagement sub-region of the nozzle and the fitting engagement sub-region of the stopper needs not necessarily be the same in terms of composition. For example, as the carbonless refractory material (fitting engagement region refractory material layer), a material “having a ZrO2 content of 75 mass % or more, and a carbon content of 5 mass % or less (including zero), a remainder mainly consisting of an oxide” may be applied to the fitting engagement sub-region of the nozzle, and a material “having a spinel (Al2O3·MgO) content of 75 mass % or more, and a carbon content of 5 mass % or less (including zero), a remainder mainly consisting of an oxide” may be applied to the fitting engagement sub-region of the stopper.
In the present invention, for example as shown in
Here, in each of the stoppers 1 illustrated in
In the nozzle or the stopper, a portion between respective ones of the plurality of through-holes each serving as the gas outlet may be composed of one of the refractory material for the fitting engagement region (fitting engagement region refractory material) and the main body refractory material. In other words, each of the through-holes may be formed to be in contact with one of the fitting engagement region refractory material and the main body refractory material, or may be formed to penetrate through one of the fitting engagement region refractory material and the main body refractory material, or through a boundary therebetween.
Alternatively, mortar may be provided between the fitting engagement region refractory material and the main body refractory material, and the through-holes may be formed in the mortal.
With regard to a stress relaxation effect in the case where a plurality of through holes are provided in the boundary area between the fitting engagement region refractory material layer (carbonless refractory material) and the main body refractory material, calculation was conducted based on the above findings in a simplified manner by a finite element method. A result of the calculation is shown in Table 1.
In the field “Forming Method” in Table 1, “Integral” means a case where two mixtures of different refractory materials are simultaneously and integrally formed into a single body having a continuous microstructure, and “Segmented” means a case where two segments formed separately are fixed together by a dry joint. The maximum stress index is a value obtained based on the assumption that the maximum stress in Comparative Example 1 is 100. A smaller maximum stress index means a better stress relaxation effect.
As seen from comparison between Comparative Example 1 and Inventive Example 1, wherein the forming method of them is “Integral”, Inventive Example 1 with through-holes is superior in terms of the stress relaxation effect. Further, as seen from comparison between Comparative Example 2 and Inventive Example 2, wherein the forming method of them is “Segmented”, Inventive Example 2 with through-holes is superior in terms of the stress relaxation effect.
Here, sample Nos. 2, 7 and 10 contain no carbon.
In
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-044562 | Mar 2019 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2020/009058 | 3/4/2020 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2020/184320 | 9/17/2020 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 3253307 | Griffiths | May 1966 | A |
| Number | Date | Country |
|---|---|---|
| H06182528 | Jul 1994 | JP |
| 6-297118 | Oct 1994 | JP |
| 9-314292 | Dec 1997 | JP |
| H10258342 | Sep 1998 | JP |
| 2006-61943 | Mar 2006 | JP |
| 2013-184199 | Sep 2013 | JP |
| 2014034052 | Feb 2014 | JP |
| 2017-64778 | Apr 2017 | JP |
| Entry |
|---|
| International Preliminary Report on Patentability, dated Aug. 25, 2021, with Written Opinion for PCT/JP2020/009058 (English translation). |
| International Search Report (dated Mar. 15, 2020) and Written Opinion (dated Apr. 7, 2020) for PCT/JP2020/009058, filed Mar. 4, 2020. |
| Number | Date | Country | |
|---|---|---|---|
| 20220111436 A1 | Apr 2022 | US |
