The continuous casting process is a core step in steel production, and the stable operation of the dummy bar is crucial. In previous production processes, the dummy bar was subjected to prolonged high temperatures, which easily caused deformation, affecting the proper drawing of the billet and production continuity. Conventional dummy plates had limited heat dissipation capacity and could not effectively cope with high temperatures. To address this issue, the steelworks’ technical team conducted in-depth research and bold innovation, proposing a unique solution: replacing the dummy plates with water-cooled plates.
Water-cooled plates operate based on the principle of heat exchange. Circulating water quickly dissipates the significant heat generated during the dummy process, effectively reducing the temperature around the dummy bar. Compared to traditional plates, water-cooled plates offer significant advantages in heat dissipation efficiency, dissipating heat quickly and significantly reducing the effects of baking on the dummy bar.
The water-cooled plate modification project presented numerous challenges. From the plate’s structural design to the optimal layout of the cooling water circuits, meticulous planning and repeated evaluation were required. In the structural design, the team fully considered the mechanical properties and heat transfer requirements during the dummy bar process, ensuring that the guard plate can achieve optimal heat dissipation while withstanding high temperatures and mechanical shock. The cooling water circuit design underwent multiple simulations and optimizations to ensure the circulating water’s flow rate, volume, and uniform distribution for efficient cooling.
After the modification was completed, the water-cooled guard plate showed immediate results, significantly reducing the surface temperature of the dummy bar, effectively minimizing damage to the dummy bar material and preventing deformation. This not only extends the dummy bar’s service life and reduces equipment replacement costs, but also ensures the stability and continuity of continuous casting production, reduces downtime caused by equipment failure, and improves production efficiency. Furthermore, the stable operation of the dummy bar further improves the quality of the ingot, reduces defects caused by dummy bar problems, and provides higher-quality raw material for subsequent rolling processes.
