Secondary Cooling System for Non-Ferrous Continuous Casting

Product Specifications

Technical details and manufacturing context for Secondary Cooling System

Definition

The Secondary Cooling System is a critical component of a Continuous Casting Machine for Non-Ferrous Metals. It is responsible for the controlled cooling of the metal strand after it exits the mold (primary cooling zone). This system manages the heat extraction rate to ensure proper solidification structure, prevent surface defects like cracks, and achieve the desired metallurgical properties in the final cast product. It typically operates on the solidified shell of the billet, bloom, or slab. The system consists of multiple cooling zones (sprays or chambers) arranged along the casting strand's path. A coolant (typically water, water-air mist, or a specialized fluid) is precisely sprayed onto the metal surface. The flow rate, pressure, spray pattern, and temperature of the coolant in each zone are automatically controlled based on casting speed, alloy type, and desired thermal profile. This extracts heat uniformly to complete solidification and control the temperature gradient, minimizing thermal stress. The system is designed for non-ferrous metals and includes components such as stainless steel nozzles and headers, carbon steel piping and framework, copper alloy spray nozzles, and polymer/composite spray headers and seals. Key parameters include cooling water flow rate (80–200 m³/h), water pressure (0.4–0.8 MPa), spray nozzle quantity (120–240 pcs), cooling zone length (3–6 m), billet temperature range (800–1100 °C), water temperature (20–35 °C), control accuracy (±2%), response time (≤1 s), electrical supply (380–480 V AC, IEC 60038), power consumption (15–45 kW), ingress protection (IP54–IP65, IEC 60529), noise level (≤85 dB(A), ISO 3744), weight (1500–3000 kg), and material grade (304/316, ASTM A240). These values are reference ranges and must be verified for the specific model and application. Always confirm model-specific values and standards with the legal manufacturer or supplier.

Working Principle

The system operates by spraying coolant onto the moving strand in multiple zones. Each zone has individually controlled flow rate, pressure, and spray pattern, adjusted automatically based on casting speed and alloy. The coolant extracts heat uniformly, completing solidification and controlling the temperature gradient to minimize thermal stress. The control system uses sensors and actuators to maintain precise cooling, with response time ≤1 s and control accuracy ±2%.

Common Materials

Stainless Steel (Nozzles, Headers), Carbon Steel (Piping, Framework), Copper Alloys (Spray Nozzles), Polymer/Composite (Spray Headers, Seals)

Technical Parameters

Parameter	Typical range	Notes & selection driver
Cooling Water Flow Rate	80–200 m³/h	Determines cooling intensity and billet surface temperature.
Water Pressure	0.4–0.8 MPa	Affects spray atomization and cooling uniformity.
Spray Nozzle Quantity	120–240 pcs	More nozzles improve cooling uniformity.
Cooling Zone Length	3–6 m	Longer zones allow gradual cooling.
Billet Temperature Range	800–1100 °C	Typical surface temperature after secondary cooling.
Water Temperature	20–35 °C	Higher temperatures reduce cooling efficiency.
Control Accuracy	±2 %	Precision of flow control for consistent cooling.
Response Time	≤1 s	Fast response to changes in casting speed.
Electrical Supply	380–480 V AC	Three-phase, 50/60 Hz.IEC 60038
Power Consumption	15–45 kW	Includes pumps and control system.
Ingress Protection	IP54–IP65	Protection against water and dust.IEC 60529
Noise Level	≤85 dB(A)	At 1 m distance.ISO 3744
Weight	1500–3000 kg	Depends on configuration and materials.
Material Grade	304/316	Stainless steel for corrosion resistance.ASTM A240

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Spray Nozzle Array
Distributes coolant uniformly over the metal strand surface in a specific pattern (flat fan, full cone).

Material: Stainless Steel, Copper Alloy
Cooling Water Header/Piping
Manifold system that supplies coolant from the main pump to the individual spray zones and nozzles.

Material: Carbon Steel, Stainless Steel
Flow Control Valves
Regulates the flow rate and pressure of coolant to each spray zone, often automated via PLC.

Material: Stainless Steel, Brass
Spray Chamber/Support Structure
Encloses the spray area, contains splashing, and provides structural support for nozzles and piping.

Material: Carbon Steel (frame), Stainless Steel (liners)
Control System and Sensors
Reads strand temperature and casting speed and sets each zone's water flow.

Manufacturers of Secondary Cooling System

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Frequently Asked Questions

What is the primary function of the secondary cooling system?

It controls the cooling rate of the metal strand after it leaves the mold, ensuring proper solidification and preventing defects.

What are typical operating parameters?

Water flow rate 80–200 m³/h, pressure 0.4–0.8 MPa, nozzle count 120–240, zone length 3–6 m, and billet temperature 800–1100 °C. These are reference ranges; confirm for your model.

Which materials are used in construction?

Stainless steel for nozzles and headers, carbon steel for piping and framework, copper alloys for spray nozzles, and polymer/composite for headers and seals.

What standards apply?

Electrical supply per IEC 60038, ingress protection per IEC 60529, noise per ISO 3744, and material grade per ASTM A240. Verify compliance with the manufacturer.

Data Basis

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Preliminary Technical Classification

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pressure:	Up to 10 bar (system operating pressure)
flow rate:	50-500 m³/h (coolant circulation capacity)
temperature:	20-80°C (coolant temperature range)
slurry concentration:	Up to 15% solids by weight (for slurry-based systems)

Secondary Cooling System

Product Specifications

Industrial Ecosystem & Supply Chain Structure

Application Fit & Sizing Matrix

Reliability & Engineering Risk Analysis

Compliance & Manufacturing Standards