The modernization of continuous steel casting at Železiarne Podbrezová took place from September 1 to October 10, 2013, and included the construction of a new third-generation casting line supplied by the Italian company Danieli & C. Officine Meccaniche.
The project involved the complete dismantling of the old equipment (350 tons of steel structure), nonstop installation works with up to 200 workers on site each day, and the assembly of a new multi-strand casting machine equipped with advanced technologies such as electromagnetic stirring of liquid steel and hydraulic mould oscillation.
The goal of the reconstruction was to improve the quality of cast steel billets, increase reliability, and upgrade the technological level of steel production.
00:00The joint stock company, Jeleziana Podbrezova, originally used traditional methods, casting liquid steel into ingots,
00:08which were subsequently re-rolled and processed into other products.
00:12In the 1960s, however, the company started using a new technology, namely the continuous casting of steel,
00:18for which the first vertical continuous casting machine was used.
00:22At this time, Jeleziana Podbrezova were one of just seven metallurgical companies in the world using this technology.
00:29Twenty years later, the original casting machine was shut down, and in 1982, a new four-lane radial casting machine was built.
00:38This machine was in service at Jeleziana Podbrezova for more than three decades.
00:43The renowned Italian company, Daniele, is the supplier of the latest casting machine, for which the delivery contract was signed in May 2012.
01:07After the technical preparation and processing of the project documentation at the Daniele company, in partnership with a major supplier,
01:16Jeleziana Podbrezova decided to construct and supply some of the components for the new casting machine themselves, at the factory here in Podbrezova.
01:25Among these components, which were produced in-house, were the water cooling management of the primary, secondary, tertiary and emergency circuit,
01:34the cooling towers, the sand filters, the pumps, the treatment of the casting stand,
01:40the tundish adjustment for a higher volume of liquid steel, the furnace for heating of the dip tubes,
01:46all the new support steel structures, the supply of copper inserts of the solidification mould,
01:52the secondary cooling nozzles, the transition conveyor and the deliveries of the distribution pipelines for hydraulics, cooling water and energy.
02:01All the associated dismantling, assembly and installation work was also performed by our team here at Jeleziana Podbrezova.
02:10The final cast on the old equipment was done on 31 August 2013.
02:15Over the next few days, the old continuous casting machinery was completely dismantled.
02:21The total weight of this equipment came to 350 tons.
02:25Between the 4th and 30th of September 2013, the assembly of the new machinery was carried out.
02:33Then, at the beginning of October, the cold tests of the individual technological stages took place.
02:39On the site, we were working 24 hours a day, 7 days a week.
02:43During this period of most intensive work, we had up to 200 people working there every day.
02:49We ran the first hot test on the 10th of October 2013, just 40 days after the old machine ceased production.
02:57Multi-point straightening of the new 3-lane facility from the Danielli Company has the base radius R1 equals 9 metres,
03:19Multi-point straightening breaks the force required to straighten the blooms into five modules of the drawing and straightening stand in one casting stream,
03:31thus reducing the risk of cracking during the straightening and ensures greater dimensional stability of the product.
03:38Installed electromagnetic stirring of molten steel in the solidification mould MEMS positively affects the cleanliness of steel in the meniscus region,
03:48removes non-metallic inclusions and gas bubbles, cleans the front of solidification mould and helps the formation of a quixiated crystal zone.
03:58A new feature is the hydraulic oscillation of the solidification mould.
04:02The hydraulic method of the oscillation table drive allows flexible and high precision setting of the oscillation parameters path,
04:10thus contributing to the high surface quality of cast blooms and longer lifetime of the solidification mould liners.
04:18The newly built air atomised secondary cooling is characterised by a higher cooling power regulation range,
04:25while ensuring a high uniformity of cooling.
04:28The result is a lower risk of reheating, respectively over cooling of the casting crust and thus the higher surface quality of cast blooms.
04:37The new information and management system with the embedded dynamic model of solidification of castings helps effectively analyse and manage processes of continuous casting.
04:50The dynamic model of solidification in real time calculates the temperature profile in a congealing material
04:57and thus provides information about important thermotechnological casting parameters.
05:03Continuous steel casting machines are a highly important part of the steel manufacturing process.
05:10Zeliziane Pogbrezova has chosen a highly reputable company to supply the machinery,
05:17which should ensure the highest quality casting of steel blooms for the foreseeable future.
05:23Let's do this!
05:28Oh yes..
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