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Discussion on Consumption of Cooling Water in Continuous Aluminum Billet Casting

Release time:

Aug 03,2023

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Aluminum and aluminum alloys are more and more widely used in daily life. The continuous aluminum billet casting equipment at home and abroad is also increasing day by day, and the degree of automation is getting higher and higher. However, equipment manufacturers, engineering designers and users pay less attention to the amount of cooling water in the mold of continuous aluminum billet casting machines. The result is that the conditions proposed by the equipment side are becoming more and more conservative, and the amount of cooling water and the temperature difference between the inlet and outlet water seem to have a feeling of "the bigger the better". At the same time, water cannot be supplied on demand during production, so that the equipment cannot be run at full capacity. So, what determines the cooling water consumption of the continuous aluminum billet casting machine? Today, we will analyze it in detail for you.

What is Continuous Aluminum Billet Casting?

Continuous aluminum billet casting technology is the main production technology of ingots at present, and its development trend is to improve the quality of ingots, increase production efficiency and reduce production costs.

continuous aluminum billet casting

The mold of aluminum billet casting plays a forming role. The ingot is mainly cooled by the crystallizer. The cooling heat exchange process is divided into three stages. First, the aluminum liquid is poured into the crystallizer and contacts with the cold wall to form a cooling. The heat is transferred to the water through the wall and cooled rapidly, so that the molten aluminum solidifies to form an ingot with a hard shell. At this time, about 10% to 15% of the heat is taken away, and the ingot shrinks slightly in the radial direction, forming a gas between the cast and the wall. Gap. Since the thermal conductivity of air in the air gap is much lower than that of aluminum, the heat exchange quickly drops to a minimum. Secondary cooling is carried out between the solidified ingot and water spray, which can take away about 70%~80% of heat. The ingot is cooled in the water pool as the third cooling, which takes away little heat and has little effect on the crystallization effect of the billet!

Continuous Aluminum Billet Casting Cooling Water Consumption

The amount of water supplied to the mold of the casting machine and the casting speed, the flow rate of the molten aluminum, the shape, size, and number of the billet, the alloy composition of the billet, the casting quality, the type of the crystallizer, the temperature difference between the supply and return water, and the water vapor drained from the casting well The quantity and other conditions are related, and there are many influencing factors, and the main influencing factor is the direct heat exchange between water and aluminum ingots.

Aluminum Billet

When the temperature difference of circulating cooling water entering and leaving the crystallizer is 28°C (60-32°C) and the temperature difference of pure aluminum is 630°C (cooling from 690°C to 60°C), the maximum hourly calculated water consumption per ton of pure aluminum is 10.12m3. The vaporization heat absorption of water into water vapor, the heat taken away by the cold air accompanied by water vapor, and the heat exchange efficiency between water and aluminum ingots (whether the water spray effect of the crystallizer is good or bad) are not considered.

Aluminum Alloy Billet

If the aluminum alloy is required by the process, even if the initial and final cooling temperature difference of the aluminum alloy is 50°C, considering the latent heat of fusion, the heat corresponding to the temperature difference accounts for about 5% of the total heat, which has no major impact on the results. In addition, the specific heat capacity of aluminum alloy is about 0.87~1.13k J/Kg·℃, which is about 10~30% smaller than the average specific heat capacity of pure aluminum 1.26k J/Kg·℃. In this way, when the temperature difference of the circulating cooling water is 28°C (60-32°C), the maximum hourly calculated water consumption per ton of aluminum alloy is about 6~9 m3.

Epilogue

In the actual design work, the actual water consumption of the crystallizer should also be determined in combination with the measured data of the water consumption of the crystallizer, and adjusted according to the actual situation on site.

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Refractory Lining in Induction Furnace

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How to Reduce Aluminum Burning Loss in Casting?

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