Caster Technology Consulting En

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www.siemens-vai.com

Metals Technologies

Caster TechnologyConsultingExpert assistance for improved performance in continuous casting


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Caster Technology ConsultingIn pursuit of excellence

Your challenge:

Because quality and productivity requirements in

continuous casting are continually increasing, producers

must respond and adapt in order to remain competitive.

Rapidly changing market demands call or lexible plants

that can be quickly adjusted with a minimum in

production downtime. Sometimes producers incur

additional costs because they are conronted with qualityproblems that can result in downgraded and even rejected

products. In other cases, equipment deiciencies may

result in unexpected caster standstills and additional

maintenance costs. The objective is to ensure permanent

production excellence on a cost-eective basis. Expert

advice rom a highly experienced supplier o casting

technology is what is required to maximize the

perormance o your plant.

Our solution:

Siemens VAI, a leading supplier o continuous casting

technology, oers expert consulting services that help

producers to achieve and maintain high standards in

production excellence. On the basis o decades o

experience in the engineering, installation, start-up and

commissioning o continuous casting machines

worldwide, our specialists are skilled in identiying casterdeiciencies and weak spots. Detailed concepts are

proposed or improving plant perormance, reliability,

lexibility and saety. Our expertise is available on short

notice and covers all aspects o continuous casting

technology or billet, bloom, beam-blank and slab casters

rom any supplier. Using our proposed improvement

solutions helps producers to better meet their production,

quality and business targets as well as to save money.

Discover why - Siemens VAI.

Our competencies or every job

Caster

TechnologyConsulting

Quality

Simulation

Component design

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Advantages of Caster

Technology Consulting:

Immediate support

ast proposal o solution concept

More than 50 references

that also include non-Siemens VAI-

supplied continuous casting plants

Comprehensive technological

training or qualiied personnel

Major improvements

in productivity, process stability,

product quality and yield

Expert advice pays off

proven ast return on investment

(ROI)

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Process steps or Caster Technology Consulting

Presentation of results

and proposoals

Implementation

Elaboration of study

Caster fitness check

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Caster fitness check

This itness check is comprised o two

modules: An online questionnaire is irst

completed by the customer in advance o

a visit. Thats ollowed by a thoroughon-site evaluation o the plant by

Siemens VAI experts. Weak spots are

identiied in the casting process in

addition to the installed equipment and

systems.

Elaboration of study and presentation

of results and proposoals

Plans or a detailed investigation are

discussed with the customer and areas o

deiciency are addressed with proposals

or solutions as well as a presentation o

the expected costs and beneits.

First step: online questionnaire Second step: on-site inspection

Caster Technology ConsultingGet in shape to excel in the market

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Additional support can be provided by

external laboratories and universities

with which we have a long-term working

relationship. This way quality-related

inluences are identiied. Improvement

recommendations are then made with

respect to, or example, optimization o

the casting process, use o alternative

consumables (e.g., casting powder,

reractories), modiications to the

automation system and the related

training or operators and metallurgists.

acquire a deeper insight into the steel-

solidiication process. The additional

expertise provides the basis or superior

equipment design and casting

operations. The applied simulation

techniques include FEM (inite element

method) and CFD (computational luiddynamics).

machine availability. That way, when itcomes to new steel grades and product

dimensions, we can help you meet the

increasing market demands. The

installation o long-lietime components

will also signiicantly reduce maintenance

expeditures. Solutions and services can

be implemented in casters o any size, o

any type and rom any supplier.

Quality

Simulation

Component design

The basis for casting excellence

When a customer is aced with quality-

related problems, experts rom

Siemens VAI are available or support.

Investigations begin with a

comprehensive evaluation o all actors

that have a potential eect on product

quality. This begins with steelmaking,

and includes the entire continuous

casting process. Statistical evaluations as

well as detailed metallographic deect

analyses are carried out on-site.

The tools to see inside the strand

To optimize the casting process and to

achieve a high level o product quality

within the shortest possible time,

simulation techniques were developed by

Siemens VAI in the late 1970s. Thanks to

the enormously expanded computercapacity and improved sotware

algorithms, our technologists can

simulate even complex processes and

conditions in real time. Advanced

simulation models make it possible to

Profit from our experienceThe highest machine perormance,

lexibility and reliability is only achieved

when the installed equipment,

components and systems are thoroughly

designed and ully integrated with each

other. When our experts make a itness

check o your machine, we identiy the

weakest links in the process chain, and

propose quick and eective replacement

solutions. We can oer special

components or develop them to enhance

Good advice is well worth the price

Scope of consulting capability

Caster Technology Consulting

rom Siemens VAI stands orexpertise in quality

improvement, numerical

simulation and special

component design. In order to

provide the ideal solution to

meet the speciic requirements

o each producer, we can call

on our disposal caster experts

and access our comprehensive

metallurgical and operational

database. By taking even small

steps towards a solution, you

can achieve dramatic

improvements in cost-eective

and reliable production.

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Metallurgical investigations

Optimization o casting parameters

Recommendations or secondary metallurgy

Metallographic sample analyses

Chemical analyses o ladle and mold slag

Surface-quality optimization

Advanced mold-plate design and adjustment

Optimized SEN design

Precise mold-level control

Selection o optimum mold powder

Check o secondary cooling

On-site plant analysis and optimization Improvement o operational reliability

Fine-tuning o casting parameters

Maintenance recommendations

Customized engineering solutions

Advanced mold-plate cooling-slot design

Solutions or higher uptime

Improved strand-guide concepts

New bender design to prevent scale build-up

Improved straightener geometry

Water treatment considerations

Automation setup optimization

Modiications to produce new steel grades

Adjustments to individual casting situations

Technological training

Strand solidiication in mold

Secondary cooling requirements

Casting control

Slab deects

Internal quality improvements

Steel temperature

Steel composition

Settings or DynaGap SotReduction Electromagnetic stirring (EMS)

Equipment failure analysis Metallographic investigations o ailure parts

Reduction o breakouts with improved oscillator

accuracy

Stabilization o mold level with improvements o

BB caster pinch rollers

Laboratory spray-nozzle testing

Arrangement and checking o cooling nozzles,

including water-spray pattern in modern testing

acilities

Equipment check

Checking o mold-level control, oscillator and

strand-guide system, etc.

Computational Fluid Dynamics

Simulation o steel low in tundish

Simulation o steel low in mold

Thermomechanical simulation

Secondary cooling strategy

Strand mechanics

Liquid-core reduction, sot reduction, hardreduction

Adaption o casting speed

Equipment quality simulation

Load calculations (segments, rollers, etc.)

Mold temperature distribution and taper

Thermodynamic simulation

Phase transormation

Material parameters to produce new steel

grades

Experimental simulation

Water models or tundish and mold

Spray nozzles

Slab quality improvement

CFD Simulation o tundish low

Check o spray nozzle

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Headquarters:

Siemens VAI

Metals Technologies GmbH

P.O. Box 4, Turmstrasse 44

4031 Linz, Austria

Phone: +43 732 6592-6682

E-mail: [email protected]

www.siemens-vai.com

Order No. E10001-M3-A60-V2-7600

Dispo No.: 21661 K-No.: 28103 | Printed in Austria

SPS SVAI-11-00509 PA 12111. | 12.2011, Siemens AG

The inormation provided in this brochure contains merely generaldescriptions or characteristics o perormance which in actual case o

use do not always apply as described or which may change as a result

o urther development o the products. An obligation to provide the

respective characteristics shall only exist i expressly agreed in the

terms o contract.

All rights reserved. Subject to change without prior notice.

SIMETAL is a trademark o Siemens AG.

Through the voluntary acquisitiono emission reduction certifcates thisprint product actively contributes toenvironmental protection.

Ident-Nr. A-10556

Caster Technology Consulting En

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