Technological Papers

Know-How in Process Control

Danieli Davy Distington

State-of-the-art slab caster for stainless steels at ThyssenKrupp Acciai Speciali Terni (TKAST), Italy

Introduction

1 Bulging and epsilon of Ferritic stainless grades at Vc=1.4 m/min.

and 400 families (austenitic, ferritic and martensitic grades). This state-of-the-art caster producing 215 mm thick slabs replaced an existing thin slab caster. This paper summarizes the reasons for installing the new plant, which was designed, manufactured, erected and commissioned by Danieli. It also describes the technological solution, the main features, and the excellent results of this state-of-the-art caster.

Edited by R. Deli M. Proietti-Cerquoni W. Rossberg [ ThyssenKrupp Acciai Speciali ]

G. Paulon C. P. Piemonte [ Danieli Davy Distington ]

E. Plazzogna [ Danieli Automation ]

> A new slab caster with hot charge roller table, supply of mechanical and hydraulic equipment, and installation; > Supply and installation of Level 1 and Level 2 systems; > Supply and installation of dedicated water treatment plant, compressed air plant, and iron powder exhaust system for torch cutting machine to serve caster production.

Technical solution: design concept To meet the strict quality requirements for slab quality at ThyssenKrupp Stainless, Danieli Davy Distington considered the following criteria in its design: Optimised roller geometry As the product mix covers a wide range of stainless grades, such as 300 and 400 series (austenitic, ferritic and martensitic grades), and the slab is 215 mm thick, the newly built Danieli caster is a vertical curved type machine with an 8.5 m radius and over 2.8 m vertical length, followed by multi-point bending and straightening. This design allows sufficient inclusion flotation as well as appropriate

212

0.30

0.20

Flat products

On April 23, 2009, a new single-strand slab caster at ThyssenKrupp Acciai Speciali Terni (TKAST) was successfully started up with the first cast of AISI 304 grade in the Terni plant of central Italy. TKAST is the Italian company of ThyssenKrupp Stainless group. The new caster is designed for a total capacity of approximately 900,000 t/y of stainless steel slabs covering the complete range of stainless grades, including AISI 300

0.40

Epsilon % Bulging values (mm)

Specifically conceived to cast the full range of stainess steel grades, this new caster embodies all state of the art Danieli technological features to satisfy “top notch” stainless steel flat product users.

In the 1990s, ThyssenKrupp Acciai Speciali Terni (TKAST) decided to install a thin slab caster to feed the existing hot strip mill via roller-type tunnel furnace. The caster was designed to provide the finishing mill with thin slabs in hot charge mode, by-passing the walking beam furnaces and the rougher mill as an alternative to the original conventional route through caster-reheat furnace-roughing mill. In 2007, TKAST decided to replace the CSP caster with a state-of-the-art conventional caster for 215 mm thick, 800-1,600 mm wide slabs. Only the existing ladle turret, casting floor equipment and steel structure could be reused. All the rest had to be rebuilt. The original roller furnace between CSP caster and mill has been replaced by a 200 meter long roller way for hot charging of slabs. The main purpose of this challenging job is to improve slab quality and cut operating costs. Therefore, with the new caster, the inspection and grinding of the slabs before rolling are minimized thanks to hot charging. The scope of work of Danieli Davy Distington includes:

0.10

0.00 0

20

40

60

80

100

Roll number Total Epsilon Epsilon due tu Bulging Epsilon due to Bending/Unbending Epsilon due to Misalignment Bulging

1

bending/straightening stress. The typical Epsilon graph is shown in Figure 1. The 27.3 m machine length allows the maximum casting speed of 1.45 m/min for austenitic grades and 1.4 m/min for ferritic and martensitic grades. As we know, the b.c.c. structured ferrite leads to deformation and creep in stainless steel. So the best support for the slabs has to be taken into account when calculating the roll diagram. Especially in the upper part of the caster, sufficient support is crucial. The selected roll geometry has to overcome the dynamic bulging near the meniscus, particularly at high casting speed. To keep a balance between the stringent dimensional requirements and the deformation tendency due to small roller diameter, multiple split rollers are adopted. Three split rolls are used for the bending and straightening zones and two split rolls for other areas. As far as secondary cooling and closed machine cooling are concerned, special care is taken to secure the best slab quality under all casting conditions.

213

Danieli Davy Distington

State-of-the-art slab caster for stainless steels at ThyssenKrupp Acciai Speciali Terni (TKAST), Italy

Introduction

1 Bulging and epsilon of Ferritic stainless grades at Vc=1.4 m/min.

and 400 families (austenitic, ferritic and martensitic grades). This state-of-the-art caster producing 215 mm thick slabs replaced an existing thin slab caster. This paper summarizes the reasons for installing the new plant, which was designed, manufactured, erected and commissioned by Danieli. It also describes the technological solution, the main features, and the excellent results of this state-of-the-art caster.

Edited by R. Deli M. Proietti-Cerquoni W. Rossberg [ ThyssenKrupp Acciai Speciali ]

G. Paulon C. P. Piemonte [ Danieli Davy Distington ]

E. Plazzogna [ Danieli Automation ]

> A new slab caster with hot charge roller table, supply of mechanical and hydraulic equipment, and installation; > Supply and installation of Level 1 and Level 2 systems; > Supply and installation of dedicated water treatment plant, compressed air plant, and iron powder exhaust system for torch cutting machine to serve caster production.

Technical solution: design concept To meet the strict quality requirements for slab quality at ThyssenKrupp Stainless, Danieli Davy Distington considered the following criteria in its design: Optimised roller geometry As the product mix covers a wide range of stainless grades, such as 300 and 400 series (austenitic, ferritic and martensitic grades), and the slab is 215 mm thick, the newly built Danieli caster is a vertical curved type machine with an 8.5 m radius and over 2.8 m vertical length, followed by multi-point bending and straightening. This design allows sufficient inclusion flotation as well as appropriate

212

0.30

0.20

Flat products

On April 23, 2009, a new single-strand slab caster at ThyssenKrupp Acciai Speciali Terni (TKAST) was successfully started up with the first cast of AISI 304 grade in the Terni plant of central Italy. TKAST is the Italian company of ThyssenKrupp Stainless group. The new caster is designed for a total capacity of approximately 900,000 t/y of stainless steel slabs covering the complete range of stainless grades, including AISI 300

0.40

Epsilon % Bulging values (mm)

Specifically conceived to cast the full range of stainess steel grades, this new caster embodies all state of the art Danieli technological features to satisfy “top notch” stainless steel flat product users.

In the 1990s, ThyssenKrupp Acciai Speciali Terni (TKAST) decided to install a thin slab caster to feed the existing hot strip mill via roller-type tunnel furnace. The caster was designed to provide the finishing mill with thin slabs in hot charge mode, by-passing the walking beam furnaces and the rougher mill as an alternative to the original conventional route through caster-reheat furnace-roughing mill. In 2007, TKAST decided to replace the CSP caster with a state-of-the-art conventional caster for 215 mm thick, 800-1,600 mm wide slabs. Only the existing ladle turret, casting floor equipment and steel structure could be reused. All the rest had to be rebuilt. The original roller furnace between CSP caster and mill has been replaced by a 200 meter long roller way for hot charging of slabs. The main purpose of this challenging job is to improve slab quality and cut operating costs. Therefore, with the new caster, the inspection and grinding of the slabs before rolling are minimized thanks to hot charging. The scope of work of Danieli Davy Distington includes:

0.10

0.00 0

20

40

60

80

100

Roll number Total Epsilon Epsilon due tu Bulging Epsilon due to Bending/Unbending Epsilon due to Misalignment Bulging

1

bending/straightening stress. The typical Epsilon graph is shown in Figure 1. The 27.3 m machine length allows the maximum casting speed of 1.45 m/min for austenitic grades and 1.4 m/min for ferritic and martensitic grades. As we know, the b.c.c. structured ferrite leads to deformation and creep in stainless steel. So the best support for the slabs has to be taken into account when calculating the roll diagram. Especially in the upper part of the caster, sufficient support is crucial. The selected roll geometry has to overcome the dynamic bulging near the meniscus, particularly at high casting speed. To keep a balance between the stringent dimensional requirements and the deformation tendency due to small roller diameter, multiple split rollers are adopted. Three split rolls are used for the bending and straightening zones and two split rolls for other areas. As far as secondary cooling and closed machine cooling are concerned, special care is taken to secure the best slab quality under all casting conditions.

213

State-of-the-art slab caster for stainless steels

Danieli Davy Distington

2

2 Roll geometry of the caster. 3 Specific secondary cooling flow rate as a function of Vc for stainless steel grades.

1.80

1.20

4 Installation of OPTIMUM segment.

Layout From a layout viewpoint, the caster design had to take into account the need to reuse the existing casting platform and civil works, with a casting floor at 14.7 meters from ground level (level dictated by the vertical design of the old CSP caster). As a consequence, the new passline of the caster is located at a height of about 3.3 meters from ground level. Hence, the caster body as well as the slab torch cutting and bottom dummy bar parking area have been installed on an elevated supporting structure. Specific structural simulations have been carried out on this supporting structure in order to ensure caster rigidity even under severe mechanical and thermal load, preventing vibrations and unwanted deformations. From the end of the caster to the charging area of the mill, (an area previously occupied by a thin slab, roller-type tunnel furnace) an inclined roller table has been installed (230 meters in length) to gradually transfer the slab from the 3.3-meter elevated platform level to the 800-mm mill entry level.

0.90

0.60 SS Ferritic SS Austenitic

0.30

0.00 0.70

0.90

1.10

1.30

1.50

Casting speed (m/min)

In the top zone, water nozzles are installed for hard cooling at high flow rates for ferritic grades. In the bending area and in the following segments, air-mist cooling is applied for fine tuning. All secondary cooling is controlled by means of a dynamic model that continuously adapts the cooling fluid flow rate and pressure in order to guarantee the proper slab temperature profile, predicted with virtual sensor mathematical modelling that takes into account the “live” status of all the parameters of the casting process that affect slab temperature (superheat, casting speeds, flows, roll cooling, etc.), as well as specific steel grade solidification behavior and metallurgical needs. In order to cope with the different slab widths to be cast (from 800 to 1600 mm), and to avoid overcooling of narrow slabs, the lateral zoning in the secondary cooling area is considered separate from the bending zone. As illustrated in Figure 5, a total of 19 independent control loops are shown. In addition to the secondary cooling nozzles, a dedicated set of tangential water nozzles are placed along the caster in order to promote scale detachment from the roll surface (hence reducing the risk of scale “printing” on the slab surface).

4

Mechanical solution Mold and its oscillating, width adjustment devices Strict control of oscillating parameters as well as limitation of lateral movements on the mold and oscillation marks are particularly important in casting stainless steels. This INMO (INtegrated MOtion) mold and

5 Control loops for secondary cooling.

1

4

11

19

33

26 22

29

40 36

54

47 43

50

61 57

oscillating system has been developed by Danieli to provide very precise guidance of the oscillating mold with respect to the strand passline, as well as wide flexibility of operation in terms of the applied stroke, frequency and waveform. This now makes it possible to provide the best oscillation condition for both good mold lubrication and the best conditions for good surface quality for the wide range of casting speeds and/or steel grades. The “Spring free” guiding system with eight rolling elements and two servo-controlled hydraulic cylinders constitutes the precise oscillating system. This system also uses socalled "inverse oscillation," where frequency decreases and stroke increases as casting speed increases.

75

68 64

71

82 78

89 85

96 92

102 99

2

214

215

Flat products

Cooling control during slab solidification Apart from the optimized roll diagram, another paramount issue for getting the best slab quality is to properly control the slab temperature during cooling. In Figure 3, the correlation between the specific flow rate of secondary cooling water and the casting speed for austenitic and ferritic steel grades is shown. Due to the wide range of steel grades to be produced, different solidification characteristics have to be taken into consideration during the design of the secondary cooling system. As a result, water cooling and air-mist cooling are employed.

3 Water flow rate/steel output (l/Kg)

Surface quality is the most critical issue for stainless steel production. And, the accurate control of the temperature between the slab and the roller surface plays a key role in preventing scale formation. For this reason, peripherally drilled rolls (PDR) are adopted in the segments as long as the roller diameter can stand load, i.e., starting at segment 4 and continuing downstream. The roll geometry shown in Figure 2 guarantees even load distribution on the rolls and can effectively counteract thermal distortion under variable heat fluxes, which is of great importance during casting speed transition.

State-of-the-art slab caster for stainless steels

Danieli Davy Distington

2

2 Roll geometry of the caster. 3 Specific secondary cooling flow rate as a function of Vc for stainless steel grades.

1.80

1.20

4 Installation of OPTIMUM segment.

Layout From a layout viewpoint, the caster design had to take into account the need to reuse the existing casting platform and civil works, with a casting floor at 14.7 meters from ground level (level dictated by the vertical design of the old CSP caster). As a consequence, the new passline of the caster is located at a height of about 3.3 meters from ground level. Hence, the caster body as well as the slab torch cutting and bottom dummy bar parking area have been installed on an elevated supporting structure. Specific structural simulations have been carried out on this supporting structure in order to ensure caster rigidity even under severe mechanical and thermal load, preventing vibrations and unwanted deformations. From the end of the caster to the charging area of the mill, (an area previously occupied by a thin slab, roller-type tunnel furnace) an inclined roller table has been installed (230 meters in length) to gradually transfer the slab from the 3.3-meter elevated platform level to the 800-mm mill entry level.

0.90

0.60 SS Ferritic SS Austenitic

0.30

0.00 0.70

0.90

1.10

1.30

1.50

Casting speed (m/min)

In the top zone, water nozzles are installed for hard cooling at high flow rates for ferritic grades. In the bending area and in the following segments, air-mist cooling is applied for fine tuning. All secondary cooling is controlled by means of a dynamic model that continuously adapts the cooling fluid flow rate and pressure in order to guarantee the proper slab temperature profile, predicted with virtual sensor mathematical modelling that takes into account the “live” status of all the parameters of the casting process that affect slab temperature (superheat, casting speeds, flows, roll cooling, etc.), as well as specific steel grade solidification behavior and metallurgical needs. In order to cope with the different slab widths to be cast (from 800 to 1600 mm), and to avoid overcooling of narrow slabs, the lateral zoning in the secondary cooling area is considered separate from the bending zone. As illustrated in Figure 5, a total of 19 independent control loops are shown. In addition to the secondary cooling nozzles, a dedicated set of tangential water nozzles are placed along the caster in order to promote scale detachment from the roll surface (hence reducing the risk of scale “printing” on the slab surface).

4

Mechanical solution Mold and its oscillating, width adjustment devices Strict control of oscillating parameters as well as limitation of lateral movements on the mold and oscillation marks are particularly important in casting stainless steels. This INMO (INtegrated MOtion) mold and

5 Control loops for secondary cooling.

1

4

11

19

33

26 22

29

40 36

54

47 43

50

61 57

oscillating system has been developed by Danieli to provide very precise guidance of the oscillating mold with respect to the strand passline, as well as wide flexibility of operation in terms of the applied stroke, frequency and waveform. This now makes it possible to provide the best oscillation condition for both good mold lubrication and the best conditions for good surface quality for the wide range of casting speeds and/or steel grades. The “Spring free” guiding system with eight rolling elements and two servo-controlled hydraulic cylinders constitutes the precise oscillating system. This system also uses socalled "inverse oscillation," where frequency decreases and stroke increases as casting speed increases.

75

68 64

71

82 78

89 85

96 92

102 99

2

214

215

Flat products

Cooling control during slab solidification Apart from the optimized roll diagram, another paramount issue for getting the best slab quality is to properly control the slab temperature during cooling. In Figure 3, the correlation between the specific flow rate of secondary cooling water and the casting speed for austenitic and ferritic steel grades is shown. Due to the wide range of steel grades to be produced, different solidification characteristics have to be taken into consideration during the design of the secondary cooling system. As a result, water cooling and air-mist cooling are employed.

3 Water flow rate/steel output (l/Kg)

Surface quality is the most critical issue for stainless steel production. And, the accurate control of the temperature between the slab and the roller surface plays a key role in preventing scale formation. For this reason, peripherally drilled rolls (PDR) are adopted in the segments as long as the roller diameter can stand load, i.e., starting at segment 4 and continuing downstream. The roll geometry shown in Figure 2 guarantees even load distribution on the rolls and can effectively counteract thermal distortion under variable heat fluxes, which is of great importance during casting speed transition.

Danieli Davy Distington

State-of-the-art slab caster for stainless steels

6-7 INMO (INtegrated MOtion) mold and oscillator in Danieli workshops.

7

6

In order to prevent any negative influence on surface quality, an important role is played by the cladding used for the casing rolls. The correct balance in surface hardness has to be selected in order to avoid the risk of slab damage, but also to ensure the proper roll service life. The correct balance is achieved by multiple-layer roll cladding with stainless steel of different mechanical properties and final heat treatment. The selection of these parameters was agreed between Danieli and the customer, considering their specific experience on stainless steel slab casters.

Main Control Pulpit.

9

MOREIntelligence a Danieli Automation multidimensional data analysis system.

As mentioned above, special emphasis was placed on defining roll diameter and pitch distribution (multiple split type), secondary cooling and machine cooling, for the purpose of ensuring the best strand support and actively counteracting creep and dynamic bulging under all casting conditions. The Danieli OPTIMUM segment, mechanically designed for the application of the soft reduction process, has been adopted for containment purposes.

216

From an automation perspective, Danieli Automation installed a new L1 and L2 advanced control system with client/server architecture and a complete set of mathematical models for casting process control, including: > Slab width control in mold; > Dynamic control of hydraulic oscillation parameters; > Advanced breakout prevention system with both mold thermal mapping and main rows temperature trends, as shown in Figure 10.

Operating results After a flawless commissioning and performance test period, the caster was fully accepted by the customer with the signing of the Final Acceptance Certificate in September 2009, only five months after the first heat. During commissioning, austenitic grades were produced together with a significant amount of ferritic grades. As for the quality results, they are in line with TKAST expectations and internal standards, namely:

10Mold breakout prevention system HMI with thermal mapping.

> After only a few weeks TKAST - with the new caster - was able to produce slabs that met all the quality standards of the existing caster. > Around 85% of cast slabs did not require any kind of conditioning prior to rolling. These statistical data collected during the performance tests are quite significant since they are based on almost 94% of cast slabs that were inspected for testing purposes. Thanks to this performance the machine is presently running according to production schedule, limited only by market demand.

Automation system Strand guide system

Of particular interest is the advanced MORE Intelligence tool for multi-dimensional analysis of the process, and plant data and performance. This innovative engineering and production tool developed by Danieli Automation offers a totally new approach to process data analysis for steelmaking and casting plants. Simple and economically efficient, it offers to the customer the possibility to collect, in real time, data of all production aspects, with particular attention to productivity and quality items, as shown in Figure 9.

11 Handshake between TKAST and Danieli site managers at the end of caster commissioning.

Conclusion Stainless steel producers are among the most demanding as regards the quality (namely surface quality) of the slabs they use in their mills. The Danieli concepts for process and mechanical engineering guarantee the ultimate product quality for stainless steel, as well as virtually eliminating all off-line inspections before rolling with this new TKAST caster.

217

Flat products

For the new Terni caster, the maximum frequency is 300 opm and the maximum stroke setting is + / - 6mm. The copper mold plates are designed to provide uniform cooling around the slab surface, especially in the critical meniscus area. The mold is capable of being adjusted remotely to any width in the design range, both during and outside the casting operation. The mold’s wide face tapers are fixed; the narrow face tapers are automatically changed during width changes to suit the slab width and steel grade being produced.

8

Danieli Davy Distington

State-of-the-art slab caster for stainless steels

6-7 INMO (INtegrated MOtion) mold and oscillator in Danieli workshops.

7

6

In order to prevent any negative influence on surface quality, an important role is played by the cladding used for the casing rolls. The correct balance in surface hardness has to be selected in order to avoid the risk of slab damage, but also to ensure the proper roll service life. The correct balance is achieved by multiple-layer roll cladding with stainless steel of different mechanical properties and final heat treatment. The selection of these parameters was agreed between Danieli and the customer, considering their specific experience on stainless steel slab casters.

Main Control Pulpit.

9

MOREIntelligence a Danieli Automation multidimensional data analysis system.

As mentioned above, special emphasis was placed on defining roll diameter and pitch distribution (multiple split type), secondary cooling and machine cooling, for the purpose of ensuring the best strand support and actively counteracting creep and dynamic bulging under all casting conditions. The Danieli OPTIMUM segment, mechanically designed for the application of the soft reduction process, has been adopted for containment purposes.

216

From an automation perspective, Danieli Automation installed a new L1 and L2 advanced control system with client/server architecture and a complete set of mathematical models for casting process control, including: > Slab width control in mold; > Dynamic control of hydraulic oscillation parameters; > Advanced breakout prevention system with both mold thermal mapping and main rows temperature trends, as shown in Figure 10.

Operating results After a flawless commissioning and performance test period, the caster was fully accepted by the customer with the signing of the Final Acceptance Certificate in September 2009, only five months after the first heat. During commissioning, austenitic grades were produced together with a significant amount of ferritic grades. As for the quality results, they are in line with TKAST expectations and internal standards, namely:

10Mold breakout prevention system HMI with thermal mapping.

> After only a few weeks TKAST - with the new caster - was able to produce slabs that met all the quality standards of the existing caster. > Around 85% of cast slabs did not require any kind of conditioning prior to rolling. These statistical data collected during the performance tests are quite significant since they are based on almost 94% of cast slabs that were inspected for testing purposes. Thanks to this performance the machine is presently running according to production schedule, limited only by market demand.

Automation system Strand guide system

Of particular interest is the advanced MORE Intelligence tool for multi-dimensional analysis of the process, and plant data and performance. This innovative engineering and production tool developed by Danieli Automation offers a totally new approach to process data analysis for steelmaking and casting plants. Simple and economically efficient, it offers to the customer the possibility to collect, in real time, data of all production aspects, with particular attention to productivity and quality items, as shown in Figure 9.

11 Handshake between TKAST and Danieli site managers at the end of caster commissioning.

Conclusion Stainless steel producers are among the most demanding as regards the quality (namely surface quality) of the slabs they use in their mills. The Danieli concepts for process and mechanical engineering guarantee the ultimate product quality for stainless steel, as well as virtually eliminating all off-line inspections before rolling with this new TKAST caster.

217

Flat products

For the new Terni caster, the maximum frequency is 300 opm and the maximum stroke setting is + / - 6mm. The copper mold plates are designed to provide uniform cooling around the slab surface, especially in the critical meniscus area. The mold is capable of being adjusted remotely to any width in the design range, both during and outside the casting operation. The mold’s wide face tapers are fixed; the narrow face tapers are automatically changed during width changes to suit the slab width and steel grade being produced.

8

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