Integrated Cooling System

The Integrated Cooling System is a critical component within the Integrated Continuous Casting Production System, responsible for the controlled solidification of molten metal as it passes through the casting machine. It ensures uniform cooling rates, prevents thermal stress and defects, and maintains the structural integrity and dimensional accuracy of the cast product throughout the solidification zone. The system typically employs a series of water-cooled copper molds and secondary cooling zones (spray chambers). As the molten metal enters the mold, the primary cooling initiates solidification, forming a solid shell. The strand then passes through secondary cooling zones where controlled water sprays extract heat, allowing the core to solidify progressively and uniformly along the casting direction. The system is designed for integration into existing continuous casting lines, with parameters such as cooling capacity (500–2000 kW), water flow rate (100–400 m³/h), operating pressure (1.0–1.6 MPa), and temperature control accuracy (±2 °C). Cooling water inlet temperature should be 20–35 °C, and outlet temperature 40–60 °C to prevent steam formation. Electrical supply is three-phase 380–480 V AC (IEC 60038), with power consumption of 15–45 kW including pumps and control system. The system has an IP rating of IP54–IP65 (IEC 60529) for electrical enclosures, and noise level ≤85 dB(A) at 1 m distance (ISO 3746). Wetted parts are made of stainless steel 304/316L (ASTM A240) for corrosion resistance. The skid-mounted unit weighs 1500–3500 kg and has typical dimensions of 3000×1500×1800 mm (L×W×H). Materials on file include copper alloy for molds, stainless steel for piping and headers, and carbon steel for structural framework. All values are reference ranges and must be verified for the specific model and application with the legal manufacturer or supplier. The system is a component, not a standalone machine, and its performance depends on casting speed, section size, and other process conditions.

The system uses water-cooled copper molds for primary cooling, initiating a solid shell. Then, in secondary cooling zones, controlled water sprays extract heat, allowing progressive and uniform solidification of the core. Cooling water flow and temperature are regulated to maintain uniform cooling rates and prevent defects.