A Technological Breakthrough for Steel Manufacturing: ABB’s Electromagnetic Technology
ABB, a global leader in power and automation, has been awarded a contract to supply its innovative Flow Control Mold (FC Mold G3) electromagnetic technology to ArcelorMittal Nippon Steel India (AM/NS India). The groundbreaking technology will be used in a new two-strand slab caster at AM/NS India's Hazira plant in Gujarat, as part of an expansion project aimed at increasing steel production capacity.
This latest technological development in the steel industry promises to transform the casting process, improving product quality, increasing operational efficiency, and dramatically reducing the defect rates of the steel slabs produced. With an ongoing expansion of the Hazira plant’s capacity from 9 million metric tons per annum (MTPA) to 15 MTPA, ABB’s cutting-edge solution will play a pivotal role in achieving the ambitious goals set for the plant’s growth.
FC Mold G3 Technology: A Unique Solution for Cleaner, Faster Steel Production
ABB’s FC Mold G3 system utilizes electromagnetic stirring & braking technology, setting a new industry standard for continuous slab casting. This advanced technology helps in controlling the flow of molten steel during the casting process by generating three independent magnetic fields. These fields play a crucial role in stirring and braking the molten steel simultaneously, ensuring better flow dynamics, reduced defects, and higher-quality steel output.
The technology works by optimizing the meniscus flow speed, minimizing downward flow, and allowing gas bubbles to float to the surface. This process prevents gas bubbles from being trapped inside the solidifying steel, which is a common cause of surface and internal defects. The simultaneous stirring and braking enable better control of the steel’s solidification process, ensuring the production of uniform slabs with fewer imperfections.
Impact of FC Mold Technology on Quality and Productivity
The FC Mold G3 system has demonstrated a remarkable ability to reduce surface defects and internal flaws by at least 50%, significantly improving the final product quality. By enabling more consistent steel production, this technology also helps minimize reject ratios, with some installations reporting a reduction of up to 80% in scrap or defective products.
Zaeim Mehraban, Global Head of Sales for Metallurgy at ABB, highlighted the technological advances of the FC Mold G3, emphasizing its proven track record across more than 40 installations worldwide. He noted that this technology has consistently led to improvements in productivity, resource efficiency, and operational costs, making it a reliable investment for steelmakers aiming to improve their production processes.
The unique ability of the FC Mold G3 system to operate effectively at different casting speeds makes it suitable for both new installations and upgrades. This feature allows it to be seamlessly integrated into AM/NS India’s Hazira plant, ensuring that the steelmaker can boost its capacity without compromising on product quality.
Collaboration with Danieli: Enhancing the Slab Caster Design
ABB's role in the expansion project goes hand-in-hand with its collaboration with Danieli, a world-renowned supplier of equipment for steel production. Danieli will supply the new two-strand slab caster, which will feature ABB’s FC Mold G3 system. The integration of both companies’ technologies will create a state-of-the-art casting line capable of producing thicker, high-quality steel slabs at higher speeds.
The use of Danieli’s slab caster in conjunction with ABB’s electromagnetic technology ensures that the system works in perfect harmony. Danieli’s caster technology allows for continuous slab casting, while ABB’s FC Mold technology ensures that the casting process is highly controlled, resulting in greater uniformity, better quality slabs, and fewer defects. The outcome is a highly efficient, modern steel production line that sets a new standard for the industry.
Operational Efficiency & Cost Savings: A Win-Win for AM/NS India
The FC Mold G3 system’s ability to reduce defects and increase casting speeds is expected to significantly lower production costs for AM/NS India. The more efficient casting process leads to fewer rejected products, lower scrap rates, and reduced waste in the overall production chain. This, in turn, translates to better resource efficiency and faster time-to-market for steel products.
Furthermore, ABB’s electromagnetic technology offers a quick return on investment (ROI), with reports indicating that many installations worldwide see an ROI within one year of implementing the technology. The ability to reduce defects, increase productivity, and streamline the casting process makes ABB’s technology not only beneficial from a quality standpoint but also cost-effective in the long run.
The improvements brought by ABB’s technology go beyond just quality control. The system's efficiency contributes to a sustainable production model by reducing energy consumption and minimizing the environmental impact of steel production. As AM/NS India ramps up its production capacity to 15 MTPA, ABB’s solution will ensure that the Hazira plant remains competitive in a rapidly evolving steel industry.
FC Mold G3: Proven Global Impact
ABB’s FC Mold G3 technology has been successfully implemented in over 40 installations globally, showcasing its reliability and effectiveness in enhancing steel production. The technology’s versatility, adaptability, and proven success across diverse markets provide AM/NS India with a proven solution to its expanding production needs.
The system’s ability to maximize efficiency and reduce operational costs has made it a favorite among leading steelmakers worldwide. As part of AM/NS India’s plant expansion, ABB’s technology ensures that the steelmaker’s products will meet the growing global demand for high-quality steel, while also driving improvements in resource management and sustainability.
The Road Ahead for AM/NS India: A Technological Edge in Steel Production
As AM/NS India moves forward with its capacity expansion, the integration of ABB’s Flow Control Mold G3 technology is a key element in achieving both increased production volume and enhanced product quality. With the addition of ABB’s system, the Hazira plant will be equipped to meet the growing global demand for high-quality steel while also reducing production costs.
The expansion project at the Hazira plant marks a new chapter in AM/NS India’s journey toward becoming a global leader in sustainable steel production. ABB’s technology will play a vital role in ensuring that the company remains competitive and efficient in an ever-demanding market.
Key Takeaways:
• ABB supplies Flow Control Mold G3 electromagnetic technology for AM/NS India’s Hazira plant.
• The technology enhances steel quality, productivity, and cost-efficiency in thick slab casting.
• The FC Mold G3 system uses three independent magnetic fields to stir & brake molten steel simultaneously, reducing defects by at least 50% and lowering reject ratio by up to 80%.
• AM/NS India’s Hazira plant expands from 9 million metric tons per annum (MTPA) to 15 MTPA, supported by ABB’s technology.
• FC Mold technology allows for higher casting speeds, faster ROI, and improved production rates.
• The collaboration with Danieli will create a state-of-the-art two-strand continuous caster.
• ABB’s technology reduces energy consumption, minimizes waste, and enhances overall sustainability.
• Over 40 installations worldwide have proven the reliability and effectiveness of ABB’s FC Mold technology.
