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Danieli to Provide New Slab Caster, RH Degasser for Carsid
06/30/2008 - Danieli will provide a major upgrade of Carsid’s slab production complex in Charleroi, including the supply of a new wide slab caster and new RH degassing plant.
Carsid, Belgium, recently awarded an order to Danieli Davy Distington for a major upgrade of its slab production complex in Charleroi, including the supply of a new wide slab caster and new RH degassing plant.
The purpose of the Carsid slab production facility in Marcinelle (Charleroi), Belgium, is to feed slabs to Duferco mills located in La Louvière and Clabecq. Carsid is adding the new casting facility in order to enlarge its product mix and further penetrate the market of top applications for heavy plates.
The new casting facility will be capable of producing about 2 million tonnes of slabs per year ranging from 1300 to 2600 mm in width, from 4500 to 13,000 mm in length, and from 200 to 350 mm in thickness. The 2600 mm maximum width and 350 mm maximum thickness represents a significant increase from the facility’s present 1600 mm maximum width and 220 mm maximum thickness. The new single-strand caster will be installed on the foundations of an existing SMS Demag caster, which is to be dismantled. The existing ladle turret, tundish turret, and casting floor will be reused, while all remaining equipment will be replaced.
For Danieli, the project is a complete turnkey project except for the foundation modifications. It comprises dismantling of the existing caster, supply and installation of the new caster and maintenance equipment, and supply and installation of new electricals, Level 1 and Level 2 automation, and process control systems. Danieli will also supply startup and commissioning services, and an operators training package. The machine will be converted from a vertical-curved design into a curved geometry with a main radius of 10.2 meters. The curved geometry is designed to optimize internal and external quality without requiring any additional work on the concrete foundations, except for the demolition of the existing oscillator supporting walls.
The total machine containment length of 28.4 meters, obtained with 15 segments, will allow maximum casting speeds up to 1.5 meters/minute. For improved internal and external slab quality, the caster will feature INMO mold with remote width adjustment system; hydraulic oscillation, replacing the existing mechanical system; breakout prevention system with mold thermal mapping; dynamic soft reduction; multiple split rolls, new roll diagram with 10.5-meter main radius, and new progressive unbending. The caster will also feature internal water cooling with peripherally drilled design (PDR), and air-mist secondary cooling, with dynamic control.
Danieli Automation will install a new L1 and L2 advanced control system with client/server architecture plus a complete set of mathematical models for casting process control, including slab width control in mould; dynamic control of hydraulic oscillation parameters; advanced breakout prevention system with complete mould thermal mapping; and dynamic secondary cooling.
This is the second substantial slab caster project Duferco Carsid has awarded to Danieli Davy Distington for the Marcinelle site; it follows the revamping of a two-strand machine (originally supplied by SVAI) carried out in 2002.
The new plant, called CC3, will be designed to process a wide range of steel grades for quality slabs, including microalloyed, medium-carbon and high-carbon grades. It is scheduled to be in production in the first quarter of 2010.
Carsid is part of the Duferco Group,
