Zirconia Metering Upper Nozzles

Zirconia Metering Upper Nozzles are high-performance refractory flow-control components used in the tundish of continuous casting systems.

Installed in the tundish steel-flow passage, the upper nozzle guides molten steel toward the downstream metering or exchangeable nozzle while its zirconia working section provides high resistance to molten-steel erosion and corrosion.

For steel producers, the purpose of a zirconia metering upper nozzle is not simply to withstand high temperature. The nozzle must maintain a stable internal bore, work reliably with the downstream nozzle and stopper system, and help maintain consistent molten-steel flow throughout the casting sequence.

Qingdao Dongye High Temperature Materials Co., Ltd. manufactures zirconia metering upper nozzles according to customer drawings, tundish design, casting conditions, and required dimensions.

What Is a Zirconia Metering Upper Nozzle?

A zirconia metering upper nozzle is a stationary refractory nozzle installed in the tundish of a continuous casting machine.

Its primary function is to provide a controlled passage for molten steel from the tundish toward the downstream nozzle system.

In a typical arrangement, the upper nozzle works together with a metering or exchangeable nozzle to control the steel flow into the mold.

The zirconia working area is positioned where resistance to molten steel, inclusions, and high-temperature corrosion is particularly important.

Research on zirconia metering nozzles confirms that these nozzles are installed at the bottom of the tundish and are exposed to the corrosive effects of liquid steel during continuous casting.

Why Zirconia Is Used in Metering Upper Nozzles

The working area of a tundish nozzle is continuously exposed to molten steel.

If the internal bore becomes excessively eroded or enlarged during casting, the actual steel flow rate can change. This may affect casting speed and the stability of the casting process.

Zirconia is therefore used in the working section of many metering nozzle designs because it can provide a refractory surface with strong resistance to high-temperature erosion and corrosion.

Commercial zirconia metering nozzle designs commonly use a zirconia working insert together with an outer refractory body, although the exact structure depends on the nozzle design and service conditions.

How a Zirconia Metering Upper Nozzle Works

A typical continuous casting flow path can be understood as:

Tundish → Zirconia Metering Upper Nozzle → Metering / Exchangeable Nozzle → SEN → Mold

The upper nozzle provides the stationary passage through which molten steel leaves the tundish.

The downstream metering nozzle controls the effective steel-flow opening.

The condition of the upper nozzle therefore directly affects the stability of the complete flow-control system.

A properly selected upper nozzle should maintain its internal geometry during service and provide reliable contact and alignment with the surrounding refractory components.

Key Performance Requirements

1. Stable Internal Bore

The internal bore is the most important working area of the nozzle.

If erosion gradually enlarges the bore, the steel-flow rate may increase even when the downstream control system remains unchanged.

Maintaining bore stability helps the casting system achieve more predictable flow behavior.

2. High Erosion Resistance

The inner surface is continuously exposed to flowing molten steel.

The refractory must therefore resist mechanical and chemical erosion during the casting sequence.

Zirconia working inserts are commonly used in metering nozzle applications because of their resistance to severe molten-steel service conditions.

3. Corrosion Resistance

The nozzle may also interact with inclusions and other aggressive components present in the molten steel.

Corrosion can change the surface and internal dimensions of the nozzle.

Studies of zirconia tundish metering nozzles have specifically identified corrosion and infiltration phenomena occurring in the hot-face region during steel casting.

4. Thermal Shock Resistance

The nozzle is exposed to a significant thermal transition when molten steel enters the tundish flow path.

The refractory structure must be capable of handling rapid temperature changes without unacceptable cracking or damage.

The exact material design should therefore be selected according to preheating practice, casting temperature, and operating conditions.

5. Dimensional Stability

Dimensional accuracy is especially important for a metering nozzle.

The bore diameter, overall dimensions, seating surface, and connection geometry must match the customer’s tundish and downstream nozzle system.

A small dimensional difference can affect installation, alignment, or flow-control performance.

6. Reliable Compatibility with the Nozzle System

The upper nozzle does not operate independently.

It works with:

· Tundish

· Stopper system

· Metering nozzle

· Exchangeable nozzle

· Submerged entry nozzle

· Mold

The interfaces between these components should therefore be considered when selecting the upper nozzle.

Zirconia Metering Upper Nozzle Structure

The exact structure depends on the customer’s equipment and casting requirements.

A typical zirconia metering upper nozzle may consist of:

· Zirconia working insert

· Refractory outer body

· Molten-steel flow bore

· Seating or connection area

· Customized external geometry

Some designs use a zirconia insert within an outer high-alumina refractory body. Other configurations may be supplied as a different composite or solid design depending on the application.

The appropriate structure should be confirmed according to the customer’s existing nozzle system.

Stationary Upper Nozzle vs. Exchangeable Metering Nozzle

These two components should not be confused.

Stationary Upper Nozzle

The stationary upper nozzle remains installed in the tundish and provides the upper section of the steel-flow passage.

It must be capable of maintaining stable performance throughout the required casting sequence.

Exchangeable or Lower Metering Nozzle

The exchangeable nozzle is positioned downstream and can be replaced through a nozzle-changing system in applicable casting installations.

Its opening is used to determine the effective steel-flow rate.

Industry product documentation similarly distinguishes stationary upper/inner nozzles from exchangeable lower/outer metering nozzles.

This distinction is important when ordering replacement products because the dimensions and operating requirements are different.

Applications

Billet Continuous Casting

Zirconia metering nozzle systems are widely used in continuous casting applications where stable control of molten-steel flow is required.

The exact upper-nozzle design should be matched to the caster and tundish configuration.

Bloom Continuous Casting

Bloom casting can involve demanding refractory service conditions.

The upper nozzle should be selected according to the steel grade, casting temperature, flow rate, tundish design, and required casting sequence.

Slab Continuous Casting

For slab casters, the upper nozzle forms part of the tundish-to-mold steel delivery system.

Its dimensional accuracy and resistance to erosion are important for maintaining stable steel flow.

Other Continuous Casting Systems

Customized zirconia metering upper nozzles can also be evaluated for other continuous casting configurations according to the actual equipment and operating conditions.

How to Choose the Right Zirconia Metering Upper Nozzle

Selecting a nozzle based only on diameter is not sufficient.

We recommend considering the following factors.

1. Caster Type

Please identify whether the nozzle is used for:

· Billet caster

· Bloom caster

· Slab caster

· Thin slab caster

· Other continuous casting equipment

2. Tundish Design

The upper nozzle must fit correctly into the tundish refractory system.

If possible, provide the tundish drawing or the original nozzle drawing.

3. Bore Diameter

The internal bore diameter is one of the most important dimensions because it directly affects the steel-flow passage.

Please provide the required bore size or the existing nozzle specification.

4. Casting Speed

The required steel-flow rate and casting speed should be considered when selecting the nozzle dimensions and structure.

5. Steel Grade

Different steel grades can present different refractory corrosion and inclusion conditions.

Please provide the main steel grades being cast so that the nozzle material can be evaluated appropriately.

6. Casting Temperature

Operating temperature is an important consideration for refractory selection.

The actual casting temperature and preheating conditions should be considered together.

7. Required Casting Sequence

If you are experiencing premature nozzle wear, please provide information about the required casting sequence and actual service condition.

This can help identify whether the problem is related to erosion, corrosion, thermal shock, or dimensional compatibility.

Common Problems with Metering Upper Nozzles

Bore Diameter Becomes Larger During Casting

Excessive bore enlargement can be caused by erosion or corrosion of the working refractory.

When the bore becomes larger, the molten-steel flow characteristics may change.

The refractory material, steel grade, casting temperature, flow rate, and casting sequence should be evaluated together.

Nozzle Cracking During Operation

Possible causes include:

· Thermal shock

· Improper preheating

· Installation stress

· Mechanical damage

· Unsuitable material selection

· Manufacturing defects

The actual cause should be identified before simply changing the nozzle material.

Unstable Casting Speed

Unstable flow may be related to the metering nozzle system, stopper position, bore condition, nozzle alignment, or process conditions.

The complete flow-control system should be checked.

Short Nozzle Service Life

Short service life can result from:

· Excessive molten-steel erosion

· Chemical corrosion

· Thermal shock

· Steel-grade compatibility issues

· Improper installation

· Incorrect nozzle selection

Providing actual operating information can help determine the most appropriate solution.

Customized Zirconia Metering Upper Nozzles

Continuous casting equipment varies between steel mills.

For this reason, we support customized zirconia metering upper nozzles according to confirmed customer requirements.

Customization can include:

· Overall dimensions

· Bore diameter

· Bore length

· Working-end geometry

· External dimensions

· Seating dimensions

· Zirconia insert design

· Outer refractory body

· Packaging requirements

For replacement orders, customers can provide an existing sample or drawing.

Our team can use the supplied information to confirm the dimensions before production.

Manufacturing and Quality Control

A metering upper nozzle is a precision refractory component.

Quality control should therefore cover both the refractory material and the dimensional accuracy of the finished product.

Our manufacturing and inspection process focuses on:

· Raw material control

· Material preparation

· Forming process

· Thermal processing

· Dimensional inspection

· Bore inspection

· Surface inspection

· Finished-product inspection

· Packaging protection

For customers with specific inspection requirements, quality standards or acceptance criteria can be confirmed before production.

Why Choose Dongye Zirconia Metering Upper Nozzles?

Continuous Casting Refractory Experience

Qingdao Dongye High Temperature Materials Co., Ltd. focuses on refractory products for continuous casting and high-temperature metallurgical applications.

Our product range includes:

· Tundish upper nozzles

· Zirconia metering nozzles

· Monoblock stoppers

· Submerged entry nozzles

· Ladle shrouds

· Other continuous casting refractories

Application-Based Product Selection

We consider the customer’s actual casting conditions instead of treating every metering nozzle as the same standard product.

Customized Manufacturing

Nozzles can be manufactured according to drawings, samples, equipment dimensions, and confirmed technical requirements.

Focus on Dimensional Consistency

Because bore dimensions and installation geometry are critical to nozzle performance, dimensional control is an important part of product inspection.

Support for International Customers

We can communicate technical drawings, product specifications, application conditions, packaging requirements, and export requirements with overseas customers.

FAQ

What is a zirconia metering upper nozzle?

It is a stationary refractory nozzle installed in the tundish of a continuous casting machine. It provides a molten-steel flow passage and works with downstream metering or exchangeable nozzles to control steel flow.

Why is zirconia used in the nozzle?

Zirconia is used in the working area because it provides high-temperature refractory performance and good resistance to molten-steel erosion and corrosion.

Is the upper nozzle the same as a quick-change nozzle?

No.

A stationary upper nozzle remains installed in the tundish, while an exchangeable or lower nozzle is designed to work with a nozzle-changing system where applicable.

Can you manufacture according to our drawing?

Yes.

We can evaluate drawings, samples, dimensions, and equipment information to confirm a customized product specification.

Can you supply the zirconia insert separately?

The supply form should be confirmed according to the customer’s nozzle design. Depending on the application, the product can be evaluated as a complete upper nozzle or as a zirconia working insert.

What information should I provide for a quotation?

Please provide:

· Nozzle drawing or sample

· Bore diameter

· Overall dimensions

· Caster type

· Steel grade

· Casting temperature

· Casting speed

· Required casting sequence

· Current nozzle problems

· Required quantity

This information helps us evaluate the correct product and prepare a more accurate quotation.

Request a Zirconia Metering Upper Nozzle

If you are looking for a zirconia metering upper nozzle supplier for continuous casting, send us your current nozzle drawing, sample, dimensions, or casting requirements.

Qingdao Dongye High Temperature Materials Co., Ltd. can evaluate the application and provide a customized zirconia metering upper nozzle according to your tundish and casting system.

Contact us for product specifications, customized manufacturing, and quotation.

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