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Siemens VAI Implements SmartSegments with DynaGap Soft Reduction on JSW Slab Caster

04/07/2009 - Siemens VAI Metals Technologies upgraded existing segments of a JSW Steel slab caster to Smart Segments with DynaGap Soft Reduction, which will help to facilitate the production of special steel grades.

Siemens VAI Metals Technologies recently upgraded the existing segments of a JSW Steel slab caster to so-called Smart Segments with DynaGap Soft Reduction. The intent of the project was to improve slab quality and thus facilitate the production of special steel grades, and to streamline slab-thickness changes so they can be carried out more quickly and efficiently.
 
Originally supplied by Siemens VAI, the single-strand slab caster commenced production in November 2006. It is capable of producing approximately 1.5 million tonnes of steel per year, comprising low- to high-carbon steels, including micro- and low-alloyed grades. Siemens VAI UK upgraded the existing strand-guiding system to accommodate the production of high-quality line-pipe grades such as API (American Petroleum Institute) X70 grades and other microalloyed steels.
 
A total of 14 of the installed caster segments were modified to Siemens VAI Smart Segments: five in the bow section, two in the straightening section and seven in the horizontal section, as well as six additional segments in reserve. The integrated DynaGap Soft Reduction system facilitates automatic strand-taper/thickness control, and a Dynacs secondary-cooling model calculates the strand-temperature profile and the required secondary cooling-water quantities with consideration to the casting speed and steel grade. DynaGap Soft Reduction can thus precisely determine the final point of strand solidification as the basis for ensuring excellent internal slab quality.
 
With implementation of this solution, automatic strand-taper/thickness control can now be carried out as the basis for achieving best slab-centerline quality, as required for the production of pipeline grades used in the petroleum industry. The roller-gap settings can also be adapted remotely to cast slabs in thicknesses between 220 and 260 millimeters, reducing caster downtime.
 
“The caster with the Smart Segments is progressing well and the quality, especially for API X70 grades, is excellent,” commented Abhijit Sarkar, Deputy General Manager of the steel plant, following the successful restart of the upgraded caster. “We are proud to operate the first caster with Smart Segments in India and to be associated with Siemens VAI.”
 
Siemens VAI received the Final Acceptance Certificate for this caster project at the end of February 2009, within three weeks after start-up of the upgraded caster. The project is the latest in a series of orders JSW Steel has placed with Siemens VAI, including the supply of two Corex ironmaking plants, a new continuous caster, and a hot strip mill upgrade (currently in progress) to increase productivity and improve strip quality. Most recently, Siemens VAI also started up a new blast furnace at the Toranagallu site of JSW Steel, which is largest in operation in India.
 
JSW Steel, a company of the O. P. Jindal Group, is an integrated iron and steel producer located in Toranagallu in the Bellary district of the Indian federal state of Karnataka. The company produces a wide range of coated and non-coated carbon steels that are used for the construction and manufacture of automobiles, white goods, power stations, transformers, dams, bridges, ports, railways, refineries, oil barrels and drums, storage tanks, machines, buildings and transmission towers.
 
The Siemens Industry Sector (Erlangen, Germany) is a leading international supplier of production, transportation, building and lighting technologies. The Sector consists of six Divisions: Building Technologies, Drive Technologies, Industry Automation, Industry Solutions, Mobility and Osram. With around 222,000 employees worldwide Siemens Industry posted in fiscal year 2008 a profit of EUR3.86 billion with revenues totaling EUR38 billion
 
With the business activities of Siemens VAI Metal Technologies (Linz, Austria), Siemens Water Technologies (Warrendale, Pa.), and Industry Technologies, (Erlangen, Germany), the Siemens Industry Solutions Division (Erlangen, Germany) is one of the world's leading solution and service providers for industrial and infrastructure facilities. Using its own products, systems and process technologies, Industry Solutions develops and builds plants for end customers, commissions them and provides support during their entire life cycle. With around 31,000 employees worldwide, Siemens Industry Solutions achieved an order intake of EUR 8.415 billon in fiscal year 2008.
 
Smart Segment, DynaGap Soft Reduction and Dynacs are registered trademarks of Siemens AG in certain countries.