High-speed SBQ casting of blooms up to 500 mm dia at Nucor ... - IIM

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High-speed SBQ casting of blooms up to 500 mm dia at Nucor ... - IIM

QuickTime e undecompressore Animatsono necessari per visualizzaPARTNERS IN FRONT RUNNINGDANIELI INNOVACTION MEETING Highest productivity + highest quality12 OCTOBER 2010DANIELI HEADQUARTERS – ITALY= Lower cost in Continuous CastingDRI, IRONMAKING,EAF STEELMAKING,CONTINUOUS CASTINGCarlo TRAVAGLINI, Danieli Centro MetNuredin KAPAJ, Danieli Corporation


Summary• Market trends and productspecialization in long products• Fast Cast Cube (CMC Arizona) morethan 8 km-long billet cast and rolledin endless mode, up to 7.3 m/min(section 130 mm square)• Power mould technology for bigrounds (Nucor Memphis) - qualityand productivity together


Cast product market trendBeam BlankRoundsFlexBlooms > 220 mmBillet


Danieli caster references (strands since 2000)Billets562Beam blanks45Flexible (rounds & squares)39Blooms (> 220 mm) 68Rounds56


Cast product market trend


Danieli long history in continuouscasting of long productsSince 1960 more than1800 strands Since 1973 more than 1700commissioned by DanieliElectromagnetic StirringCentro Met for longSystem supplied by Danieliproducts onlyRotelec


CMC (USA)130x130 mm up to 7.3 m/min (> 56 t/h).Startup 2009, equipped with FCC


Performance highlightsCMC Casting Speeds - August 2010rationHou urs of ope1209060304 4,4 4,8 5,4 5,8 6,2Casting speed, m/minute


FCC (Fast Cast Cube) design features• Patended mould bearing-freesuspension system for superiorrigidity and Precise guiding• Patended bearing-free CilinderfittingsMould cartridgeLow inertiaOscillating TableFixed Frame


FCC (Fast Cast Cube) technology featuresFCCConventional


FCC (Fast Cast Cube) design features• Fast, compact and maintenacefriendly seut-up•Maintenance a free moving partsUltra compact (1 m 3 )fixed frame andoscillating tableMould cartridge and footrolls with waterquick-connectionsconnections


FCC (Fast Cast Cube) technology features• Extended mechanical limits forunprecedented oscillatorperformances• 50% wider oscillation range withno lateral deviations (


FCC (Fast Cast Cube) technology features• Reliable Sticking/breakoutprediction thanks to low inertiaoscillator.• Unique system for billet castersto ensure process reliability andtroubleshootingWarningLevelSafe levell


Power Mould for squaresDanieli patent - design• Very high copper rigidity• No permanent df deformations• Very efficient cooling• High and uniform heat transfer•No influence of random boiling• Optimized corner cooling• Improved taper design


Power Mould for squaresDanieli patent - technology• Ultra high-speed and productivity• Excellent quality for all steel grades• Easy and simple mould assembly• Consistent and reliable operations• Long life of moulds


Strand productivity, casting speedvs. square sectionConventionaltechnologybenchmarkty, t/hourStrand productivitSquare section, mm


Nucor Memphis (USA)267R, 311R, 343R, 412R,511R, up to 1.8 m/min startup2008, equipped with PowerMouldKeep on running …


Nucor Memphis - top performanceswith Power MouldTop productivity…With top qualityDiametersSpeedDiametersProductivityParameterValuemmm/minmmt/hDiameter < 1.2 %267 1.83267 45Ovality < 1.5 %311 13 1.3311 46Cutting accuracy < 50 mm343 1.09343 46511 0.48511 48


Nucor Memphis (USA)Top performances with Power MouldMachine Section Section Sectionradius 380 450 50012.0 34 3314.0 36 40 4014.0 45 46 4716.5 43 43 45


Power Mould for RoundsDanieli Patent - technology• Very high copper rigidity• No permanent deformations• Very efficient cooling• High and uniform heat transfer• No influence of random boiling• Optimized corner coooling• Improved taper design


Power Mould for RoundsDanieli Patent• Thanks to Power Mouldfeatures first solidificationfront is defect-free free andperfectly homogenous


ABS (Italy)160x200 up to 6.5 m/min(90 t/h), startup 2000,equipped with Power MouldKeep on running …


Sovel (Greece)140x140 up to 5.2 m/min(> 46 t/h)Tests since 2006Industrial production since2008Equipped with FCCTM


300,000000 t/y per strand square 130 mm


up to 500,000000 t/y per strand square 160 mm


Unprecedented td casting speeds and productivitytiitthat rewrite the layout and technologicalconcepts of mini- and micro-mills, allowingdirect and efficient hot charging to thedownstream process.


FAST CAST Best in class forCAPEX and OPEX• Increased productivity per strand (t/h) +36%• Reduced number of strands -33%• Reduced utility requirements - 22%• Reduced refractory consumptions -0.7 07 Euro/t• Increased process yield -0.45 Euro/t• Reduced power consumption -19 %


FAST CAST

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