First Seven-Strand Billet Caster from Siemens VAI in Operation at Dneprovsky Iron and Steel - Five Long-Product Caster Start-ups in Only Five Weeks

(PresseBox) ( Linz, Austria, )
The first seven-strand billet caster supplied by Siemens VAI was started up at the Ukrainian steel producer Dneprovsky Iron and Steel Integrated Works (DMKD). Also, within only five weeks four additional long-product casters were started up during the third quarter of 2008 in China, Germany, Italy and Saudi Arabia.

Dneprovsky Iron and Steel Integrated Works, located in Dniprodserschynsk, is a majority-ownership company of the Donbass Group. The company produces approximately 3.8 million tons of rolled steel products per year. The recently commissioned billet caster is part of an overall modernization campaign for which Siemens VAI also supplied a 250-ton ladle furnace in addition to an identical billet caster, which will be installed and commissioned at a later date. The installation of these new plants will enable DMKD to produce a wide range of steel qualities in an improved and more uniform quality.

The billet caster is capable of producing 1.7 million tons of carbon and low-alloyed steel grades per year for structural and tube-steel applications. Square billets are cast in sections between 130 and 200 millimeters. A wide range of technological packages are installed, including LevCon for the control of the steel level in the mold, DynaFlex hydraulic oscillation, Diamold high-speed mold tubes as well as a Level 2 process-optimization system with computer-aided quality assurance.

At Saudi Iron & Steel Company (Hadeed) the 6-strand Billet Casting Machine No. 3 was upgraded. New DynaFlex oscillators for the online adjustment of the mold-oscillation parameters as well as the installation of a high-pressure secondary-cooling system were installed. With the completion of this project, all 18 strands in the Steel Melt Shop No. 1 of Hadeed were modernized by Siemens VAI. The equipment was assembled and thoroughly tested prior to delivery. According to Boris Zagorodnov, project manager, "Without pre-assembly and pre-adjusting work in the workshops, a caster shut-down period of only two weeks would have not have been possible for the equipment installation and restart of the machine. The Provisional Acceptance Certificate (PAC) was issued within two days following the plant start-up of the plant."

At Georgsmarienhütte GmbH in Germany Siemens VAI supplied and installed equipment for the casting of 240-millimeter-square blooms in a 6-strand bloom caster. The scope of supply included new molds, a new secondary-cooling system in addition to new straightener cylinders. The PAC was also received within two days after the restart of the caster.

A 3-strand bloom caster, designed with the option for an extension to five strands, was started up by Siemens VAI at the Steel Plant No. 1 of Nanjing Iron & Steel United Co., Ltd (NISCO), a Chinese steel producer with an annual production capacity of approximately 6.5 million tons. A highlight of this project was the installation of DynaGap Soft Reduction which reduces centerline segregation and center porosity thus enabling steel to be cast with a highly uniform internal strand quality for the most demanding downstream applications. DynaGap Soft Reduction, supported by Level 2 process optimization, was successfully applied beginning with the first casting sequence.

A 6-strand billet caster with a casting radius of 8.1 meters was upgraded by Siemens VAI at Riva Acciaio SpA in Lesegno, Italy to increase the production output and improve product quality. The project scope included new tundishes, Diamold high-speed mold tubes with electro-magnetic stirrers (EMS) in addition to a new secondary-cooling system.

Siemens VAI is a leading supplier of continuous casting technology. During the last two decades, the company implemented 161 caster projects in the long-product sector worldwide. These projects comprised 64 new and 97 upgraded casters with a total of 715 strands. During this time specialized applications and technological packages were developed and optimized to significantly enhance caster performance and product quality. With the application of "Connect & Cast" solutions as well as the preassembly and testing of caster equipment and components in the workshop, projects can be executed and plants started up within extremely short time periods. The accumulated expertise and project experience of Siemens VAI enable numerous caster projects to be executed simultaneously.

Further information about solutions for steel works, rolling mills and processing lines is available at

DynaFlex, Diamold and DynaFlex Soft Reduction are registered trademarks of Siemens AG in certain countries.
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