CTC CASTER TECHNOLOGYCONSULTING
EXPERT ASSISTANCE FOR IMPROVEDPERFORMANCE

primetals.com

CASTER TECHNOLOGY CONSULTING
IN PURSUIT OF EXCELLENCEADVANTAGES OF CASTERTECHNOLOGY CONSULTING:• Immediate support –fast proposal of solution
concept• More than 230 references –including non-Primetals
Technologies supplied
continuous casting plants• Comprehensive technologicaltraining –for qualified personnel

YOUR CHALLENGEOUR SOLUTION

Because quality and productivity
requirements in continuous casting
are continually increasing, producers
must respond and adapt in order toremain competitive. Rapidly changing
market demands call for flexible
plants that can be quickly adjustedwith a minimum in production
downtime. Sometimes producers
incur additional costs because they
are confronted with quality problems
that can result in downgraded andeven rejected products. In other cases,
equipment deficiencies may resultin unexpected caster standstills andadditional maintenance costs. The
objective is to ensure permanent
production excellence on a costeffective basis. Expert advice from ahighly experienced supplier of casting
technology is what is required tomaximize the performance of yourplant.

Primetals Technologies, a leading
supplier of continuous casting
technology, offers expert consulting
services that help producers toachieve and maintain high standards
in production excellence. On thebasis of decades of experience in theengineering, installation, start-up andcommissioning of continuous castingmachines worldwide, our specialists
are skilled in identifying casterdeficiencies and weak spots. Detailed
concepts are proposed for improving
plant performance, reliability, flexibility
and safety. Our expertise is available
on short notice and covers all aspectsof continuous casting technology forbillet, bloom, beam-blank and slab
casters from any supplier. Using ourproposed improvement solutions
helps producers to better meet theirproduction, quality and businesstargets as well as to save money.
Discover why - Primetals Technologies.

• Major improvements –in productivity, process
stability, product quality andyield• Expert advice pays off –proven fast return on
investment (ROI)

Quality
CASTERTECHNOLOGYCONSULTING

Simulation

Component design

Our competencies for every job

23

CASTER TECHNOLOGY CONSULTING GET IN
SHAPE TO EXCEL IN THE MARKET

Caster fitness check

Elaboration of study

Presentation of results
and proposoals

Implementation

Process steps for Caster Technology Consulting
First step: questionnaire

Second step: on-site inspection

CASTER FITNESS CHECKELABORATION OF STUDY AND PRESENTATIONOF RESULTS AND PROPOSOALSThis fitness check is comprised of two modules: Anquestionnaire is first completed by the customer in advanceof a visit. That’s followed by a thorough on-site evaluationof the plant by Primetals Technologies experts. Weak spots
are identified in the casting process in addition to theinstalled equipment and systems.

4Plans for a detailed investigation are discussed with thecustomer and areas of deficiency are addressed withproposals for solutions as well as a presentation of theexpected costs and benefits..

5

SCOPE OF CONSULTING CAPABILITY
GOOD ADVICE IS WELL WORTH THE PRICE
Caster Technology Consulting from Primetals Technologies
stands for expertise in quality improvement, numericalsimulation and special component design. In orderto provide the ideal solution to meet the specificrequirements of each producer, we can call on ourdisposal caster experts and access our comprehensive
metallurgical and operational database. By taking evensmall steps towards a solution, you can achieve dramatic
improvements in cost-effective and reliable production.

Slab quality
improvement

CFD Simulation oftundish flow

QUALITYCOMPONENT DESIGNTHE BASIS FOR CASTING EXCELLENCE“THE TOOLS TO SEE INSIDE THE STRAND”

PROFIT FROM OUR EXPERIENCE

When a customer is faced with qualityrelated
problems, experts from Primetals Technologies areavailable for support. Investigations begin with acomprehensive evaluation of all factors that have apotential effect on product quality. This begins withsteelmaking, and includes the entire continuous
casting process. Statistical evaluations as well as
detailed metallographic defect analyses are carriedout on-site. Additional support can be provided byexternal laboratories and universities with which
we have a long-term working relationship. This way
quality-related influences are identified. Improvement
recommendations are then made with respect to,for example, optimization of the casting process,use of alternative consumables (e.g., casting powder,refractories), modifications to the automation
system and the related training for operators andmetallurgists.

To optimize the casting process and to achieve ahigh level of product quality within the shortest
possible time, simulation techniques were developedby Primetals Technologies in the late 1970s. Thanks
to the enormously expanded computer capacity andimproved software algorithms, our technologists cansimulate even complex processes and conditions
in real time. Advanced simulation models makeit possible to acquire a deeper insight into thesteelsolidification process. The additional expertiseprovides the basis for superior equipment design andcasting operations. The applied simulation techniques
include FEM (finite element method) and CFD(computational fluid dynamics).

The highest machine performance, flexibility andreliability is only achieved when the installed
equipment, components and systems are thoroughly
designed and fully integrated with each other. When
our experts make a “fitness check” of your machine,
we identify the weakest links in the process chain, andpropose quick and effective replacement solutions.
We can offer special components or develop themto enhance machine availability. That way, when it
comes to new steel grades and product dimensions,
we can help you meet the increasing market demands.
The installation of long-lifetime components will
also significantly reduce maintenance expeditures.
Solutions and services can be implemented in castersof any size, of any type and from any supplier.

METALLURGICAL INVESTIGATIONSTHERMOMECHANICAL SIMULATION• Fine-tuning of casting parameters• Optimization of casting parameters• Secondary cooling strategy• Maintenance recommendations• Recommendations for secondary metallurgy• Strand mechanics

CUSTOMIZED ENGINEERING SOLUTIONS• Metallographic sample analyses• Liquid-core reduction, soft reduction, hard reduction• Advanced mold-plate cooling-slot design• Chemical analyses of ladle and mold slag

• Adaption of casting speed• Solutions for higher uptime

SURFACE-QUALITY OPTIMIZATIONEQUIPMENT QUALITY SIMULATION• Improved strand-guide concepts• Advanced mold-plate design and adjustment• Load calculations (segments, rollers, etc.)• Optimized SEN design• Mold temperature distribution and taper• Precise mold-level control

THERMODYNAMIC SIMULATION• Selection of optimum mold powder• Check of secondary cooling
AUTOMATION SETUP OPTIMIZATION
Check of spray nozzle

SIMULATION• Modifications to produce new steel grades• Adjustments to individual casting situations
TECHNOLOGICAL TRAINING• Strand solidification in mold
• Secondary cooling requirements• Casting control• Slab defects
INTERNAL QUALITY IMPROVEMENTS• Steel temperature

COMPUTATIONAL FLUID DYNAMICS• Simulation of steel flow in tundish• Simulation of steel flow in mold• Phase transformation• Material parameters to produce new steel grades
EXPERIMENTAL SIMULATION• Water models for tundish and mold
• Spray nozzles

ON-SITE PLANT ANALYSIS AND OPTIMIZATION• Improvement of operational reliability• New bender design to prevent scale build-up• Improved straightener geometry• Water treatment considerations
EQUIPMENT FAILURE ANALYSIS• Metallographic investigations of failure parts• Reduction of breakouts with improved oscillator
accuracy• Stabilization of mold level with improvements of BB
caster pinch rollers
LABORATORY SPRAY-NOZZLE TESTING• Arrangement and checking of cooling nozzles,
including water-spray pattern in modern testing
facilities
EQUIPMENT CHECK• Checking of mold-level control, oscillator andstrand-guide system, etc.

• Steel composition• Settings for DynaGap SoftReduction• Electromagnetic stirring (EMS)67

Primetals Technologies Austria GmbHA Group Company of Mitsubishi Heavy Industries

Turmstrasse 444031 Linz
Austriaprimetals.com
Brochure No.: T03-0-N091-L9-P-V6-EN
Printed in Austria© 2023 Primetals Technologies Ltd. All rights reserved
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in this document contains merely general descriptions or
characteristics of performance based on estimates andassumptions which have not been verified.
It is no representation, does not constitute and/or evidence acontract or an offer to enter into a contract to any extent and is
not binding upon the parties. Any obligation to provide and/ordemonstrate respective characteristics shall only exist if expressly
agreed in the terms of the contract.
These estimates and assumptions have to be analyzed on acase-to-case basis and might change as a result of further
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to the recipient shall be subject to applicable confidentiality
obligations and for the own convenience of and of the solerisk of the recipient.