High-speed SBQ casting of blooms up to 500 mm dia at Nucor ... - IIM
High-speed SBQ casting of blooms up to 500 mm dia at Nucor ... - IIM
High-speed SBQ casting of blooms up to 500 mm dia at Nucor ... - IIM
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QuickTime e undecompressore Anim<strong>at</strong>sono necessari per visualizzaPARTNERS IN FRONT RUNNINGDANIELI INNOVACTION MEETING <strong>High</strong>est productivity + highest quality12 OCTOBER 2010DANIELI HEADQUARTERS – ITALY= Lower cost in Continuous CastingDRI, IRONMAKING,EAF STEELMAKING,CONTINUOUS CASTINGCarlo TRAVAGLINI, Danieli Centro MetNuredin KAPAJ, Danieli Corpor<strong>at</strong>ion
Su<strong>mm</strong>ary• Market trends and productspecializ<strong>at</strong>ion in long products• Fast Cast Cube (CMC Arizona) morethan 8 km-long billet cast and rolledin endless mode, <strong>up</strong> <strong>to</strong> 7.3 m/min(section 130 <strong>mm</strong> square)• Power mould technology for bigrounds (<strong>Nucor</strong> Memphis) - qualityand productivity <strong>to</strong>gether
Cast product market trendBeam BlankRoundsFlexBlooms > 220 <strong>mm</strong>Billet
Danieli caster references (strands since 2000)Billets562Beam blanks45Flexible (rounds & squares)39Blooms (> 220 <strong>mm</strong>) 68Rounds56
Cast product market trend
Danieli long his<strong>to</strong>ry in continuous<strong>casting</strong> <strong>of</strong> long productsSince 1960 more than1800 strands Since 1973 more than 1700co<strong>mm</strong>issioned by DanieliElectromagnetic StirringCentro Met for longSystem s<strong>up</strong>plied by Danieliproducts onlyRotelec
CMC (USA)130x130 <strong>mm</strong> <strong>up</strong> <strong>to</strong> 7.3 m/min (> 56 t/h).Start<strong>up</strong> 2009, equipped with FCC
Performance highlightsCMC Casting Speeds - August 2010r<strong>at</strong>ionHou urs <strong>of</strong> ope1209060304 4,4 4,8 5,4 5,8 6,2Casting <strong>speed</strong>, m/minute
FCC (Fast Cast Cube) design fe<strong>at</strong>ures• P<strong>at</strong>ended mould bearing-freesuspension system for s<strong>up</strong>eriorrigidity and Precise guiding• P<strong>at</strong>ended bearing-free CilinderfittingsMould cartridgeLow inertiaOscill<strong>at</strong>ing TableFixed Frame
FCC (Fast Cast Cube) technology fe<strong>at</strong>uresFCCConventional
FCC (Fast Cast Cube) design fe<strong>at</strong>ures• Fast, compact and maintenacefriendly seut-<strong>up</strong>•Maintenance a free moving partsUltra compact (1 m 3 )fixed frame andoscill<strong>at</strong>ing tableMould cartridge and footrolls with w<strong>at</strong>erquick-connectionsconnections
FCC (Fast Cast Cube) technology fe<strong>at</strong>ures• Extended mechanical limits forunprecedented oscilla<strong>to</strong>rperformances• 50% wider oscill<strong>at</strong>ion range withno l<strong>at</strong>eral devi<strong>at</strong>ions (
FCC (Fast Cast Cube) technology fe<strong>at</strong>ures• Reliable Sticking/breakoutprediction thanks <strong>to</strong> low inertiaoscilla<strong>to</strong>r.• Unique system for billet casters<strong>to</strong> ensure process reliability andtroubleshootingWarningLevelSafe levell
Power Mould for squaresDanieli p<strong>at</strong>ent - design• Very high copper rigidity• No permanent df deform<strong>at</strong>ions• Very efficient cooling• <strong>High</strong> and uniform he<strong>at</strong> transfer•No influence <strong>of</strong> random boiling• Optimized corner cooling• Improved taper design
Power Mould for squaresDanieli p<strong>at</strong>ent - technology• Ultra high-<strong>speed</strong> and productivity• Excellent quality for all steel grades• Easy and simple mould assembly• Consistent and reliable oper<strong>at</strong>ions• Long life <strong>of</strong> moulds
Strand productivity, <strong>casting</strong> <strong>speed</strong>vs. square sectionConventionaltechnologybenchmarkty, t/hourStrand productivitSquare section, <strong>mm</strong>
<strong>Nucor</strong> Memphis (USA)267R, 311R, 343R, 412R,511R, <strong>up</strong> <strong>to</strong> 1.8 m/min start<strong>up</strong>2008, equipped with PowerMouldKeep on running …
<strong>Nucor</strong> Memphis - <strong>to</strong>p performanceswith Power MouldTop productivity…With <strong>to</strong>p qualityDiametersSpeedDiametersProductivityParameterValue<strong>mm</strong>m/min<strong>mm</strong>t/hDiameter < 1.2 %267 1.83267 45Ovality < 1.5 %311 13 1.3311 46Cutting accuracy < 50 <strong>mm</strong>343 1.09343 46511 0.48511 48
<strong>Nucor</strong> Memphis (USA)Top performances with Power MouldMachine Section Section Sectionradius 380 450 <strong>500</strong>12.0 34 3314.0 36 40 4014.0 45 46 4716.5 43 43 45
Power Mould for RoundsDanieli P<strong>at</strong>ent - technology• Very high copper rigidity• No permanent deform<strong>at</strong>ions• Very efficient cooling• <strong>High</strong> and uniform he<strong>at</strong> transfer• No influence <strong>of</strong> random boiling• Optimized corner coooling• Improved taper design
Power Mould for RoundsDanieli P<strong>at</strong>ent• Thanks <strong>to</strong> Power Mouldfe<strong>at</strong>ures first solidific<strong>at</strong>ionfront is defect-free free andperfectly homogenous
ABS (Italy)160x200 <strong>up</strong> <strong>to</strong> 6.5 m/min(90 t/h), start<strong>up</strong> 2000,equipped with Power MouldKeep on running …
Sovel (Greece)140x140 <strong>up</strong> <strong>to</strong> 5.2 m/min(> 46 t/h)Tests since 2006Industrial production since2008Equipped with FCCTM
300,000000 t/y per strand square 130 <strong>mm</strong>
<strong>up</strong> <strong>to</strong> <strong>500</strong>,000000 t/y per strand square 160 <strong>mm</strong>
Unprecedented td <strong>casting</strong> <strong>speed</strong>s and productivitytiitth<strong>at</strong> rewrite the layout and technologicalconcepts <strong>of</strong> mini- and micro-mills, allowingdirect and efficient hot charging <strong>to</strong> thedownstream process.
FAST CAST Best in class forCAPEX and OPEX• Increased productivity per strand (t/h) +36%• Reduced number <strong>of</strong> strands -33%• Reduced utility requirements - 22%• Reduced refrac<strong>to</strong>ry consumptions -0.7 07 Euro/t• Increased process yield -0.45 Euro/t• Reduced power consumption -19 %
FAST CAST
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