Kardemir Upgrades Production Capacity with SMS Concast’s Combi-Continuous Caster
Kardemir Karabük Demir Çelik Sanayi ve Ticaret A.Ş., a leading steel manufacturer in Türkiye, has made a significant step towards enhancing its steel production capabilities with an order for a five-strand combi-continuous caster from SMS Concast, part of the globally recognized SMS group. The new continuous caster, slated to enter service at the company’s Karabük facility by the end of 2025, represents a key milestone in Kardemir’s expansion and commitment to staying at the forefront of the Turkish steel sector.
A New Era of Flexibility and Efficiency in Steel Production
The new casting plant is designed to offer enhanced flexibility, allowing Kardemir to meet the dynamic demands of the steel industry with greater efficiency. With the ability to produce a diverse range of steel grades and formats, including three square billet sizes, one bloom size, and one beam blank section size, the new system will significantly boost Kardemir's production capacity. The overall annual output from the plant is expected to reach 1.2 million metric tons, marking a notable increase in production volume for the company.
At the heart of this new facility is its five-strand design, which allows for quick changeovers between product formats, improving efficiency and reducing downtime. This adaptability ensures that Kardemir can quickly respond to shifting market needs, including high-demand sectors such as construction and rail industries, by producing specialized steel grades such as high-carbon rail grades.
Advanced Technology for Optimal Quality and Reliability
The continuous caster is equipped with cutting-edge features that ensure stable production and high product quality. The casting plant’s 10.25-meter radius is paired with a large, long-life tundish and the CONFLOW stopper mechanism, which maintains precise steel levels in the mold. This mechanism is crucial for ensuring consistent casting and minimizing defects, thus enhancing the overall quality of the steel produced.
SMS’s advanced CONVEX mold tubes further contribute to the quality improvements by increasing casting speed and improving internal product quality. In addition, the system includes CONSTIR electromagnetic stirrers, which further enhance the final product’s internal structure, ensuring superior quality for a variety of steel grades.
The precision of the process is further ensured through the use of the CONDRIVE oscillation drive. This advanced feature allows for precise, online adjustments to the casting mold, providing independent control of key parameters such as amplitude, frequency, and oscillation profile, ensuring optimal conditions for steel casting.
Automation Systems for Seamless Operations
In addition to the physical upgrades, the plant will be equipped with advanced automation systems designed to control and optimize operations. The Level 1 and Level 2 automation systems include cutting-edge technical solutions that ensure efficient operation and production reliability. The Level 2 systems, in particular, incorporate fault-tolerant hardware that guarantees continuous operation and helps minimize human error, leading to consistent product quality.
These automation systems play a vital role in improving the plant’s availability by reducing reliance on operator input and enhancing the ability to monitor and optimize production processes. Additionally, the systems are integrated with solutions for product certification, enabling smoother compliance with industry standards and further ensuring the plant’s overall performance.
A Strong Partnership with SMS Group
Kardemir’s partnership with SMS Concast spans over 25 years, and the collaboration on this latest project further strengthens their relationship. Both companies have emphasized the mutual commitment to technological innovation, and SMS Concast’s state-of-the-art solutions are expected to contribute to Kardemir’s long-term success. The new continuous casting plant underscores this continued collaboration, setting the stage for further advancements in both production technology and operational excellence.
The management team at Kardemir has expressed their confidence in the project, with the company’s leadership praising the trustful and longstanding relationship with SMS Group. They are optimistic about the seamless execution of the project, which is expected to set new benchmarks for the Turkish steel industry and further cement Kardemir’s position as a key player in the sector.
The Road Ahead: Enhancing Digitalization and Efficiency
As part of the continued collaboration, SMS and Kardemir are also planning to explore digital solutions to enhance the operational efficiency of the plant. One area of future focus will be AI-driven systems that optimize caster operation and improve production efficiency. These advancements will further strengthen Kardemir's competitiveness and operational agility, allowing the company to keep up with the evolving demands of the global steel market.
The new continuous casting facility also paves the way for Kardemir to achieve greater sustainability goals, as the plant’s advanced automation and improved efficiency can help minimize waste and energy consumption. As the steel industry faces increasing pressure to decarbonize, Kardemir’s investment in cutting-edge technology signals its commitment to environmental responsibility while enhancing production capabilities.
