Kametstal, a prominent Ukrainian steel manufacturer, has completed a significant modernization project at its Continuous Casting Machine No. 2 located within its BOF Shop. This ambitious overhaul aims to enhance the efficiency, stability, and overall quality of the steel casting process, reflecting Kametstal's commitment to innovation and maintaining its competitive edge in a rapidly evolving market.
Reconstruction Process: A Two-Stage Project
The reconstruction of CCM-2 was carried out in two well-structured stages. The first phase, which was completed in 2023, focused on modernizing the first, second, and third casting streams. The second phase, completed earlier in 2024, upgraded the fourth, fifth, and sixth casting streams to meet higher standards of operational efficiency.
The project aimed primarily to address the reliability of the electrical equipment and enhance the automation system of the casting machine. These measures were designed to stabilize the casting speed, a critical factor in ensuring the accurate cutting of billets and minimizing metal losses during production.
Key Innovations and Technological Enhancements
Several cutting-edge technologies were integrated into the CCM-2 to optimize its performance and provide enhanced control over the casting process. The main upgrades include:
1. Siemens Frequency Drives: The installation of Siemens frequency drives significantly improved the regulation of electric motors throughout the casting system. These drives provide a smoother operation, helping to ensure consistent casting speeds, thereby reducing operational disruptions and enhancing product quality.
2. Encoders on Motors: To maintain precise and stable casting speeds, encoders were installed on the electric motors. This technology allows for real-time monitoring and adjustments, ensuring a high degree of control over the entire casting process.
3. Upgraded Control Systems: The control systems for secondary cooling zones were completely replaced with more advanced and reliable systems. This update ensures that the cooling process remains steady and efficient, critical to producing high-quality billets.
4. Real-Time Process Visualization and Monitoring: One of the standout features of this upgrade is the implementation of a real-time process visualization and monitoring system. Equipped with control panels installed directly on CCM-2, this system allows operators to track key process parameters in real time, receive important feedback signals, and make quick adjustments when necessary. This leads to improved response times, reduced errors, and enhanced overall control over the casting process.
Improved Casting Speed and Product Quality
The modernization efforts have significantly enhanced the stability of the casting process. According to Alexander Degtyarenko, the lead engineer in charge of the project, the new automation system has helped stabilize the casting speed, leading to smoother and more accurate billet production. As a result, the quality of the finished products has improved, and the consistency of output has become more reliable.
Another significant benefit of the upgrade is the introduction of compression algorithms. These algorithms help produce smoother bloomers, improving both the aesthetic and structural qualities of the final steel products. This innovation not only enhances the production process but also gives Kametstal a competitive advantage in the high-quality steel market.
Operational Efficiency and Competitiveness
The improvement in efficiency and precision has translated into significant operational benefits. By stabilizing the steel casting process and minimizing metal losses, Kametstal is now able to produce higher-quality steel at a lower cost. This increased efficiency has made the company more competitive in the global steel market.
Furthermore, these innovations have positioned Kametstal to offer a broader range of products, including those with higher precision and enhanced durability. This is particularly important as the steel industry increasingly focuses on meeting the demands for advanced steel grades used in industries like automotive, construction, and energy.
Long-Term Benefits of the Upgrade
The successful completion of this CCM-2 reconstruction represents more than just a short-term boost in production capacity. It is part of Kametstal’s long-term strategy to maintain its position as a leader in the steel industry by leveraging cutting-edge technologies and automation to enhance product quality and manufacturing efficiency.
By investing in advanced automation systems, real-time monitoring, and process stabilization technologies, Kametstal has taken a significant step toward achieving its goals of sustainability and market leadership. These investments will help ensure that the company remains agile in responding to the evolving needs of the global market and capable of delivering top-quality steel products for a variety of industries.
Additionally, Kametstal’s BOF Shop has achieved a new milestone in continuous casting technology, thanks to the locking mechanisms added to CCM-1. This technology has helped expand the range of high-quality products and increased overall production output. Together with the upgrades on CCM-2, Kametstal’s steelmaking capacity has significantly improved, allowing the company to meet the growing demand for high-performance steel in domestic and international markets.
Key Takeaways:
• Kametstal has completed a large-scale reconstruction of Continuous Casting Machine No. 2 (CCM-2) at its BOF Shop, improving the reliability and efficiency of its steel production process.
• The modernization project was carried out in two stages, spanning from 2023 to 2024, with a focus on upgrading electrical equipment, automation systems, and control mechanisms.
• The installation of Siemens frequency drives and encoders has significantly improved the stability and precision of the casting speed, leading to higher-quality billets.
• A new real-time process visualization and monitoring system has been introduced, enabling operators to monitor key parameters and make quick adjustments to improve process control.
• The compression algorithms implemented during the upgrade have contributed to the formation of smoother bloomers, enhancing the quality of the final steel products.
• Kametstal’s BOF Shop has also reached new heights in continuous casting technology, including locking mechanisms on CCM-1, improving overall production output and expanding the product range.
• The completion of this upgrade strengthens Kametstal’s competitiveness, providing the company with the ability to produce high-quality steel products efficiently and sustainably, securing its position in the global market.
