Caster Technology Consulting En
Transcript of 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.
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