Spray Nozzles

for Secondary Cooling in

Continuous Casting Machines
Lechler - Advanced Spray Technology
Based on 125 Years Experience

Today’s steel producers have

to operate in a tougher en-
vironment than ever before,
caused by:

■ Customer demand for

improved quality

■ Constant pressure on costs

■ Fluctuating demand

■ Tighter pollution controls

Pioneers in harnessing
spray technology to steel
production

Nozzles and spray systems

are used in virtually every
stage of steel production and
their performance can have a to shape control in cold rolling teed. This applies to every one
major impact on product quali- mills and descaling, Lechler of the 20,000 plus nozzle vari-
ty and manufacturing costs. has a proven solution. ants in our product portfolio,
For over 125 years, Lechler which differ by size, material
has pioneered developments Lechler - synonymous with and spray characteristics.
in spray technology for all quality
stages of primary metals pro- Serving steel producers
duction, designing, developing The Lechler policy of conti- worldwide
and manufacturing products nuous improvement and meti-
of outstanding reliability and culous inspection is evidence Lechler is a truly international
performance. All accompa- of our commitment to whole company, offering sales and
nied by expert advice based life quality. From development, technical support to the metals
on a thorough knowledge of through manufacture to instal- industry worldwide. In addition
the industry, providing both lation, Lechler products are to over 500 employees at our
conventional and innovative subject to continuous quality Metzingen headquarters in
solutions. management. State of the art Germany, affiliated companies
Today, Lechler offers the most test and inspection methods, have plant and offices in the
comprehensive range of nozz- often in excess of our ISO USA, the UK, India, China,
les and spray systems for iron, 9001 certification, guarantee France, Belgium, Sweden,
steel and non-ferrous metals the durability, reliability and Finland and Hungary. We also
producers. From secondary longevity of Lechler spray have a network of sales offices
cooling for continuous casting nozzles and systems. and representation covering
many other countries.
Automated production for
consistent performance

Many of Lechler’s automated

manufacturing processes
have been custom developed
to guarantee not only opti-
mum productivity, but also
consistency of product para-
meters to exacting tolerances.
Not only does every nozzle
look like another of its type,
but their spray characteristics
will also be identical - guaran-

2
Efficient Secondary Cooling -
a Prerequisite for Optimising
Steel Quality

Spray Cooling Methods For these reasons, airmist dependant on slab size and In zones further down the
cooling is the favoured spray height - a single spray strand, a single flat jet nozzle
In Continuous Casting the method for modern slab nozzle, a pair of nozzles or a can be installed in each roller
secondary cooling system has casting. series of nozzles are installed gap. To cover the slab width,
an important influence on the between the support rollers it is recommended that wide
quality of the cast products. Heat transfer considerations covering the full width of the angle flat jet nozzles with 120°
Two different spray cooling slab. The arrangement is desi- up to 140° spray angles, or
methods are possible: Careful evaluation of data gned to ensure a uniform even with rectangular spray
1. Conventional cooling, via obtained by measurements liquid distribution across the patterns, are specified.
single fluid nozzles using only has confirmed that heat trans- slab width throughout all ope- Choice can be made from
water. fer depends on two major fac- rating conditions. series 100 Twinorifice Block,
2. Airmist cooling via ‘twin tors - the density of the spray- Mastercooler or Slabcooler
fluid’ nozzles using compres- ed water and its kinetic Foot roller installations nozzle types.
sed air and water. energy.
For installations in the narrow More common in modern
Whilst single fluid nozzle The degree to which one or gap between the mould and casting plants is a multi-nozzle
systems are less expensive to the other factor dominates foot rollers, an array of single arrangement of airmist nozzles
install and run, consuming depends on the nozzle design fluid flat jet nozzles( Lechler in every gap, providing very
less energy, twin fluid systems and operating conditions. This series 660, 664 or 665) is uniform liquid distribution
have three significant advanta- is due to a condition called often used. These are speci- across the full width of the
ges in continuous casting, the Leidenfrost Phenomenon, fied due to their narrow spray slab from minimum to maxi-
which outweigh initial and run- in which a steam/vapour layer pattern, but oval cone nozzles mum water flows. This arran-
ning costs: prevents the sprayed water (Lechler series 400) can also gement also facilitates edge
making direct contact with the be used. control by allowing the outer
■ Wider water control range, target surface. nozzles to be switched on and
typically from a ratio of 1:5 Bending and straightening off.
up to 1:25. However, when water droplets installations
with a high kinetic energy Mastercooler and Slabcooler
■ Higher Heat Transfer Coeffi- break through this vapour For these applications, stan- nozzles are designed to provi-
cient values at identical layer, the heat transfer coeffi- dard single fluid flat jet nozzles de such extremely uniform
nozzle flow rates. cient is significantly increased, and 148 series Block nozzles spray patterns.
with consequent higher cool- are generally installed with a
■ Larger water and air bores, ing efficiency. large overlap, due to their
which virtually eliminate The configuration of nozzles is parabolic liquid distribution.
nozzle clogging. This aids uniform liquid distri-
bution across the slab width
throughout the turndown ratio
range (minimum to maximum
water flow/pressure). It also
contributes to safety as, if a
nozzle clogs, the two adjoining
nozzles will cool its target
area, preventing that section of
the slab surface from recei-
ving no cooling at all.

3
Choose the Right Nozzle
for Your Application

Twin Fluid Nozzles

.
Product Slab Thin Slab Bloom Billet Beam-Blank Round

Spray
pattern

✘ ✘ ✘ ✘ ✘ ✘

_ _ ✘ ✘ ✘ _

✘ _ _ _ _ _

_ _ ✘ ✘ _ _

Single Fluid Nozzles

✘ ✘ ✘ ✘ ✘ ✘

✘ ✘ ✘ ✘ ✘ _

_ ✘ ✘ ✘ _ _

_ ✘ ✘ ✘ _ _

✘ _ ✘ ✘ _ _

4
Twin Fluid Nozzles

.
. VWater [l/min] and Material Connection Advantages/
Spray angle

Nozzle size from – up to

Turn down ratio

at 2 bar air (1 bar/7 bar water)

Applications
Product no.
Spray characteristics/
water distribution

VAir [Nm3/hr] at 2 bar air (acc. to size) Features

constant

Air

Brass, nickel plated

1 bar 2 bar 7 bar Water
Example of
Water Water Water
nozzle type

303 SS
Water

Water

Water

Brass
Air

Air

Air

min. 1,5 28 5,5 23,5 16 13

3
/8 NPT 3/8 NPT
1:10 3
100.XXX 150° X X /8 BSPP 3/8 BSPP Slab
1:20
Console Console

Flat jet/ max. 1,8 60 13,5 40 42 20

parabolic ■ Finest droplet
spectrum

■ Wide turn
down ratio of
flow rate
min. 0,45 14 2,0 10 6,5 4
■ Large, free
30° cross sections
Billet,
138.XXX 60° 1:15 X X Console Console
Bloom ■ Strong flow
90°
impuls

Full cone/ max. 0,95 25,2 4,2 18 13,6 7,2 ■ Quick and
circular easy cleaning

■ Patented
mixing insert

■ Self aligning
min. 0,5 19 1,6 18 4 16,5 tip
30°
60° 1
/4 NPT 3/8 NPT Billet,
148.XXX 90° 1:35 X X /4 BSPP 3/8 BSPP Bloom,
1

120° Console Console Slab

140°
Flat jet/ max. 0,95 70 8,5 50 28 28
parabolic

■ High HTC
values
min. 0,7 3,8 1,7 3,2 5 1,4 ■ Stable spray
90° angle at all
124.XXX 130° Slab, pressures
1:7 X X X Console Console Thin and flows
128.XXX or
to suit (Tip) slab
■ Uniform water
max. 16 41 29 37 65 26 distribution
Flat jet/
even ■ Nozzle lenght
to suit

Subject to technical modifications.

5
Twin Fluid Nozzles

.
. VWater [l/min] and Material Connection Advantages/
Spray angle

Turn down ratio

at 2 bar air (1 bar/7 bar water)

Applications
Product no.
Spray characteristics/
water distribution

Nozzle size from – up to

VAir [Nm3/hr] at 2 bar air (acc. to size) Features
constant

Brass, nickel plated

1 bar 2 bar 7 bar Water Air
Example of
Water Water Water
nozzle type

303 SS
Water

Water

Water

Brass
Air

Air

Air ■ High HTC

values
■ Stable spray
80° min. 2,25 9,8 3,6 9,5 8,6 6,8 angle at all
pressures
90° and flows
Billet,
100° ■ Uniform water
1:5 3
/8 BSPP 3/8 BSPP Bloom, distribution
184.XXX 120° X X X 1
(1:8*) /2 BSPP /2 BSPP Slab, ■ Nozzle lenght
1
130° (Tip) to suit
thin
or to Other features
slab possible:
Flat jet/ suit max. 8 60 18 55 50 23,5
– 2 piece pipe
even – Bent pipe
– Oval spray

■ High HTC
values
■ Stable spray
80° min. 2,25 9,8 3,6 9,5 8,6 6,8 angle at all
90° Billet, pressures
and flows
100° Bloom, ■ Uniform water
1:5
186.XXX 120° X X X Console Console Slab, distribution
(1:8*)
130° (Tip) Thin ■ Nozzle lenght
to suit
or to slab Other features
Flat jet/ suit max. 8 60 18 55 50 23,5 possible:
even – 2 piece pipe
– Bent pipe
– Oval spray

* In case of variable air pressure Subject to technical modifications.

6
Single Fluid Nozzles

.
VWater [l/min] min/max Material Connection Applications Advantages/
Spray angle

Turn down ratio

(1 bar/7 bar water)
Product no.
Spray characteristics/
water distribution

(acc. to size) Features

at p [bar]

Brass, nickel plated

Example of
nozzle type

303 SS
Brass
2,0
1,0

7,0

min. 0,71 1,00 1,87

60° Dovetail
660.XXX 90° 1:2,65 X X – Retaining nut
3
120° /8 BSPP

Flat jet/ max. 7,07 10,0 18,71

parabolic
Slab, Bloom:
footroller area,
first segments

60°
652.XXX 90° min. 0,71 1,00 1,87 1:2,65 X X – Retaining nut
3
120° /8 BSPP

Flat jet/
parabolic ■ Compact,
defined
spray pattern

■ High energy
spray jet
min. 4,45 6,3 11,79

60° Dovetail
664.XXX 90° 1:2,65 X – – Retaining nut
3
120° /4 BSPP
Flat jet/
rectangu- max. 28,28 40,00 74,83
lar, even
Slab, Bloom:
single nozzle
arrangement

min. 4,45 6,3 11,79

60°
Retaining nut
656.XXX 90° 1:2,65 X – – 3
/4 BSPP
120°
Flat jet/
rectangu- max. 28,28 40,00 74,83
lar, even

Subject to technical modifications.

7
Single Fluid Nozzles

.
VWater [l/min] min/max Material Connection Applications Advantages/
Spray angle

Turn down ratio

(1 bar/7 bar water)
Product no.
Spray characteristics/
water distribution

(acc. to size) Features

at p [bar]

Brass, nickel plated

Example of
nozzle type

303 SS
Brass
2,0
1,0

7,0

min. 0,76 1,0 1,65

Billet, Bloom
45° 1
(Rounds):
1: 2,2 /8 BSPT
60° 1
as well as ■ Stable
460.XXX up to X X – /4 BSPT
90° 3
Slabcaster for spray angle
1: 2,5 /8 BSPT
120° narrow side or
footroller area
Full cone/ max. 7,58 10,0 16,51
circular,
even

min. 0,76 1,0 1,65 Billet, Bloom

45° (Rounds):
1: 2,2
468.XXX 60° Retaining nut as well as ■ Stable
up to X X –
SZU 90° 3
/8 BSPT Slabcaster for spray angle
1: 2,5
120° narrow side or
Full cone/ footroller area
max. 7,58 10,0 16,51
circular,
even

min. 1,36 1,8 2,97

468.XXX Retaining nut Thin slab, Slab ■ Stable

90° 1: 2,2 X – –
SZUQ 3
/8 BSPT (footroller area) spray angle

Full cone/ max. 7,58 10,0 16,51

square,
even

min. 0,95 1,25 2,06

1
60° /4 BSPT
75° 3
/8 BSPT Thin slab, Slab ■ Stable
464.XXX 1: 2,2 X X X
85° 1
/8 NPT (footroller area) spray angle
1
115° /4 NPT

Full cone/ max. 7,58 10,0 16,51

square,
even

Subject to technical modifications.

8
Single Fluid Nozzles

.
VWater [l/min] min/max Material Connection Applications Advantages/
Spray angle

Turn down ratio

(1 bar/7 bar water)
Product no.
Spray characteristics/
water distribution

(acc. to size) Features

at p [bar]

Brass, nickel plated

Example of
nozzle type

303 SS
Brass
2,0
1,0

7,0

min. 0,71 1,0 1,87

■ Large free
60° 1
cross
/4 BSPT Billet, Bloom
422.XXX 90° 1: 2,6 X – X 3
sections,
/8 BSPT (Rounds):
120° nonclogging
sensitive
Full cone/ max. 11,31 16,0 29,9
circular,
even

min. 3,37 4,45 7,34

1 Thin slab, Slab

/8 BSPT
400.XXX 90° 1: 2,2 X – – 1
/4 BSPT (e.g. footroller ■ Stable spray
1
/8 BSPT area) angle

Full cone/ max. 5,1 6,85 11,31

oval,
even

min. 1,5 2,1 3,95

45°
50° Billet casters
1 ■ Stable spray
486.XXX 65° 1: 2,6 X – – /4 BSPT inner
3 from
80° /8 BSPT inner angle
CONCAST
90°
Full cone/ max. 9,85 14 26,1
circular,
even

Subject to technical modifications.

9
Improved Performance Measurement
Optimises Nozzle Design

The basis for optimising the

design of nozzles is the ability
to accurately and precisely Liquid Distribution
LIQUID DISTRIBUTIONSingle Nozzle NOZZLE
SINGLE (Example)
(Example)
measure and analyse perfor- Pro.-No.: 124.688.35.33.00.0
mance. Lechler has developed Date: 20.03.95

its own techniques to produce Liquid Pressure:

Liquid Flow rate:
2,00 bar
4,60 l/min
Nozzle Height:
Spray Width:
80 mm
368 m
reliable data on volume, dro- Air Pressure: 2,00 bar Mes. Point Dist.: 16 m
plet size, liquid distribution Air Flow Rate: 7,30 m3/h i.N.

and heat transfer. Such data is

then applied in the develop- Remark:
ment, design and manufacture
of nozzles to optimise their
performance.
Every nozzle comes with com-
plete documentation detailing
its performance characteri-
1
stics, typically including:

■ Water/air flow diagram

■ Water flow diagram
■ Spray width diagram 0 0,45 1,05 1,02 1,02 1,07 1,15 1,06 1,13 1,09 1,04 1,11 0,91

■ Liquid distribution diagram 0,73 1,09 1,02 1,01 1,11 1,07 1,08 1,11 1,04 1,05 1,07 0,50

■ Heat Transfer Coefficient Comparative Value to Mean Value

diagram (on special

request)

Pressure-Flowrate-Diagram (Example) Spray Width Diagram (Example)

p = 1.00 bar
p = 2.00 bar
p = 4.00 bar
p = 7.00 bar

10
Heat Transfer Coefficient Measurement

When designing cooling The HTC fluctuates as the

systems for Continuous nozzle moves over the thermo-
Casting plants, engineers couple, with maximum HTC,
need to know the heat transfer signified by the peak values,
coefficient to determine the occurring when water directly
specific nozzle arrangement, impinges on its position.
taking into account the surface
conditions of the metal to be
cooled.

The heat transfer can be

affected by the Leidenfrost
Phenomenon, which results
when, due to the high surface
temperatures, the water eva-
porates so intensely that a film
of steam completely covers
the surface, preventing the
coolant reaching the hot metal.
The objective is to simulate
The measurement of the heat spray cooling of a moving
transfer coefficient (HTC) has steel strand.
to cover the full range of surfa- The spray is restricted by two
ce temperatures that can cylindrical shapes represen-
occur in spray cooling proces- ting the rolls used in conti-
ses in the metals industry. nuous casting. Both the nozzle
and ‘cylinders’ are installed in
Lechler measure the HTC by a moveable bed, enabling
means of the ‘Moving Nozzle them to be moved parallel
Test’, in which a steel plate is with, and longitudinally to, the
heated to 1200°C in inert gas plate.
and then cooled down to the
temperature of the sprayed When the desired temperature
water. has been reached, the com-
puterised control retracts the
deflector and starts the quen-
ching by switching on the
nozzle motor. This moves the
nozzle from left to right with
the deflector open and rever-
ses with the deflector closed.

The plate measures

600 x 320 mm with a thick-
ness of 24 mm, and 24 ther-
mocouples are uniformly
positioned 3 mm below the
quenched surface to measure
temperatures.
By continuously recording the
data from these thermocou-
ples a complete distribution of
heat transfer rates can be
computed.
A typical result is shown
below, where the surface tem-
perature from one thermo-
couple has been recorded.

11
 Lechler GmbH
Precision Nozzles · Nozzle Systems
P.O. Box 13 23
72544 Metzingen / Germany
Phone: +49 (0) 71 23 962-0
Fax: +49 (0) 71 23 962-333

E-Mail: [email protected]
Internet: www.lechler.de

World Headquarters
Lechler Companies
Sales Offices

Edition 04/04 · GB · 1000 · LEC04114 · www.walliser-partner.de · M · S · Subject to technical modifications

Belgium: Lechler S.A./N.V. · Avenue Mercatorlaan, 6 · 1300 Wavre · Phone: (10) 225022 · Fax: (10) 243901 · [email protected]
China: Lechler Intl. Trad. Co., Ltd. · Beijing Office · Rm.1305 CTS Plaza · No.2 Bei San Huan Dong Lu · Phone: (86) 1064661986, Fax: (86) 1064660196 · [email protected]
Finland: Lechler Oy · Kalliotie 2 · 04360 Tuusula · Phone: (358) 98709844 · Fax: (358) 98709847 · [email protected]
France: Lechler France, S.A. · Immeuble CAP2 C51 · 66-72, Rue Marceau · 93558 Montreuil · Phone: (1) 49882600 · Fax: (1) 49882609 · [email protected]
Great Britain: Lechler Ltd. · 1 Fell Street, Newhall · Sheffield, S9 2TP · Phone: (0114) 2492020 · Fax: (0114) 2493600 · [email protected]
India: Lechler (India) Pvt. Ltd. · Plot # A-109 · Road # 18 · Wagle Industrial Estate · Thane-400 604 · Phone: (22) 25811196 · Fax: (22) 25821262 · [email protected]
Sweden: Lechler AB · Box 158 · 68324 Hagfors · Phone: (46) 56325570 · Fax: (46) 56325571 · [email protected]
Spain: Lechler S.A. · Avda. Pirineos 7 · Oficina B7, Edificio Inbisa I · 28700 San Sebastián de los Reyes, Madrid · Phone: (34) 916586346 · Fax: (34) 916586347 · [email protected]
USA: Lechler Inc. · 445 Kautz Road · St. Charles, IL. 60174 · Phone: (630) 377-6611 · Fax: (630) 377-6657 · [email protected]