2003 NORTH AMERICAN CONTINUOUS CASTER MARKET STUDY Final Report
by:
AIM Report No. 320
June 2003
FOREWORD This Report was prepared by AIM Market Research. Neither AIM Market Research, nor any person acting on its behalf: a) makes any warranty, express or implied, with respect to the use of any information, apparatus, method, or process disclosed in this Report or that such use may not infringe privately owned rights; or b) assumes any liabilities with respect to the use of or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this Report. AIM Market Research is a privately owned market research and development firm.
Copyright 2003 as a published work by AIM Market Research. All rights reserved. This report or its contents either in whole or in part may not be reproduced, stored in a data retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the express written consent of AIM Market Research. Unauthorized and/or unlicensed copying of any part of this report or its appendices is in violation of copyright law. 2003 North American Continuous Caster Market Study June 2003
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CONTENTS LIST OF APPENDICES .............................................................................................................. vi LIST OF FIGURES.....................................................................................................................viii LIST OF TABLES.......................................................................................................................xvi EXECUTIVE SUMMARY ...................................................................................................... ES-1 PROSPECT ANALYSIS .......................................................................................................... S-1 CONCLUSIONS...................................................................................................................... C-1 INTRODUCTION.................................................................................................................... IN-1 Section 1 - Characterizing the Continuous Casters Surveyed Steel Production of Casters Surveyed.................................................................... 1-1 Comparing 2003 with 2003 Steel Production................................................... 1-2 Number Of Strands................................................................................................. 1-7 Ladle Capacity of Casters Surveyed ...................................................................... 1-7 Casting Time Per Heat ......................................................................................... 1-10 Sequence Casting ................................................................................................ 1-13 Production Rate of Casters .................................................................................. 1-17 Continuous Cast Steel Production by Grades Cast (AK, SK, vs. Stainless) ......... 1-20 Continuous CastSteel Production by Carbon Grades Cast (Medium/High, Low, ULC’s) .......................................................................................................... 1-23 Casting Machine Suppliers ................................................................................... 1-27 Dimensions of Continuous Cast Product .............................................................. 1-29 Age of Casters Surveyed...................................................................................... 1-35 Fundamental Priorities of Continuous Caster Operation Surveyed ...................... 1-36 Casters Surveyed Not Satisfied with Present Level of Automation................ 1-37 Section 2 - Characterizing the Existing Oscillator and It’s Performance Type of Oscillator ...........................................................................................................2-1 Oscillator Performance ..................................................................................................2-2 Problems, Concerns, or Issues with Operation of the Existing Oscillator .....................2-4
2003 North American Continuous Caster Market Study June 2003
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Section 3 - Characterizing the Tundish Tundish Parameters.......................................................................................................3-1 Tundish Capacity ....................................................................................................3-1 Tundish Depth.........................................................................................................3-2 Tundish Practices...........................................................................................................3-3 Tundishes on Hand.................................................................................................3-3 Dams and Weirs .....................................................................................................3-4 The Types of Tundish Flux Used............................................................................3-4 The Use of a Permanent Tundish Mechanical Cover ............................................3-5 The Use of Continuous Temperature Monitoring ...................................................3-5 Tundish Refractory.........................................................................................................3-6 The Safety Lining ....................................................................................................3-6 Working Lining ........................................................................................................3-7 Heats Per Tundish Working Lining .........................................................................3-8 Changing the Tundish on the Fly..........................................................................3-10 Tundish Preheating and Drying ...................................................................................3-11 Type of Preheating or Drying Equipment .............................................................3-11 Tundish Preheating and Drying Equipment Suppliers..........................................3-11 Year Preheating or Drying Equipment Installed ...................................................3-12 Satisfaction with Performance of Tundish Preheating and Drying Equipment ..........................................................................................3-12 Planning to Add or Replace This Preheating or Drying Equipment .....................3-13 Is Tundish Insulated?............................................................................................3-13 Tundish Level Control ..................................................................................................3-14 Measuring Tundish Level......................................................................................3-14 Type of Tundish Level Measurement System ......................................................3-15 Tundish Flow Control ...................................................................................................3-16 Type of Tundish Level Measurement System ......................................................3-16 The Use of Stopper Rods without a Porous Plug.................................................3-17 Types of Pouring Tubes Used ..............................................................................3-18 SEN (Submerged Entry Nozzle) Suppliers...........................................................3-18 Metering Nozzle Suppliers ....................................................................................3-19 Gas Purging ..........................................................................................................3-19 Nozzle Port Configuration of SEN and SES Nozzles...........................................3-20 Casters That Experience an Undesirable Affect From the Current Method of Flow Control..................................................................................3-20 When Diminished Flow Dictates Aborting Flow Through a Strand / Nozzle ............................................................................................................3-21 Return of Investment Required for Adapting a New Flow Control Technology.....................................................................................................3-22 What Priority Would be Given to Such an Investment .........................................3-23
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Section 4 - Characterizing the Mold and Mold Level Control Systems Mold Shape ....................................................................................................................4-1 Is the Caster Mold Adjustable?...............................................................................4-1 Mold Level Measurement System .................................................................................4-2 Eddy Current Mold Level Sensor - Years Used .....................................................4-3 Radioactive Mold Level Sensor - Years Used........................................................4-4 Satisfaction with Your Current Mold Level Measurement System .........................4-5 Casters Considering or Might Consider Replacing Their Present Mold Level Measurement System ............................................................................4-6 The Importance of Technical Support, Service, and Availability of Spare Parts Regarding Mold Level Measurement Systems ......................................4-8 More Accurate Measurement of Casting Speed to Improve Mold Level Control..............................................................................................................4-8 Section 5 - The Caster Cut System The #1 Problem with the Caster Cutting Process .........................................................5-1 The Impact on Production of Improving the Caster Cut Process..................................5-2 Outsourcing Total Service of Cut-off Machines, Etc......................................................5-3 Real Time Cut Optimization...........................................................................................5-3 Section 6 - Process Improvement Priorities and Plans For Caster Upgrades The Process Improvement Priorities for the Caster Operation .....................................6-1 Plans to Address these Priorities and / or to Upgrade the Caster.................................6-2 Section 7 - Caster Maintenance Characterizing the Current Maintenance Program........................................................7-1 Equipment or Systems in Caster Operations Surveyed that Requires the Highest Level of Maintenance ................................................................................7-2 Outsourcing Caster Maintenance Services ...................................................................7-4 Leading Outsourced Services.................................................................................7-5 Other Outsourced Services ....................................................................................7-6 Suppliers of Outsourced Maintenance Services ....................................................7-7 Strand Conditioning Monitoring Systems ....................................................................7-13 Casters that Do Not Have Strand Conditioning Monitoring..................................7-13 Section 8 - Segment Rebuilding and Bearings Outsourcing Segment Rebuilding..................................................................................8-1 Outsourced Segment Repair Work.........................................................................8-1 Who Decides Which Bearings or Rolls to Use? .....................................................8-2 The Most Critical Segments...........................................................................................8-2 What is the Target Life for These Segments?........................................................8-4 The Type of Roll Materials Used in These Segments............................................8-6 What Lasts Longer in the Most Critical Segments - Rolls or Bearings? .......................8-6 The Average Life of the Element of the Segment that Lasts Longer Rolls or Bearings..............................................................................................8-7
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Section 9 - Bearings and Bearing Rework Bearings .........................................................................................................................9-1 The Types of Bearings Used ..................................................................................9-1 Are Environmental (Waste Treatment) Issues a Factor in the Selection of Bearings? .....................................................................................................9-2 Are Environmental (Waste Treatment) Issues a Trade-Off for Longer Life?..................................................................................................................9-2 Bearing Rework..............................................................................................................9-3 Are Caster Bearings Reworked? ............................................................................9-3 What is the Weak Link in Segment Rebuilding - Bearings or Rolls? .....................9-4 Prospects for a Roll or Bearing Total Solution........................................................9-5 Section 10 - The Use of High Temperature Lubricants The Most Critical Issues Regarding the Use of High Temperature Lubricants.......................................................................................................10-1 Consumption of Lubricant(s) Used In High Temperature Applications ................10-2 Most Important Factors in a Lubricant Product for a Continuous Casting Operation .......................................................................................................10-3 Satisfaction with the Bearing Lubricant Products .................................................10-4 Leading Lubricant Supplier ...................................................................................10-5 The Likelihood of Considering a New Lubricant Supplier.....................................10-6 What Factors Would Prevent You From Buying This Product? ...........................10-6 Where are Lubricants Purchased? .......................................................................10-7 Who Specifies High Temperature Lubricant for Continuous Casting?.................10-8
2003 North American Continuous Caster Market Study June 2003
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LIST OF APPENDICES The following Appendices provide the information specified for each of the plants surveyed: Appendix 1:
List of Firms Contacted
Appendix 2:
Individuals Contacted
Appendix 3:
Prospect Analysis
Appendix 4:
Characterizing the Caster Operation
Appendix 5:
Characterizing the Caster Operation (Cont.)
Appendix 6:
Fundamental Priorities and Automation
Appendix 7:
Characterize Existing Oscillator and It's Performance
Appendix 8:
Characterize the Tundish
Appendix 9:
Characterize the Tundish Refractory
Appendix 10:
Preheating and Drying Equipment, Emissions Concerns and Insulation
Appendix 11:
Tundish Level Control
Appendix 12:
Tundish Flow Control
Appendix 13:
Tundish Flow Concerns and Benefits of Improvement
Appendix 14:
Tundish Diminished Flow and ROI For Better Flow
Appendix 15:
Tundish Flow - New Technology
Appendix 16:
Characterizing the Mold and Mold Level Measurement
Appendix 17:
Ways to Improve Mold Level Measurement
Appendix 18:
Mold Level Measurement Support and Measuring Casting Speed
Appendix 19:
Caster Cut
2003 North American Continuous Caster Market Study June 2003
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LIST OF APPENDICES (Cont.) Appendix 20:
Caster Cut - Outsourcing Services and Real Time Optimization Services
Appendix 21:
Process Improvement Priorities and Plans for Caster Upgrades
Appendix 22:
Capital Expenditures
Appendix 23:
Caster Maintenance Program
Appendix 24:
Caster Maintenance Services Outsourced
Appendix 25:
Strand Condition Monitoring
Appendix 26:
Segment Rebuilding and Bearings
Appendix 27:
Caster Maintenance
Appendix 28:
Caster Maintenance (Cont.)
Appendix 29:
Caster Bearing Rework
Appendix 30:
Segment Rebuilding
Appendix 31:
Continuous Caster Bearing Lubricant Maintenance Key Qualifier
Appendix 32:
Most Critical Issues Regarding the Use of These Lubricants
Appendix 33:
Lubricant Consumption and Most Important Factors in Lubricants for Casting Operation
Appendix 34:
Satisfaction With the Bearing Lubricant Product(s) Used and Overall Satisfaction
Appendix 35:
Likelihood and Obstacles to Consider Suppliers
Appendix 36:
Where Do You Purchase These Lubricants?
Appendix 37:
Specifying Lubricant Influences
Appendix 38:
Lubricant General Comments
Appendix 39:
Casting Machines Not Included In Survey Located in Plants Surveyed
Appendix 40:
Continuous Caster Questionnaire 2003 North American Continuous Caster Market Study
June 2003
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LIST OF FIGURES INTRODUCTION Figure 1 -
Functional Responsibilities of Persons Interviewed ......................................... IN-3
Section 1 - Characterizing the Continuous Casters Surveyed Figure 2 -
Projected 2003 Steel Production by Type of Caster .........................................1-1
Figure 3 -
Projected Steel Production of Casters Surveyed, % Increase over 2002, and Amount of Increase ...........................................................................1-2
Figure 4 -
Projected 2003 Steel Production of Billet Casters Surveyed & Increase over 2002.............................................................................................1-3
Figure 5 -
Projected 2003 Steel Production of Bloom Casters Surveyed & Increase over 2002.............................................................................................1-4
Figure 6 -
Projected 2003 Steel Production of Slab Casters Surveyed & Increase over 2002.............................................................................................1-5
Figure 7 -
Projected 2003 Steel Production of Thin Slab Casters Surveyed & Increase over 2002.............................................................................................1-6
Figure 8 -
Ladle Capacity - Billet Casters Surveyed ...........................................................1-7
Figure 9 -
Ladle Capacity - Bloom Casters Surveyed ........................................................1-8
Figure 10 -
Ladle Capacity - Slab Casters Surveyed............................................................1-8
Figure 11 -
Ladle Capacity - Thin Slab Casters Surveyed ...................................................1-9
Figure 12 -
Casting Time Per Heat - Billet Casters Surveyed ............................................1-10
Figure 13 -
Casting Time Per Heat - Bloom Casters Surveyed..........................................1-11
Figure 14 -
Casting Time Per Heat - Slab Casters Surveyed.............................................1-11
Figure 15 -
Casting Time Per Heat - Thin Slab Casters Surveyed.....................................1-12
Figure 16A - Number of Heats (Avg 20) per Sequence - Billet Casters Surveyed.............1-13 Figure 17 -
Number of Heats per Sequence - Bloom Casters Surveyed ...........................1-14 2003 North American Continuous Caster Market Study
June 2003
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LIST OF FIGURES (Cont.) Figure 18A- Number of Heats (Avg 20) per Sequence - Slab Casters Surveyed ............1-15 Figure 19 -
Number of Heats per Sequence - Thin Slab Casters Surveyed ......................1-16
Figure 20 -
Cast Heats per Day - Billet Casters Surveyed .................................................1-17
Figure 21 -
Cast Heats per Day - Bloom Casters Surveyed...............................................1-18
Figure 22 -
Cast Heats per Day - Slab Casters Surveyed..................................................1-18
Figure 23 -
Cast Heats per Day - Thin Slab Casters Surveyed..........................................1-19
Figure 24 -
Grades of Steel Produced by Casters Surveyed - AK, SK & Stainless (SS)...................................................................................................................1-20
Figure 25 -
Grades of Steel Produced by Billet Casters Surveyed ....................................1-21
Figure 26 -
Grades of Steel Produced by Bloom Casters Surveyed..................................1-21
Figure 27 -
Grades of Steel Produced by Slab Casters Surveyed.....................................1-22
Figure 28 -
Grades of Steel Produced by Thin Slab Casters Surveyed.............................1-22
Figure 29 -
Grades of Carbon Steels Produced by Casters Surveyed ..............................1-23
Figure 30 -
Grades of Steel Cast by Billet Casters Surveyed - Low Carbon vs Medium / High Carbon......................................................................................1-23
Figure 31 -
Grades of Steel Cast by Bloom Casters Surveyed - Low Carbon vs Medium / High Carbon......................................................................................1-24
Figure 32 -
Grades of Steel Cast by Slab Casters Surveyed - ULC, Low Carbon, & Medium/High Carbon ....................................................................................1-25
Figure 33 -
Grades of Steel Cast by Thin Slab Casters Surveyed - ULC, Low Carbon, & Medium/High Carbon .....................................................................1-26
Figure 34 -
Caster Suppliers’ Share of Casters Surveyed..................................................1-27
Figure 35 -
Suppliers’ Share of Casters Surveyed by Type of Caster................................1-28
Figure 36 -
Cross Sections Cast by Billet Casters Surveyed .............................................1-29 2003 North American Continuous Caster Market Study
June 2003
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LIST OF FIGURES (Cont.) Figure 37 -
Cross Sections Cast by Bloom Casters Surveyed...........................................1-30
Figure 38 -
Slab Thickness in Slab Casters Surveyed .......................................................1-31
Figure 39 -
Slab Widths in Slab Casters Surveyed.............................................................1-32
Figure 40 -
Slab Thickness in Thin Slab Casters Surveyed ...............................................1-33
Figure 41 -
Slab Widths in Thin Slab Casters Surveyed ....................................................1-34
Figure 42 -
Year of Start-up of Casters Surveyed by Type of Caster.................................1-35
Figure 43 -
Fundamental Priorities of Casters Surveyed....................................................1-36
Figure 44 -
Share of Casters Surveyed that are Dissatisfied with Present Level of Automation........................................................................................................1-37
Section 2 - Characterizing the Existing Oscillator and It’s Performance Figure 45 -
Types of Oscillators Used On Casters Surveyed...............................................2-1
Figure 46 -
Rating Performance of Oscillators of All Casters Surveyed...............................2-2
Figure 47 -
Rating Performance of Oscillators of Billet Casters Surveyed...........................2-2
Figure 48 -
Rating Performance of Oscillators of Bloom Casters Surveyed ........................2-3
Figure 49 -
Rating Performance of Oscillators of Slab Casters Surveyed ...........................2-3
Figure 50 -
Share of Casters Surveyed that Indicated Problems or Concerns with Oscillator .............................................................................................................2-4
Section 3 - Characterizing the Tundish Figure 51 -
Tundish Capacity (Tons) of Casters Surveyed ..................................................3-1
Figure 52 -
Tundish Depth (Inches) of Casters Surveyed ....................................................3-2
Figure 53 -
Number of Tundishes on Hand at Casters Surveyed ........................................3-3
Figure 54 -
Share of Casters Surveyed that have Dams & Weirs .......................................3-4
Figure 55 -
Types of Tundish Flux Used by Casters Surveyed............................................3-4 2003 North American Continuous Caster Market Study
June 2003
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LIST OF FIGURES (Cont.) Figure 56 -
Share of Casters Surveyed that have Permanent Covers.................................3-5
Figure 57 -
Share of Casters Surveyed that have Continuous Temperature Montoring ............................................................................................................3-5
Figure 58 -
Type of Tundish Refractory Used in Casters Surveyed.....................................3-6
Figure 59 -
Heats per Safety Lining of Casters Surveyed ....................................................3-7
Figure 60 -
Types of Working Linings of Casters Surveyed .................................................3-7
Figure 61 -
Billet Casters Working Lining - Heats per Tundish.............................................3-8
Figure 62 -
Bloom Casters Working Lining - Heats per Tundish ..........................................3-8
Figure 63 -
Slab Casters Working Lining - Heats per Tundish .............................................3-9
Figure 64 -
Thin Slab Casters Working Lining - Heats per Tundish .....................................3-9
Figure 65 -
Share of Casters Surveyed that Change Tundish On-the-fly of Casters Surveyed .............................................................................................3-10
Figure 66 -
Suppliers of Tundish Preheat & Drying Equipment for Casters Surveyed...........................................................................................................3-11
Figure 67 -
Age of Present Tundish Preheat & Drying Equipment at Casters Surveyed...........................................................................................................3-12
Figure 68 -
Casters Surveyed that have an Insulated Tundish ..........................................3-13
Figure 69 -
Casters Surveyed that Measure Tundish Level ...............................................3-14
Figure 70 -
Type of Tundish Flow Control Used at Casters Surveyed...............................3-16
Figure 71 -
Casters Surveyed that Are Using only a Stopper Rod for flow control that are neither using or considering a Porous Plug ........................................3-17
Figure 72 -
Type of Pouring Tube Used at Casters Surveyed ...........................................3-18
Figure 73 -
SEN Suppliers to Casters Surveyed that Use SENs .......................................3-18
Figure 74 -
Metering Nozzle Suppliers to Casters Surveyed..............................................3-19
Figure 75 -
Casters Surveyed that Gas Purge the Pouring Stream ...................................3-19 2003 North American Continuous Caster Market Study
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LIST OF FIGURES (Cont.) Figure 76 -
Nozzle Port Configurations Used by Casters Surveyed ..................................3-20
Figure 77 -
When Diminished Flow Dictates Aborting a Strand/Nozzle in Casters Surveyed...........................................................................................................3-21
Figure 78 -
What Return on Investment is Required for Capital Expenditures Indicated by Casters Surveyed ........................................................................3-22
Figure 79 -
Why the Other Casters Surveyed Did Not Indicate What Return on Investment is Required for Capital Expenditures .............................................3-23
Figure 80 -
If A New Technology Were Available That Would Improve Caster Flow, Would... ...................................................................................................3-23
Section 4 - Characterizing the Mold and Mold Level Control Systems Figure 81 -
Mold Shape of Casters Surveyed.......................................................................4-1
Figure 82 -
Type of Mold Level Measurement Technology Used by Casters Surveyed.............................................................................................................4-2
Figure 83 -
Number of Years Eddy Current Mold Level Measurement Technology Has Been Used by Casters Surveyed................................................................4-3
Figure 84 -
Number of Years Radioactice Mold Level Measurement Technology Has Been Used by Casters Surveyed................................................................4-4
Figure 85 -
Omitted
Figure 86 -
Rating the Importance (0-10) of Being Provided Technical Support, Service, and Availability of Spares for Mold Level Measurement Systems by Casters Surveyed ...........................................................................4-8
Section 5 - The Caster Cut System Figure 87 -
Impact on Production if Could Cut Faster, Reduce Kurf Width, and Reduce or Eliminate Slag Adhering to Cut? by Casters Surveyed....................5-2
Figure 88 -
Interest in Real-Time Cut Optimization ..............................................................5-3
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LIST OF FIGURES (Cont.) Section 7 - Caster Maintenance Figure 89 -
How Respondents Characterized Present Maintenance Program of Casters Surveyed ...............................................................................................7-1
Figure 90 -
Equipment or System in the Billet & Bloom Caster Surveyed that Requires the Highest Level of Maintenance ......................................................7-2
Figure 91 -
Equipment or System in the Slab & Thin Slab Caster Surveyed that Requires the Highest Level of Maintenance ......................................................7-3
Figure 92 -
Are Any Caster Maintenance Services Outsourced? ........................................7-4
Figure 93 -
Maintenance Services Outsourced By Casters Surveyed .................................7-5
Figure 94 -
Additional Maintenance Services Outsourced By Casters Surveyed ................7-6
Figure 95 -
Roll Refurbishing Service Suppliers’ Share of Casters Surveyed .....................7-7
Figure 96 -
Complete Mold Reconditioning Services Suppliers’ Share of Casters Surveyed.............................................................................................................7-8
Figure 97 -
Caster Roll Segment Repair Services Suppliers’ Share of Casters Surveyed.............................................................................................................7-9
Figure 98 -
Suppliers’ Providing Fabrication & Repair of Components Share of Casters Surveyed .............................................................................................7-10
Figure 99 -
Suppliers’ Providing Full Service Machining Share of Casters Surveyed...........................................................................................................7-11
Figure 100 - Suppliers’ Providing Technical Support Share of Casters Surveyed...............7-12 Figure 101 - Suppliers’ Providing Total Assembly & Delivery of Completed Machinery & Equipment Suppliers Share of Casters Surveyed ......................7-12 Section 8 - Segment Rebuilding and Bearings Figure 102 - Is Segment Rebuilding Done In-House or Outsourced at Casters Surveyed?...........................................................................................................8-1 Figure 103 - Most Critical Segments in Billet & Bloom Casters Surveyed? ...........................8-2 Figure 104 - Most Critical Segments in Slab & Thin Slab Casters Surveyed?.......................8-3 2003 North American Continuous Caster Market Study June 2003
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LIST OF FIGURES (Cont.) Figure 105 - Target Life of Most Critical Segments in Billet/Bloom Casters Surveyed.............................................................................................................8-4 Figure 106A - Target Life (< 1.5 Million Tons) of Most Critical Segments in Slab Casters Surveyed ...............................................................................................8-4 Figure 106B - Target Life (> 1.5 Million Tons) of Most Critical Segments in Slab Casters Surveyed ...................................................................................8-5 Figure 107 - Target Life of Most Critical Segments in Thin Slab Casters Surveyed..............8-5 Figure 108 - Types of Roll Materials Used in Most Critical Segments of Casters Surveyed.............................................................................................................8-6 Figure 109 - What Lasts Longer in the Most Critical Segments in Casters Surveyed, Rolls or Bearings? .............................................................................8-6 Figure 110 - Average Life of Element That Lasts Longer (Rolls or Bearings) in Most Critical Segments of Billet & Bloom Casters Surveyed.............................8-7 Figure 111 - Average Life of Element That Lasts Longer - Rolls or Bearings (Life 1 million tons) in Most Critical Segments of Slab Casters Surveyed..............8-8 Figure 113 - Average Life of Element That Lasts Longer - Rolls or Bearings in Most Critical Segments of Thin Slab Casters Surveyed ....................................8-9 Section 9 - Bearings and Bearing Rework Figure 114 - Casters Surveyed That are Using Materials other than Standard Spherical Roller Bearings ...................................................................................9-1 Figure 115 - Casters Surveyed Where Environmental Issues are a Factor in Bearing Selection................................................................................................9-2 Figure 116 - Casters Surveyed Where Environmental Issues are a Trade-Off for Longer Life ..........................................................................................................9-2 Figure 117 - Bearing Reclaim Rate of Casters Surveyed.......................................................9-3 Figure 118 - The Most Important Factors in Bearing Rework Services .................................9-4 2003 North American Continuous Caster Market Study June 2003
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LIST OF FIGURES (Cont.) Figure 119 - What is the Weak Link in Segment Rebuilding - Bearings or Rolls? .................9-4 Section 10 - Continuous Caster Lubricants Figure 120 - Most Critical Issues Regarding the Use of Lubricants .....................................10-1 Figure 121 - Consumption (Lbs. Per Year) of High Temperature Lubricants.......................10-2 Figure 122 - Most Important Factors in Lubricant Product for Continuous Casting .............10-3 Figure 123 - Leading Suppliers of Lubricants for Continuous Casting .................................10-4 Figure 124 - Where are Lubricants for Continuous Casting Purchased?.............................10-7 Figure 125 - Who Specifies High Temperature Lubricants for Continuous Casting? ..........10-8
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LIST OF TABLES INTRODUCTION Table 1 -
Table of Caster Segments for Analysis.......................................................... IN-4
Table 2 -
Location and Steel Production of Casters Surveyed..................................... IN-5
Section 1 - Characterizing the Continuous Casters Surveyed Table 3 -
Continuous Cast Steel Production by Plants Surveyed - 2003 vs. 2002....................................................................................................................1-2
Table 4 -
Number of Casters’ by Number of Strands by Type of Caster Surveyed.............................................................................................................1-7
Table 5 -
Steel Production by Type of Steel (AK, SK, AK/SK, Stainless) by Type of Caster ........................................................................................... 1-20
Table 6 -
Casters Surveyed That Are Not Satisfied With the Present Level of Automation........................................................................................................1-37
Section 2 - Characterizing the Existing Oscillator and It’s Performance Table 7 -
Casters With Poor Oscillator Performance or Problems....................................2-5
Table 8 -
Oscillator Performance Comments .............................................................. 2-6
Section 3 - Characterizing the Tundish Table 9 -
Casters Not Satisfied with Tundish Preheating and Drying Equipment.................................................................................................. 3-12
Table 10 -
Casters Planning to Replace Tundish Preheating and Drying Equipment.................................................................................................. 3-13
Table 11 -
Casters Planning to Replace Tundish Level Control.................................. 3-15
Table 12 -
Caster Operations that Would Consider Being a Beta Site for a New Flow Control Technology ................................................................... 3-24
Table 13 -
Beta Site Comments .................................................................................. 3-24
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LIST OF TABLES (Cont.) Section 4 - Characterizing the Mold and Mold Level Control Systems Table 14 -
Casters Dissatisfied with Their Mold Level Measurement System............... 4-5
Table 15 -
Technical Improvements Sought ................................................................. 4-6
Table 16 -
Prospects for Mold Level Measurement Systems........................................ 4-6
Table 17 -
Features / Improvements Sought for a New Mold Level Measurement System .................................................................................. 4-7
Section 5 - The Caster Cut System Table 18 -
The #1 Problem with the Caster Cutting Process ........................................ 5-1
Table 19 -
Casters that Would Consider Outsourcing Maintenance of their Caster Cutting Operation ............................................................................. 5-3
Table 20 -
Prospects for Real-Time Cut Optimization................................................... 5-4
Section 6 - Process Improvement Priorities and Plans For Caster Upgrades Table 21 -
Process Improvement Priorities ................................................................... 6-1
Table 22 -
The Number of Projects Identified By Each of the Caster Types ................. 6-2
Table 23 -
The Top Three (Wish List) Items to be Upgraded or Added to the Caster Operation ......................................................................................... 6-2
Table 24 -
Firm Plans for Capital Investment of Casters in North America ................... 6-3
Table 25 -
New Caster Projects Considered ................................................................. 6-4
Table 26 -
Mechanical Equipment Projects Considered ............................................... 6-4
Table 27 -
Tundish Heaters and Dryers Projects Considered ....................................... 6-5
Table 28 -
Tundish Flying System Projects Considered ............................................... 6-5
Table 29 -
Tundish Projects Considered....................................................................... 6-5
Table 30 -
Tundish Level Control or Ladle Weigh Systems Projects Considered .................................................................................................. 6-5 2003 North American Continuous Caster Market Study
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LIST OF TABLES (Cont.) Table 31 -
Flow Control Projects Considered ............................................................... 6-6
Table 32 -
Mold Projects Considered............................................................................ 6-6
Table 33 -
Mold Level Measurement & Control Projects Considered............................ 6-6
Table 34 -
Electrical and Automation Projects Considered ........................................... 6-7
Table 35 -
Oscillator Projects Considered..................................................................... 6-7
Table 36 -
Spray Chamber Projects Considered........................................................... 6-8
Table 37 -
Dimensional Measurement System Projects Considered ............................ 6-8
Table 38 -
Torch Cut Projects Considered.................................................................... 6-8
Table 39 -
Cooling Bed Projects Considered ................................................................ 6-9
Table 40 -
Run-Out Projects Considered ...................................................................... 6-9
Table 41 -
Other Applications Projects Considered ...................................................... 6-9
Section 7 - Caster Maintenance Table 42 -
Casters That Do Not Have Strand Conditioning Monitoring....................... 7-13
Section 8 - Segment Rebuilding and Bearings Table 43 -
Outsourced Segment Repair Work .............................................................. 8-1
Section 10 - Continuous Caster Lubricants Table 44 -
Casters Least Satisfied with Lubricant Product.......................................... 10-6
Table 45 -
Casters Surveyed that are Most Likely to Consider a New Lubricant Supplier...................................................................................................... 10-7
2003 North American Continuous Caster Market Study June 2003
Prepared by: AIM Market Research Page xviii Copyright 2003 as a published work by AIM Market Research
