Recently, significant progress has been made in improving the throughput of copper tubes in the No. 1 billet continuous casting machine of the new continuous casting operation area: the highest throughput of a single copper tube reached 13,952 tons, an increase of 76.6% compared with the initial stage of equipment commissioning. The cost of copper tube spare parts has been reduced to 0.18 yuan/ton, achieving a double improvement in production efficiency and economic benefits, and injecting strong momentum into the company’s stable production and efficiency.
The copper tube in the crystallizer, as the “heart” of the billet continuous casting machine, is crucial for ensuring the safe and smooth operation of molten steel casting. Its operational status directly determines the production efficiency of the continuous casting machine and the quality of the cast billets.
Since the No. 1 continuous casting machine was built and put into operation, the technical team in the work area has consistently focused on the core objective of “improving efficiency and reducing costs,” prioritizing increasing the steel throughput of the crystallizer copper tube as a key research direction. Through in-depth technological innovation and process optimization, and after repeated practical exploration, they have gradually formed a set of effective technical management systems.
To address the challenges of rapid wear and short service life of copper pipes, the work area has adopted a multi-pronged approach, employing a comprehensive technical strategy:
- By optimizing the production organization model, rationally matching the steel grade production sequence, strictly controlling the superheat of molten steel, and improving the quality of cooling water in the crystallizer, abnormal copper pipe wear was reduced from the source, effectively solving common problems such as copper pipe wear and leakage.
- Standardize the operation of key positions，In critical operations such as pouring and changing the water inlet, operators are required to precisely control the liquid level in the crystallizer and place the cold material in a precise and orderly manner to minimize the impact of crystallizer vibration and scratches on the copper tubes during the casting process.
- Optimize device parameter adaptation，Based on actual production process requirements, the inverted taper of the copper tube in the crystallizer was appropriately increased, which effectively improved the demolding effect of the cast billet and reduced the wear rate of the inner wall of the copper tube.
- Strengthen cooling water system management，Through water quality optimization and routine standardized management, the stability of various indicators of the crystallizer cooling water has been continuously improved, ensuring uniform heat exchange in the crystallizer and avoiding damage to copper tubes by local friction.
- Improve full life cycle management，The operation procedures for stopping casting and feeding the ingot rod have been further standardized, and the online status monitoring of the copper tubes in the crystallizer has been strengthened to monitor and grasp the wear of the copper tubes in a timely manner, thus realizing dynamic and refined management of the use of copper tubes.
The significant increase in the throughput of the crystallizer not only effectively improved the operating efficiency of the continuous casting machine and reduced the time for changing the crystallizer, but also directly reduced production and operating costs. Based on the annual casting volume, it is estimated that the annual cost of copper tube spare parts can be saved by more than 200,000 yuan, providing strong support for the work area to tap its internal potential and achieve the goal of cost reduction and efficiency improvement.
What is the role of a crystallizer copper tube in a billet continuous casting machine?
The crystallizer copper tube transfers heat from molten steel, helps form the initial solid shell, and directly affects casting stability and billet quality.
Why is the copper tube called the “heart” of the continuous caster?
Because its performance determines the stability of the mold zone, heat transfer efficiency, service life, billet surface quality, and overall production efficiency.
What are the main causes of copper tube wear in billet casting?
Common causes include improper steel grade sequence, excessive molten steel superheat, unstable liquid level, poor cooling water quality, mold vibration, and billet friction against the inner wall.
