TECHNOLOGICAL LEADERSHIP POWERFUL ECONOMICS Continuous casters for flat products Reference journal

Transcription

1 TECHNOLOGICAL LEADERSHIP POWERFUL ECONOMICS for flat products Reference journal SMS SIEMAG METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY for flat products 42 continuous casters 52 strands Orders and commissioning projects References are the most convincing proof of our customers' trust in the technical and economic efficiency of SMS Siemag. 42 continuous casters which we have already successfully commissioned, or will be commissioning, between 2009 and 2014 alone are eloquent proof of this successful and trustworthy cooperation with our customers. On the basis of our more than 140 years of experience in the field of metallurgical plant and rolling mill technology, we develop and implement innovative plant solutions for the world market: Ranging from turnkey integrated plants to revamps and to powerful and efficient single components, including the electrical and automation systems and the servicing. Thus, from technical lines, we create integrated valueadded chains in close cooperation with our customers and with leading research institutes.

2 CONTENTS 2013/2014 AG der Dillinger Hüttenwerke 8 Salzgitter Flachstahl GmbH 9 Jindal Steel & Power Ltd. 10 PT. Gunung 11 Siderar S.A.I.C. 12 Tata Steel Ltd Fuxin Special Steel 18 Salzgitter Flachstahl GmbH 20 Tata Steel Ltd. 22 Jindal South West Steel Ltd. 22 SAIL Rourkela Steel Plant Bhushan Steel Ltd. 26 Maghreb Steel 28 Essar Steel Ltd. 30 Severstal North America 32 Bhushan Steel Ltd. 34 Jindal Stainless Ltd. 35 Jindal South West Ltd Dillinger Hüttenwerke 40 ArcelorMittal Burns Harbour LLC 42 Bhushan Power and Steel Ltd. 44 Salem Steel Plant 45 Peiner Träger GmbH 46 Salzgitter Flachstahl GmbH 48 Tokyo Steel Manufacturing Co. Ltd ArcelorMittal Lazaro Cardenas 54 China Steel Corp. (CSC) 56 Magnitogorsk Iron and Steel Works 58 Maanshan Iron and Steel Company 60 Wuhan Iron and Steel Corp. (Wisco) 62 Jindal Stainless Hisar 64

3 REFERENCES 2013/

4 AG DER DILLINGER HÜTTENWERKE Germany Sixth installation from SMS Casting concept successful for 50 years Customer-specific: World's thickest slabs SALZGITTER FLACHSTAHL GMBH Germany Modernization Four continuous casters from SMS automation SMS-know-how: Erection concept with minimum downtimes Two-strand caster for thick slabs With a total volume of around 300 million Euro, Dillinger Hütte is investing in the manufacture of high-quality slabs for the demanding production of heavy plates. As part of this investment scheme, SMS Siemag was awarded the biggest-ever contract in the history of continuous casting. SMS Siemag supplies the casting floor, moulds, hydraulic oscillator, strand guide system, edge-controlled secondary cooling and position-controlled segment gap adjustment as well as the pinch-roll units for the dummy bar and hot strand. The complete is also included in the supply. The continuous caster is equipped with the proven technological systems for mould-level control, hydraulic oscillator, hydraulic segment gap adjustment with dynamic soft reduction and load compensation control. In cooperation with the department of Dillinger Hütte, SMS Siemag has developed a hydraulic adjustment system for the pinch rolls specially for this continuous slab caster. Use is made of dynamic soft reduction for the diameter range in question to manufacture semifinished products with optimized internal quality. This involves pressing the strand shell together during casting in such a way as to enable the material properties to be homogeneous right into the core. The adjustment mechanisms otherwise customary in continuous casters will be extended by a further dimension on the basis of experience gained with rolling technology. The result will be a further enhancement of the soft reduction rates, as implemented successfully for the CC5 in Dillingen. In conformity with the customer's specifications, the vertical external walls of the deep parts of the foundation are not, as otherwise usual, built on a rectangular ground-plan area but on a circular area. The self-supporting effect of this cross-sectional layout makes it possible to do without costly and time-consuming horizontal anchors, which makes it easier to perform the work on site. The design of the CC6 essentially corresponds to that of the CC5 continuous caster. This results in substantial synergy effects for operation, servicing and maintenance. The commissioning of the two-strand vertical-type continuous caster is scheduled for spring Technical data AG der Dillinger Hüttenwerke 2014 Continuous 1 two-strand vertical-type caster with slab casting turning equipment Ladle contents 190 t Annual production 1,200,000 tpy Slab dimensions 300 to 500 mm 2,200 mm approx. 6.7 to 11 m Metallurgical length 17.4 m Number of segments 9 SMS Siemag awarded contract for modernization of caster 2, Salzgitter Flachstahl Salzgitter Flachstahl, Germany, has awarded SMS Siemag a contract for the supply of a new ladle turret for the continuous caster no. 2 in its Salzgitter works. SMS Siemag's scope of supply comprises all mechanical, hydraulic and electrical components, the necessary foundation work as well as the complete erection and installation. The two-strand caster no. 2 is located between casters no. 1 and 3 and the space available for dismantling and erection is very confined. Ongoing production in the adjoining areas must not be impaired during the revamp. To ensure this, SMS Siemag has developed a special erection concept with the aim of minimizing the downtime of continuous caster no. 2 while continuing production on the other continuous casters except for a short shut-down period of 10 hours. Replacement of the ladle turret is scheduled for the summer of Salzgitter Flachstahl operates four continuous casting lines at this location; all of them were supplied by SMS Siemag. Continuous caster no. 2 started operation in Technical data Salzgitter Flachstahl 2013 Continuous 1 two-strand bow-type caster casting Ladle contents 210 t Annual production 1,800,000 tpy Slab dimensions 250 mm, 1,100 to 2,040 mm Metallurgical length 30.1 m Machine radius m Number of segments 12 Bending points multi-point bending 8 9

5 JINDAL STEEL & POWER LTD. India Modernization India's largest slab cross section Extension of product portfolio Large variety of products PT. GUNUNG Bekasi, Indonesia All major production lines were supplied by the SMS group. Large variety of products SMS-know-how: Intelligent Slab Casting SMS Siemag awarded contract for modernization of JSPL caster India's largest slab cross section SMS Siemag modernizes the slab caster at the Raigarh, Chhattisgarh, works of Jindal Steel & Power Limited. The revamp is designed to expand JSPL's line of quality steel grades and slab dimensions. Added to the portfolio will be high-tech pipe and tube grades (API), High Carbon Steels and microalloyed peritectic grades. The current slab size of max. 2,600 mm width and max. 280 mm thickness will be increased to 3,000 mm width and 300 mm thickness. The caster will thus be rated for an annual production of 1.5 million t of steel slabs. The caster was bought in 2006 as second-hand unit and commissioned by SMS Siemag in SMS Siemag supplies a completely new strand guide system, while the foundations and the ladle turret will be maintained. The existing hydraulic systems will be upgraded in line with the new requirements. The modernization scope will also include SMS Siemag's supply of the dummy bar system, new moulds, new torch cutting units as well as a new slab removal system. Also included in the supply scope will be the basic and detail engineering, the supply of all mechanical components and the complete automation package, including the control systems and models. The equipment of the caster includes several Intelligent Slab Casting (ISC ) modules which determine quality and production. Among these are the remotecontrolled mould narrow faces for width change during casting (online) and the position-controlled segments for performing Dynamic Soft Reduction. The manufacture of slabs of a high internal quality is thus guaranteed Technical data JSPL 2013 by the above in combination with the width-dependent air-mist secondary cooling and the Dynamic Solidification Control model. The Integrated Production Quality System IPQSslab safeguards the slab quality through the monitoring of all relevant measured data. Commissioning is scheduled for the autumn of Continuous 1 single-strand bow-type caster casting Ladle contents nom. 100 t Annual production > 1,450,000 tpy Slab dimensions 180 to 300 mm, 1,250 to 3,000 mm 3.5 to 12.0 m Metallurgical length 23.5 m Machine radius 12.0 m Number of segments 12 Bending points continuous straightening Slab caster ensures higher added value At their Bekasi works, PT. Gunung operate a long-product line for the production of sections and wire rods, as well as a flat-product line for the production of heavy plates and pipes. All major production lines were supplied by companies of the SMS group. In 2011, SMS Siemag was awarded a contract for the supply of a single-strand slab caster for operation in the Bekasi works. The caster with an annual production capacity of 1.2 million t of slabs will produce 220 and 250 mm thick slabs which are between 800 and 2,100 mm wide. The range of grades produced will comprise structural steels as well as pipe and heavy-plate grades. With its new caster, PT. Gunung will produce high-quality slabs for further ing in its own Steckel and heavy-plate mill. In the past, slabs were bought out. Now, a higher added value accompanied by better quality can be achieved. The caster will be equipped with modules from the Intelligent Slab Casting (ISC ) package, which will ensure an optimum productivity and slab quality. These modules will include the hydraulically powered resonance oscillator, the mould with remote-adjustable narrow faces for changing the slab width during casting, as well as the Mould Monitoring System. The horizontal part of the strand guide system will use position-controlled CyberLink segments. Dynamic Soft Reduction in combination with the metallurgical module Dynamic Solidification Control (DSC) to control secondary cooling will allow the production of segregation-free slabs. SMS Siemag's scope of supply includes the engineering, mechanical equipment and hydraulic system plus the which will be commissioned according to the proven "Plug & Work" concept. Commissioning of the caster is scheduled for the middle of Technical data - PT. Gunung 2013 Continuous 1 single-strand vertical bending caster casting Ladle contents max. 120 t Annual production > 1,200,000 tpy Slab dimensions 220/250 mm 800 to 2,100 mm 4.5 to 11.0 m Metallurgical length 29 m Machine radius 9.5 m Vertical length 2.5 m Number of segments

6 SIDERAR S.A.I.C. Argentina Large variety of products Converter meltshop plus another continuous caster from SMS Siemag Two-strand slab caster for the San Nicolás works, Buenos Aires Siderar S.A.I.C., Argentina, has awarded SMS Siemag an order for the supply of a two-strand slab caster for operation in their San Nicolás, Buenos Aires, works. The caster is rated for the production of 200 or 250 mm thick slabs that range in width between 750 and 1,900 mm. The annual production capacity is around 2.3 million t of slabs. Strand guide system and segment removal guide rails. The caster will be equipped with the Intelligent Slab Casting (ISC ) technologies that ensure a high productivity and slab quality. Included are the hydraulically powered resonance oscillator and the mould with remote-adjusted narrow faces to change the width during casting. The horizontal part of the strand guide system uses position-controlled CyberLink segments. Dynamic Soft Reduction in combination with the technological module Dynamic Solidification Control (DSC ) to control secondary cooling will allow the production of segregation-free slabs. The scope of supply includes the engineering, the supply of the mechanical core components and the automation system, plus commissioning according to the tried-and-tested "Plug & Work" concept. Technical data Siderar S.A.I.C Continuous 1 two-strand vertical bending caster casting Ladle contents max. 200 t Annual production > 2,300,000 tpy Slab dimensions 200 mm 750 to 1,900 mm 6.0 to 12.5 m Metallurgical length 26.6 m Machine radius 8.0 m Vertical length 2.5 m Number of segments 12 Thanks to the new caster, Siderar will be able to fully utilize the capacity of the upstream meltshops and increase its production capacity for low to medium-carbon steels and peritectic grades. In its San Nicolás works Siderar operates a BOF meltshop and a continuous caster. Both units were supplied by SMS Siemag and have since been modernized

7 TATA STEEL LTD. India Economic: High-capacity installation Customer-specific: India's most powerful installation India's most powerful two-strand slab caster Tata Steel Ltd., India, has awarded SMS Siemag a contract for the supply of a two-strand slab caster for their Kalinganagar works in the East Indian federal state of Orissa. Tata Steel is India's largest privately owned steelmaker and with this order it is implementing an ambitious project which envisages an annual steel production of three million t. The two-strand continuous slab caster is designed for the production of slabs with a thickness of 230 mm and widths from 1,000 to 2,150 mm. The scope of supply comprises the detail engineering, mechanical equipment, hydraulic system, as well as the complete automation package including models. The mould with resonance oscillator is equipped with a remote adjustment system for the narrow faces, which allows the casting width to be adjusted in operation. The oscillator with variable lifting frequency, lifting height and curve shape yields a consistently good slab surface. The caster comes equipped with the SMS Siemag-patented Dynamic Soft Reduction and hydraulically adjusted CyberLink segments. The entire for the continuous caster is set up completely in the SMS Siemag test centre before commissioning and then tested and optimized by means of plant-specific simulation software. Technical data Tata Steel Ltd Continuous 1 two-strand vertical bending caster casting Ladle contents 310 t Annual production 3,000,000 tpy Slab dimensions 200 mm 1,000 to 2,150 mm 6.0 to 11.5 m Metallurgical length 35.6 m Machine radius 9.59 m Vertical length 2.7 m Number of segments 16 Bildbeschriftung Control pulpit on the casting floor

8 REFERENCES

9 FUXIN SPECIAL STEEL CO. LTD. China Continuous caster for stainless steel grades SMS-know how: - Electro-magnetic strand stirrer developed by SMS - Slab store with sloweddown slab cooling SMS Siemag also supplies the upstream steelmaking plant Stainless steel slab caster for an annual production of 720,000 t Fuxin Special Steel Company has awarded SMS Siemag a contract for the planning and supply of a complete steelworks for stainless steels. The works will be built in Zhangzhou in the southeast of the Chinese Province Fujian. The works is designed for a steel production of 720,000 t per year. Commissioning of the special-steel works is scheduled for the end of Technical data Fuxin Special Steel Co. Ltd The works layout already makes provision for a second construction stage, allowing production capacity to be doubled. The new project includes all equipment for the scrap-based production of stainless steel (duplex route), a continuous slab caster as well as a large number of facilities for environmental protection. The range of grades produced by the steelworks comprises ferritic, austenitic and martensitic stainless steels which are ed on the continuous caster to produce 200 or 220 mm thick slabs. During casting, the slab width can be set steplessly from 800 to 1,600 mm. The plant is equipped with the latest-generation ISC modules (Intelligent Slab Casting). These include the hydraulically powered resonance oscillator for the mould, the position-controlled CyberLink segments and the metallurgical Dynamic Solidification Control (DSC) model for control of the secondary cooling. Together with the electro-magnetic strand stirrer (EMS). This allows the production of slabs with a very high quality. Continuous casting 1 single-strand vertical bending caster Ladle contents 180 t Annual production 720,000 tpy Slab dimensions 200 /220 mm 800 to 1,600 mm 5.0 to 12.0 m Metallurgical length 25.8 m Machine radius 8.0 m Vertical length 2.5 m Number of segments 12 The supply scope comprises the complete basic and detail engineering, the supply of mechanical and electrical core components, the automation package including the Level 1 automation and the Level 2 metallurgical models, all free-issue parts and the supervision of erection and commissioning. This is how the segment workshop is planned in 3D

10 SALZGITTER FLACHSTAHL GMBH Germany Modernization Large variety of products Economic: Increased production capacity Expansion of continuous caster no. 3 Salzgitter Flachstahl GmbH placed an order with SMS Siemag for the expansion of the single-strand slab caster no. 3. The aim is to maintain and also increase the casting speed, in particular for small casting widths, thereby enhancing the production capacity. With continuous caster no. 3 supplied by SMS Siemag in 2004 for slabs with thicknesses of 250 mm and widths of 850 to 2,100 mm, Salzgitter Flachstahl's range of steel grades was expanded with a focus on IF steel, C steels, I steels, microalloyed and sourgas-resistant steels. To allow its future expansion, the continuous caster had been designed for the inclusion of three segment places, i.e. segments 13 to 15. Segment 13 will now be installed to increase the production capacity. SMS Siemag's scope of supply includes segment 13, the mechanical equipment, the adaptations of the electrical and s and hydraulic equipment, the supervision of erection and schedules as well as commissioning. The expansion will take place in 2012 during a short shutdown phase and without interrupting the production of other continuous casters. Plant engineering and technologies Vertical bending machine of pure segment design, with widths ranging from 850 to 2,100 mm Mould with remote-controlled narrow faces for altering the width during casting Spring-guided resonance oscillator with hydraulic actuator Segments in horizontal section of CyberLink design Hydraulic segment adjustment and dynamic soft reduction in horizontal section Dynamic spray-water model for setting the optimum slab temperature and for determining the solidification point Breakout prediction system Technical data Salzgitter Flachstahl GmbH 2012 Continuous 1 single-strand vertical bending caster casting Ladle contents 210 t (max. 230 t) Slab dimensions 250 mm 850 to 2,100 mm 5.2 to 12.4 m Metallurgical length 33.4 m Machine radius 9.0 m Vertical length 2.6 m Number of segments 13 Strand guide system. Ladle turret

11 TATA STEEL LTD. India Expansion of challenging product portfolio Customer-specific: Supply of company's own automotive production SAIL ROURKELA STEEL PLANT India Expansion of product portfolio by large slab cross-section Four continuous slab casters from SMS Siemag Customer satisfaction for more than 20 years CSP plant for the production of 2.4 m t of hot strip Continuous slab caster with large slab cross-section The CSP plant will complement the conventional type hot strip mill supplied by SMS Siemag in It will allow our customer to specialize on a line of high-quality products comprising strip made from silicon grades, pipe and tube steels and dual-phase steels. Tata Steel will use a portion of its hot strip to supply the group's own automotive factories. Rourkela Steel Plant (Steel Authority of India Limited), India, has awarded SMS Siemag a contract for the supply of a continuous caster for its Rourkela works in the federal state of Orissa. The single-strand caster will be used to produce 220, 250 and 300 m thick slabs ranging in width from 1,300 to 2,500 mm. The contract includes the supply of the complete mechanical equipment plus the s. The CSP plant is rated for an annual capacity of 2.4 million t of 900 to 1,680 mm wide and 1.0 to 20.0 mm thick hot strip. Depending on the requirements of the and the final product, the slab thickness can be steplessly adjusted in ranges of 50 to 70 mm and 70 to 90 mm. The CSP plant consists of two vertical bending type casters, two tunnel furnaces with swivel transfer car, a rolling mill with six millstands, laminar strip cooling and two downcoilers. Technical data Tata Steel Ltd Continuous 2 single-strand vertical bending casters casting Ladle contents 165 t Annual production 2,400,000 tpy Slab dimensions 90 to 70 / 70 to 55 (55) mm (900) 950 to 1,680 mm steplessly by LCR 3 Metallurgical length 9.71 m Machine radius 3.25 m Number of segments 5 Bending points continuous straightening Included in the contract scope are the basic and detail engineering, the supply of all mechanical components and the complete X-Pact electrical and automation package, including the control systems and models. The caster equipment includes several Intelligent Slab Casting (ISC ) modules which determine quality and production. Among these are the hydraulically driven resonance oscillation system, remotecontrolled mould narrow faces for width change during casting and the position-controlled CyberLink segments for performing Dynamic Soft Reduction. The production of slabs of a high internal quality is thus guaranteed by the above in combination Technical data SAIL Rourkela Steel Plant 2012 Continuous 1 single-strand vertical bending caster casting Ladle contents 150 t Annual production 1,500,000 tpy Slab dimensions 220 / 250 / 300 mm 1,200 to 2,500 mm primary 6 to 10 m, secondary 2 to 4.8 m Metallurgical length 34.2 m Machine radius 9.5 m Vertical length 2.7 m Number of segments 15 with the width-dependent air-mist secondary cooling and the Dynamic Solidification Control model. Rourkela Steel Plant will mainly be producing sophisticated microalloyed steels and heavy-plate grades on the caster. Commissioning is scheduled for JINDAL SOUTH WEST STEEL LTD. India Modernization of two single-strand slab casters SMS Siemag will modernize two single-strand slab casters in the no. 1 works of Jindal South West Steel Ltd. in Toranagallu in the Indian federal state of Karnataka. The slab casters were supplied by SMS Siemag in 1999 and The aim of this modernization is to upgrade the casters to the current production conditions and to achieve a cost-effective maintenance. Technical data Jindal South West Steel Ltd Continuous 2 single-strand bow-type casters casting Ladle contents 135 t Annual production 1,800,000 tpy Slab dimensions to 1,300 mm 4.05 to 10.7 m Metallurgical length 29.4 m Machine radius 10.5 m Number of segments 15 Bending points multi-point straightening Modernization SMS-know how: cost-effective maintenance 22 23

12 REFERENCES

13 BHUSHAN STEEL LTD. India High-capacity installation: India's longest facility high-speed casting Economic: direct charging Four continuous slab casters from SMS Siemag, Conarc steelmaking plant and rolling mill Production of sophisticated pipe grades In 2009, Bhushan Steel Ltd. awarded SMS Siemag a contract for the supply of a continuous caster for the production of 1,680 mm slabs, followed in 2011 by a contract for the supply of two continuous casters each for the same slab size. Bhushan Steel produces quality steel for the automotive industry and sophisticated pipe grades for the Indian and international markets. The single-strand caster designed as vertical bending unit was successfully commissioned in November 2009 and is rated for the production of slabs ranging in width between 800 and 1,680 mm and 230 mm thickness. SMS Siemag supplied the mould with resonance oscillation, which is equipped with a model for optimized oscillation aimed at improving the surface quality of the strand, as well as the entire strand guide system including Soft Reduction for improving the internal quality. The scope of supply included the automation system including Level 2, as well as a control computer with integrated quality control system. Also included was the supervision of erection and commissioning. Among others, Bhushan Steel produces quality steel for the automotive industry and sophisticated pipe grades both for the Indian and for the international markets. Two more continuous casters for 1,680 mm wide slabs Bhushan Steel Ltd., New Delhi, India, awarded SMS Siemag AG a contract for the supply of two more single-strand continuous slab casters. The supply of the continuous casters comprises plant, and automation technology. This includes the mould with resonance oscillation, which is equipped with a model for optimized oscillation aimed at improving the surface quality of the strand, as well as the entire strand guide system including Soft Reduction for improving the internal quality. The supplies for the vertical-bending type casters consist of the mechanical, electrical and automation systems including Level 2, as well as the supervision of erection and commissioning. Technical data Bhushan Steel Ltd. 2009/2011 Continuous 3 single-strand vertical bending casters casting Ladle contents 180 t Annual production 1,800,000 tpy Slab dimensions 200 mm 800 to 1,680 mm 6 to 12.5 m Metallurgical length 42.1 m Machine radius 8.0 m Vertical length 2.7 m Number of segments 17 Bhushan also ordered from SMS Siemag a Conarc steelmaking plant with downstream rolling mill, with both units already having successfully started production. Slabs leaving the first of three continuous casters

14 MAGHREB STEEL Morocco Technical data Maghreb Steel 2011 Complete production line from SMS Economic: Direct charging SMS-know how: Slab logistics and finishing; secondary cutting unit for a slab length of at least 2 meters Morocco's first slab cast at Maghreb Steel At Maghreb Steel, Morocoo, SMS Siemag has commissioned an electric steelmaking plant and a single-strand continuous slab caster. The facilities are designed for an annual production of 1.0 million t of steel and will supply the Steckel rolling mill with input stock. The production comprises the manufacture of low and medium-carbon steels and high-strength, low alloy steels for the country's own requirements and for export. With the new works complex, the customer can cover the entire product range from liquid steel to the final product and will thus considerably enhance his capacities and the value-added chain. Continuous 1 single-strand vertical bending caster casting Ladle contents 120 t Annual production > 1,000,000 tpy Slab dimensions 200 (250 mm) 900 2,150 mm 6.0 to 12.5 m Metallurgical length 29.1 m Machine radius 9.5 m Vertical length 2.7 m Number of segments 13 The continuous caster produces slabs in widths from 900 mm to 2,150 mm and a thickness of 200 mm. The equipment of the caster includes several Intelligent Slab Casting (ISC ) modules which determine quality and production. Among these are the hydraulically powered resonance oscillation system and the position-controlled CyberLink segments to perform Dynamic Soft Reduction. The production of slabs of a high internal quality is thus guaranteed through the above in combination with the width-dependant air-mist secondary cooling and the technological Dynamic Solidification Control model. SMS Siemag supplied the detail engineering, mechanical equipment and hydraulic system, as well as the complete automation package. Maghreb Steel is one of Northern Africa's largest companies for the manufacture of cold rolled products. Most of the exported products are hot-galvanized sheets and plates. The hot strip needed for these has hitherto been imported. This new investment enables the customer to cover the entire range from liquid steel to the final product and thus allows him to achieve a higher value-added. Othman Benmlih, General Manager of Maghreb Steel: "It is the very first slab to be cast in Morocco. And we have succeeded in producing perfect slabs straight away. It couldn't have been better. SMS Siemag has done an excellent job here." Morocco's first slab. Casting floor with ladle turret

15 ESSAR STEEL LTD. India Records witnessed since commissioning Large variety of products SMS-know how: World's first three-strand CSP plant ESSAR STEEL LTD. India SMS-know how: Layout, implementation and commissioning of a secondhand facility Essar Steel: Production on the new CSP plant sets new standards On 15 July 2011, the second strand of the CSP plant (Compact Strip Production) supplied by SMS Siemag to the Indian steel producer Essar Steel Ltd. at Hazira in Gujarat, India, was successfully put into operation. Modernization of a slab caster within an extremely short period of time Essar Steel had awarded SMS Siemag a contract for the modernization of the existing slab caster that was formerly set up by Sumitomo. The scope of supply included the entire Level 1 and Level 2, inclusive of new operator control desks and HMI equipment. On the first day after commissioning of the new CSP caster, as many as twelve heats each comprising 200 t of liquid steel were cast. The second sequence consisted of ten heats. Production of the second strand proceeded without any breakouts, with 75 per cent of the rated capacity already achieved during commissioning. The thickness re - duction (Liquid Core Reduction LCR ) and width adjustment were already successfully utilized while casting the first sequence. Technical data Essar Steel Ltd., CSP Caster, 2011 Continuous 3 single-strand vertical bending casters casting Ladle contents 200 t Annual production 3,500,000 tpy Slab dimensions 80 to 65 / 70 to 55 (50) mm (850) 950 1,680 mm steplessly by LCR 3 Metallurgical length 8.01 m Machine radius 3.25 m Number of segments 4 Bending points continuous straightening New technological control systems with a high-speed mould level control and remote-adjustable mould were installed. A breakout prediction system with adaptive limit-value optimization was also included in the supply. All data for the and product quality are documented by the IPQS Integrated Product Quality System and ed further for optimization. Essar Steel can produce hot strip with widths of 950 to 1,680 mm and thicknesses of 1.0 to 25.4 mm on the CSP plant. The product range covers carbon steels as well as pipe grades, silicon and dualphase steels. The CSP offers the best prerequisites for the economical production of high-quality steel grades. SMS Siemag's scope of supply included the engineering, the manufacture of the mechanical equipment, the entire X-Pact electrical and, as well as erection and commissioning supervision. The CSP plant with the first strand was put into operation on 31 March 2011, the third strand will be installed in Essar Steel will thus have the first three-strand CSP plant worldwide with an annual capacity of 3.5 million t of hot strip. The customer granted his acceptance just two months after the first cast on 18 October SMS Siemag has thus demonstrated that such a modernization project can be successfully implemented within an extremely short period of time. Exit section of slab caster. Technical data Essar Steel Ltd Continuous 1 single-strand vertical bending caster casting Ladle contents 200 t Annual production 2,500,000 tpy Slab dimensions 210 / to 1,890 mm 4.5 to 12.0 m Metallurgical length 34 m Machine radius 8.0 m Vertical length 2.5 m Number of segments

16 SEVERSTAL COLUMBUS USA Complete production line from SMS Large variety of products X-Pact electrical equipment and Technical data Severstal North America 2011 Best run-up curve and widest hot strip produced in a CSP plant so far. The CSP plant of Severstal Columbus (formerly SeverCorr) with its two CSP strands is at the heart of the new production complex in the state of Mississippi. The first strand of the CSP plant with its upstream electric steelmaking plant has been in operation since 2007; in mid-2011, another steelmaking plant and the second CSP strand were commissioned. Continuous 1 x 2 single-strand vertical bending caster casting Ladle contents 150 t Annual production 2,700,000 tpy Slab dimensions 65 / 60 mm 914 to 1,880 mm Metallurgical length 8.01 m Machine radius 3.25 m Number of segments 4 Bending points continuous straightening This allows Severstal to supply the market with 2.7 million t of high-quality steel grades. The production embraces autobody sheets, high-strength multiphase steels for the automotive industry and ultrathin hot strips for substituting cold strip in suitable areas of application. With its CSP plant, Severstal can produce hot strip that is between 1.3 mm and 12.7 mm thick and 900 mm to 1,880 mm wide, this being a width that has never been achieved so far. SMS Siemag supplied all production line equipment from steelmaking to strip ing. Also included in the supply scope was the complete X-Pact electrical and automation package. Severstal's works complex is strategically located in the south of the USA, close to automobile and home appliance manufacturers. Jointly with SMS Siemag, Severstal Columbus is further developing the range of materials and the surface quality of the products. Sergei Kuznetsov, Chief Executive Officer, Severstal North America Both our workforce and the customers of Severstal North America are witnessing exciting times. With our current expansion we are improving on our already extremely high reliability, flexibility and profitability. By creating new jobs we benefit both our customers and also the local community. We wish to thank all involved parties for their contribution to implementing the Phase 2 program. Press release by Severstal North America on commissioning phase II Casting floor. CSP ladle turret and casting floor

17 BHUSHAN STEEL LTD. India Customer specific: unit for small sizes JINDAL STAINLESS LTD. India Continuous caster for stainless steel grades SMS-know-how: Electro-magnetic strand stirrer - developed by SMS Successful start of slab caster producing peritectic grades For Bhushan Steel Ltd., New Delhi, India, SMS Siemag AG has successfully commissioned a single-strand continuous slab caster for the production of 1,300 mm wide slabs at the Angul, Orissa, works. Single-strand continuous slab caster for stainless steel grades The slab caster designed as vertical bending unit was successfully commissioned in March 2011 and is rated for the production of stainless steel slabs ranging in width from 800 to 1,680 mm and 200 mm thickness. On executing the first cast at the end of April 2011, 70 t of liquid steel were cast and the first three slabs were produced in peritectic grades for tube manufacture. The supply scope includes plant, and automation technology. This includes the mould with resonance oscillator, which is equipped with a model for optimized oscillation aimed at improving the surface quality of the strand, as well as the entire strand guide system. Also included are all of the casting floor and removal equipment, the X-Pact electrical and automation package and the supervision of erection and commissioning. Caster for mm wide slabs. The supply scope included the complete casting floor equipment, the strand guide system comprising the mould with resonance oscillator and ten installed strand guide segments, plus the necessary removal equipment. SMS Siemag also supplied the complete X-Pact electrical and including Level 2. In the upper part of the strand guide system, an electromagnetic stirrer for the production of peritectic grades was installed. Jindal Stainless also awarded SMS Siemag a contract for the supply of a stainless steelmaking plant (duplex route) which was also successfully commissioned. Vertical-bending caster for stainless steel slabs. Among others, Bhushan Steel produces quality steel for the automotive industry and sophisticated pipe grades for the Indian and international markets. Technical data Bhushan Steel Ltd Continuous casting 1 single-strand vertical bending caster Ladle contents 65 t Annual production 500,000 tpy Slab dimensions to 1,300 mm 4 to 12.5 m Metallurgical length 18.2 m (in Phase 2: 31.1 m) Machine radius 8.5 m Vertical length 2.4 m Number of segments 10 Jindal Stainless is India's largest producer of stainless steels; in addition to hot and cold-rolled flat products it also manufactures ferroalloys and stainless-steel slabs. Technical data JSL Stainless Ltd Continuous casting 1 single-strand vertical bending caster Ladle contents 150 t Annual production 1,000,000 tpy Slab dimensions 160 to 220 mm 850 to 1,680 mm 5.5 to 14 m Metallurgical length 21.3 m Machine radius 8.0 m Vertical length 2.7 m Number of segments

18 JINDAL SOUTH WEST LTD. India SMS-know-how: Integrated plant layout featuring four continuous casters Cost-effective: Steep run-up curve Steep run-up curves, professional cooperation: three continuous casters in three years Jindal South West Steel Ltd. in Toranagallu in the Indian federal state of Karnataka awarded SMS Siemag contracts for the supply of two converter meltshops and three continuous slab casters. One continuous caster each was commissioned in 2009, 2010 and The three continuous slab casters are of identical design, which makes the stocking of spare parts and thus maintenance of the units much more cost-effective. The casters are each rated for the production of 220, 260 and 300 mm thick slabs. The widths are between 1,000 and 2,200 mm. The equipment of the casters includes several Intelligent Slab Casting (ISC ) modules which determine quality and production. Among these are the hydraulically operated resonance oscillation sys- tem, remote-controlled mould narrow faces for width change during casting and the position-controlled CyberLink segments for performing Dynamic Soft Reduction. The production of slabs of a high internal quality is thus guaranteed through the above in combination with the width-dependent air-mist secondary cooling and the technological Dynamic Solidification Control model. The supply scope further contains the X-Pact electrical and, erection and commissioning supervision and training of the operating personnel. All modules have been in operation since the respective commissioning. This was made possible by the cooperation among the well-trained operator crews from JSW and the experienced SMS Siemag commissioning specialists from India and Germany. The sophisticated product line includes peritectic and microalloyed grades (some according to API-5L). V. Poyyamozhi, Vice President Steel Zone, JSW Steel These grades, which account for a share of more than 50% of the total "We at JSW Steel are very impressed by the performance of the production volume, have already new SMS Siemag continuous caster. Thanks to its steep run-up been successfully cast to slabs. curve we have achieved the nominal capacity already in the first week after the first melt. The cooperation with the SMS team was highly professional; without it, we would not have been able to achieve these results. We are already looking forward to the next commissioning which will certainly take place very soon." This high monthly production rate was supported by the reliable functioning of the Breakout Prediction System (BPS). It detects "stickers" in the mould and prevents the potential breakout by considerably reducing the casting speed. Once casting operations have stabilized, the speed may be raised to its former maximum level again. Since the end of January 2011, the DSC (Dynamic Solidification Control) has also been in operation. This metallurgical model calculates the solidification of the strand and controls the various secondary cooling zones. Especially crack-critical grades must be controlled at exact temperature levels by the bending and straightening zones of the continuous caster in order to minimize flaws located close to the surface. The commissioning record dated January 2011 certifies that "the surface quality of all grades is excellent". Technical data Jindal South West Ltd Continuous casting 3 single-strand vertical bending caster Ladle contents 175 t (max. 200 t) Annual production 4,500,000 tpy Slab dimensions 220 / 260 / 300 1,000 to 2,200 mm 4.5 to 12.0 m Metallurgical length 34.1 m Machine radius 9.59 m Vertical length 2.7 m Number of segments 15 At the end of March 2011, the third continuous slab caster was successfully commissioned in meltshop no. 2, its acceptance was granted by Jindal South West in June Ladle turret. Exit area of caster

19 REFERENCES

20 DILLINGER HÜTTENWERKE Germany SMS-know-how: At 450 mm, the world's thickest slab Customer specific: This is where the raw material for offshore windpower plants is produced 450 mm The world's thickest slab The firm of "Aktien-Gesellschaft der Dillinger Hüttenwerke" has successfully recommissioned continuous caster no. 5 following its modernization and the addition of thickness 450 mm. SMS Siemag has supplied a comprehensive engineering package for this, containing new components for the revamp. The vertical-type continuous caster produces the world's thickest slabs, in the sizes 230 to 450 mm gauge and 1,400 to 2,200 mm width. The caster featuring thicknesses up to 400 mm had been supplied by SMS Siemag in Dr. Norbert Bannenberg, Board Member Technical of AG der Dillinger Hüttenwerke: "After twelve years of trouble-free production of high-quality 400 mm slabs, we felt that we had arrived at a favourable starting point for this further development. Dillinger Hütte thereby emphasizes its leading position in the continuous casting of thick slabs as input material for the production of high-grade heavy plates." Supplies comprised the extension of the vertical-type continuous caster to produce the thickness 450 mm, the reinforcement of the withdrawal and straightening units as well as various spare parts. The automation system including the planning, fabrication and programming of the electrical equipment, erection and commissioning supervision, training and support of trial operation were also included in SMS Siemag's supply. The following were renewed: The automatic control equipment for the hydraulic mould oscillator, the hydraulic segment adjustment, the hydraulic bending unit adjustment, the hydraulic adjustment system for the withdrawal and straightening units, and the load compensation control for the strand drive group. With the casting of the 450 mm slab we have once again proven the efficiency of our continuous casting technology. This applies also to the vertical-type continuous caster supplied in 1998 and the expansion to the new thickness. The segment technology, newly implemented at that time and involving Soft Reduction, continues today to ensure uniform product quality. Technical data AG der Dillinger Hüttenwerke 2010 Continuous casting 1 x 2-strand vertical bending caster Ladle contents 185 t Annual production 1,400,000 tpy Slab dimensions 230 to 450 mm x 1,400 to 2,200 mm 10.8 m Metallurgical length 15.7 m Machine radius 8 m Vertical length m Number of segments 8 View on the pinch-roll bending unit. 450 mm slab for the production of high-quality heavy plates

21 ArcelorMittal BURNS HARBOR LLC USA Mould and oscillation system for continuous slab caster Modernization SMS-know-how: Revamp of mould and oscillator to include resonance oscillation SMS-know-how: Planning of an electromagnetic mould stirrer SMS-know-how: First oscillation system to use water glycol With the aim of boosting production, improving quality and cutting costs, SMS Siemag LLC designed and supplied new moulds and hydraulic oscillation systems for the existing two-strand continuous caster no. 1 at ArcelorMittal Burns Harbor (AMBH). As part of the project, a new hydraulic mould width adjusting system, a mould sticker detection unit based on thermocouples, as well as hydraulic oscillation systems were installed. Mould length extended to 900 mm The length of the mould was raised from 700 to 900 mm. With the aid of three-dimensional modeling of the thermal and mechanical behaviour, a copper plate was developed which ensures an optimal heat transfer throughout the whole service life of the copper. Mould made from stainless steel With a view to more future improvement programs, AMBH decided to use a mould design which allows the future installation of an electromagnetic system for the stirring of molten metal and for changing its flow characteristics. For this reason the mould was made of stainless steel. Reliable slab width adjustment The mould narrow faces are adjusted with the help of a closed control circuit using position-controlled hydraulic cylinders. The narrow-face taper of the mould is practically infinitely adjustable. First oscillation system to use water glycol The tried-and-tested hydraulic oscillation unit allows both the stroke and frequency to be set online. This allows the development and use of tailored operating practices. The oscillation springs guide the mould highly accurately and are virtually non-wearing. For the oscillation system implemented here, SMS Siemag for the first time uses water glycol as hydraulic fluid. Technical data ArcelorMittal Burns Harbor LLC 2010 Continuous casting 1 x 2-strand bow-type continuous caster Ladle contents 270 t Annual production 2,900,000 tpy Slab dimensions 254 mm 965 to 1,981 mm 4.5 to 9.6 m Metallurgical length 25.9 m Machine radius m Number of segments 13 Bending points multi-point straightening "Mock-up" assembly of equipment The mould and oscillation systems were completely tested using independent control systems for the hydraulic system and automation package. Again, our Plug & Work concept was successfully used for commissioning at the customer. Advance assembly and testing of all mechanical and hydraulic equipment as well as of the electrical system and automation package. Revamped mould and oscillator at ArcelorMittal Burns Harbour. Two-strand slab caster

22 BHUSHAN POWER & STEEL India Large variety of products SMS-know-how: Liquid Core Reduction SALEM STEEL PLANT India Continuous caster for stainless grades Customer specific: Unit for small sizes Successful expansion - capacity doubled In 2010, the second CSP casting strand was successfully commissioned at Bhushan Power & Steel, Orissa. This has doubled Bhushan Power & Steel's production capacity to 1.6 million tpy and allows it to now also produce very thin strips. The CSP plant, which had been commissioned in April 2008, achieved a production of 800,000 t of hot strip per year in the first stage of construction. The maximum strip width is 1,300 mm. Continuous slab caster for the production of 300,000 t of stainless steel grades per year commissioned For Salem Steel Plant, a company of the SAIL group (Steel Authority of India), SMS Siemag has successfully commissioned a single-strand slab caster for the production of stainless steel grades. The unit produces slabs with a thickness of 140 to 200 mm and widths ranging from 600 to 1,300 mm. It is rated for an annual production of 300,000 t. Together with Bhushan Power & Steel, the plant was optimized so as to be able to also safely roll strips with a thinner gauge. The minimum final gauge was reduced step by step until, on 19 July 2010, Bhushan Power & Steel successfully produced the first strip with a gauge of 1.0 mm. After casting the first thin slab with a gauge of 58 mm, the second strand started its production oper a- tion on 19 September Like strand 1, the new casting strand has a metallurgical length of 6,340 mm and three segments. Thanks to Liquid Core Reduction (LCR 3), this casting strand can produce thin strips infinitely variable between 58 and 50 mm. Technical data Bhushan Power & Steel Ltd Continuous casting 2 x 1-strand vertical bending caster Ladle contents 80 t (90 t) Annual production 1,600,000 tpy Slab dimensions 58 to 50 (48) mm 800 to 1,300 mm infinitely variable with LCR 3 Metallurgical length 6.34 m Machine radius 3 m Number of segments 3 Bending points continuous straightening The supply scope comprised the supply of the complete caster including all equipment for utilities as well as the complete X-Pact electrical and automation package inclusive of the models. Salem Steel, located in the federal state of Tamil Nadu, India's southernmost federal state, offers a wide range of hot and cold-rolled as well as surface-treated stainless steel strip. The new slab caster will in the future cover the continuous demand for slabs. Technical data SAIL Salem Steel Plant 2010 Continuous casting 1 x 1-strand vertical bending caster Ladle contents 60 t Annual production 300,000 tpy Slab dimensions 140 to 200 mm 600 to 1,300 mm 5.0 to 10.5 m Metallurgical length 18.2 m Machine radius 8.5 m Vertical length 2.2 m Number of segments 10 Economic: CSP plant. Tail-out of first slab

23 PEINER TRÄGER GMBH Germany Customer specific: World's largest beam blank size SMS-know-how: Combination caster for the production of BBL and slabs Large variety of products Germany's first combination caster for beam blanks and slabs At Peiner Träger GmbH in Peine, SMS Siemag has revamped a two-strand continuous caster for beam blanks into a combination caster which can now also produce slabs. The first slabs were cast in February 2010, after a change of section size also beam blanks. The two-strand combination caster is now rated for the production of 250 mm thick and 500 to 1,100 mm wide slabs and for size 1,150 mm x 490 mm x 130 mm beam blanks. Continuous Caster No. 2 of Peiner Träger is the first combination caster in Germany for casting of beam blanks and slabs. The world's widest beam blank size is produced on the caster. The scope of supply of SMS Siemag comprised all strand guiding components required for the continuous slab caster, the slab mould as well as the automation package including the technological models. Pinch roll units 3 and 4 (driven segments 8 and 9) are used for all casting sizes, i.e. for slabs and beam blanks. They do not need to be changed when section sizes and shapes are changed. This reduces changing times and increases production. A design innovation of the beam blank caster is the ability to replace segments 3 to 5 by the equipment required for the blow-off device and the edge heater. In total, SMS Siemag supplied forty segments. With the successful commissioning of an electric steelmaking plant that was also supplied by SMS Siemag, the annual production has almost been doubled while still meeting the increased demands placed on the steel quality. At the Peine location, the worldrenowned Peiner Träger ("Peine Beams") are produced, as well as a great many other sectional steel grades, such as European steel beams, sheet piling sections and special sections. A ladle placed over the tundish: The existing equipment may continue to be used. Technical data Peiner Träger GmbH 2010 Slab Continuous casting Ladle contents Annual production Slab dimensions Overview of plant: from the casting floor to the strand guide system. 1 x 2-strand bow-type continuous caster 100 t > 900,000 tpy 250 mm 500 to 1,100 mm 5.1 to 12.0 m Metallurgical length 22.9 m Machine radius 12.0 m Number of segments 9 Bending points multi-point straightening Beam Blank Continuous casting 1 x 2-strand bow-type continuous caster Ladle contents 100 t Annual production > 900,000 tpy Dimensions BB1 800 mm 440 mm 130 mm Dimensions BB3 1,150 mm 490 mm 130 mm 5.1 to 12.0 m Metallurgical length 22.9 m Machine radius 12.0 m Beams rolled from slabs. In this way 7 m long slabs become 50 m long beams. Exit area of two-strand caster. Strand guide system of modular design, both for continuous slab caster and the BBL plant. Number of segments 9 Bending points multi-point straightening 46 47

24 SALZGITTER FLACHSTAHL GMBH Germany Large variety of products SMS-know-how: Bow-type caster and "dry" operation for crack-susceptible grades Customer specific: 350 mm slab Fourth continuous slab caster supplied by SMS Siemag at Salzgitter Flachstahl - Central Europe's largest continuously cast section size SMS Siemag AG has successfully commissioned the fourth continuous slab caster for Salzgitter Flachstahl GmbH (SZFG), Germany. The single-strand bow-type caster produces slabs ranging in widths from 1,100 to 2,600 mm and in thicknesses of 250 and 350 mm. The slab dimensions of 350 x 2,600 mm currently represent the largest section size for continuous casters in Central Europe. SMS Siemag's order scope comprised the basic and detail engineering, the supply of all mechanical components and the complete automation system, including the technological control systems and models. In addition, the supply scope included the solid structures and structural steelwork, a new water supply and treatment system as well as the erection, commissioning and supervision. Salzgitter Flachstahl uses the caster for the production of highly demanding micro-alloyed steels, heavy-plate grades and sourgas-resistant tube and pipe grades according to the API-5L and HIC standards. In particular the 350 mm thickness option makes it possible to provide slabs for heavy-plate manufacture in a hitherto completely new range of dimensions that are most attractive for future requirements. Casting floor and ladle turret of CC4. The equipment of the caster includes several Intelligent Slab Casting (ISC ) modules which determine quality and production. Among these are the hydraulically powered resonance oscillation system, remote-controlled mould narrow faces for width change during casting and the position-controlled CyberLink segments to perform Dynamic Soft Reduction. The production of slabs of a high internal quality is thus guaranteed through the above in combination with the width-dependant air-mist secondary cooling and the technological Dynamic Solidification Control model. Also, in order to cast steel grades with critical crack susceptibility on the continuous caster in a reliable and productive manner, the machine has been designed as a bow-type caster with a constant radius of 11.5 m. This design minimizes stresses in the strand shell and achieves excellent surface qualities. Extract from the paper read by Dr. Markus Schäperkötter, Salzgitter Flachstahl AG, on the Steel Day 2011 In the production of sour gas resistant steel grades, a very large share of slabs without casting events (e.g., start-up, tundish change, end slabs) was attained. All HIC-tested (Hydrogen Induced Cracking) high-quality slabs were found to be free from defects. By June 2011, out of a total of 1,149,000 t, 610,000 t of steel were rolled to heavy plate, of which 250,000 t were slabs with a thickness of 350 mm. The new continuous caster made it possible to almost halve the input stock-related plate failures for size 250 mm. The quality levels of the 350 mm slabs are also very good, the slightly higher level as compared to 250 mm is due to the higher thickness involved in the. The very good product quality is also confirmed by the numerous examinations of the internal quality of the slabs produced." Technical data Salzgitter Flachstahl GmbH 2010 Continuous casting 1-strand bow-type caster Ladle contents 210 t (max. 230 t) Slab dimensions 250 / 350 mm 1,100 to 2,600 mm 4.2 to 12.4 m Metallurgical length 34.4 m Machine radius 11.5 m Number of segments 14 Bending points multi-point straightening 48 49

25 TOKYO STEEL MANUFACTURING CO., LTD. Japan Two-strand slab caster - High-quality slabs for use in the automotive industry Just four months after the first cast on the two-strand slab caster and following the successful conclusion of all guarantee tests, Tokyo Steel Mfg. Co. Ltd., Japan, granted SMS Siemag the acceptance. High-quality slabs for use in the automotive industry Economic: Direct charging SMS-know-how: Casting floor part of the steel structure and thus earthquake-proof Technical data Tokyo Steel Manufacturing Co., Ltd Continuous casting 1 x 2-strand vertical bending caster Ladle contents 300 t Annual production 2,400,000 tpy Slab dimensions 210 mm 800 to 1,625 mm 6.0 to 12.0 m Metallurgical length 34.9 m Machine radius 8.0 m Vertical length 2.5 m Number of segments 16 The vertical-bending caster with 16 segments and a metallurgical length of 35 meters is designed for a maximum casting speed of 2.2 m/min and an annual production of 2.4 million t of steel slabs. The new continuous caster will produce high-quality slabs primarily for use in automotive manufacturing. SMS Siemag's supply scope consisted of the basic and detail engineering, the supply of all mechanical core components and the entire automation system. Training of the customer personnel and the supervision of erection and commissioning were also included in the scope of SMS Siemag's services. The equipment of the caster includes several Intelligent Slab Casting (ISC ) modules which determine quality and production. The hydraulically operated resonance oscillator and the remotecontrolled mould narrow faces for width change during casting allow the casting width to be altered as required between 800 and 1,625 mm during operation. Dynamic Soft Reduction and the variable spot cooling as well as the width-dependant air-mist secondary cooling system and the technological model Dynamic Solidification Control ensure the production of slabs with a high inner quality. The roller table in the removal section of the two-slab caster allows conventional cooling in the slab store or a direct transfer to the rolling mill. The surface quality of the slab increasingly allows direct charging, which also saves energy for reheating Two-strand slab caster. Top: Ladle turret. Bottom: Casting floor

26 REFERENCES

27 ArcelorMittal LAZARO CARDENAS Mexico Modernization SMS-know-how: Improvement of slab inner quality SMS-know-how: Revamping to 14-point straightening Soft Reduction for two-strand slab caster ArcelorMittal Lázaro Cárdenas (AMLC), Mexico, produces slabs for the world market. Due to the ever more exacting requirements in terms of the internal quality of slabs, AMLC had awarded SMS Siemag a contract for the modernization of the existing two-strand slab caster no. 2 with the aim of improving the internal quality of the slabs by replacing the bottom segments. The new segment design was to improve the support of the strand while at the same time creating the conditions for the introduction of Dynamic Soft Reduction. Positions 7 and 8: Segments with stationary side frames Also included in the scope of supply: the control systems for the. New control systems were installed, among others the Dynamic Solidification Control for the control of spray water and for the calculation for the point of final solidification. Revamp to 14-point straightening To reduce the stresses caused in the boundary layer between solidified and liquid steel, the caster was revamped from four-point straightening to 14-point straightening. Strand bulging and the stresses caused by this could be reduced by replacing the existing five segments by segments with seven double-split roller pairs. In addition, each segment was equipped with a hydraulic segment adjustment, which allows the roller gaps to be adjusted online and thus Dynamic Soft Reduction. Two basic segment types were used in this modernization contract. Conventional segments with stationary side frames were installed at the straightening positions 7 and 8. On account of the reduced straightening forces this area of the caster now also allows the use of soft reduction. This is beneficial for steel grades which need to be cast at lower casting speeds and whose final solidification takes place at an earlier point in the strand guide system. New segments installed without problems The segments fit into the existing machine structure without any problems. The existing foundation frames, the segment removal rails, the cooling chamber and the segment drive units were re-used with minor changes. Maintaining the segment centerlines, the new segments were adapted to the existing supporting frames. A hydraulically operated key/bolt system was used to fasten the segments to the segment carrying frame. Using adapter plates, the existing water pipes were adjusted such that the pipes for the supply of spray and machine cooling water are automatically connected to the new segments. Positions 9 to 11: CyberLink segments with guide frame CyberLink segments were used in the horizontal part of the strand guide system, segments 9 to 11. These segments have guide frames that connect the top and bottom frame. This solution allows the top rollers to be adjusted as required. Technical data ArcelorMittal Lázaro Cárdenas 2009 Continuous casting 1 x 2-strand bow-type continuous caster Ladle contents 200 t Annual production 2,000,000 tpy Slab dimensions 200/ 225/ 250 mm 965 to 1,935 mm 5.4 to 12.0 m Metallurgical length m Machine radius 10.5 m Number of segments 12 Bending points multi-point straightening The revamped lower part of the ArcelorMittal Lázaro Cárdenas caster in 3D. Advance assembly and testing of all mechanical and hydraulic equipment as well as of the electrical and automation package

28 CHINA STEEL CORP. (CSC) Taiwan High productivity Slab caster no. 7, CSC's fifth machine supplied by SMS Siemag, has an annual capacity of 2.6 million t. The two-strand caster is rated for a maximum casting speed of 2.2 m/min, casting slabs that range in width from 900 to 1,680 mm. The SMS Siemag supply scope comprised the basic and detail engineering as well as the supply of all mechanical core components and the, including the technological control systems and models. Five continuous slab casters from SMS Siemag SMS-know-how: Electromagnetic mould stirrer SMS-know-how: Segment removal manipulator Large variety of products SMS-know-how: Casting floor part of the steel structure and thus earthquake-proof High flexibility thanks to Intelligent Slab Casting The technologies installed by SMS Siemag ensure a higher productivity plus perfect product quality and provide maximum flexibility. Examples are the hydraulically operated resonance oscillation system and the remote-controlled mould narrow faces. Constant product quality The automation systems control and monitor the es and the slab quality. The mould level control system (Level 1) prevents casting-flux inclusions and ensures a high surface quality of the slabs. Dynamic Soft Reduction in the segments subjects the slabs to a defined pressure and thus avoids core segregations and core porosities. The result is a consistently good internal quality of the slabs. Similarly, the Mould Monitoring System (Level 2), which detects the temperature profile of the mould, serves for quality control and for the prevention of breakouts. Dynamic Solidification Control controls secondary cooling and thus ensures that the required metallurgical properties are achieved. Fully developed systems The precise construction of the mechanical and SMS Siemag's wealth of experience ensured smooth commissioning and a fast start of production at CSC. The complete had been tested and optimized beforehand according to the Plug & Work method in simulation mode at SMS Siemag. This made it ready for immediate commissioning on site. Technical data China Steel Corporation (CSC) 2009 Continuous casting 1 x 2-strand vertical bending caster Ladle contents max. 260 t Annual production > 2,600,000 tpy Slab dimensions 230 / 250 mm 900 to 1,680 mm 4.5 to 10.0 m Metallurgical length 41.5 m Machine radius 9.33 m Vertical length 2.5 m Number of segments 19 Compact unit with two strands

29 MAGNITOGORSK IRON AND STEEL WORKS Russia World's largest S-shaped ladle turret designed and built by SMS Siemag Large variety of products Customer-specific: At 300 mm thickness and 2,700 mm width, MMK produces Russia's largest section size SMS-know-how: "Dry" operation for crack-susceptible grades MMK has been an SMS customer since its foundation in 1932 At the Russian Magnitogorsk Iron & Steel Works (MMK), Russia, a new continuous slab caster supplied by SMS Siemag was successfully commissioned in December The caster is designed for the production of slabs of a thickness up to 300 mm and attains a maximum casting speed of 2.0 m/min. The maximum casting width is 2,700 mm and this can be altered while operation is taking place. The ladle turret is a special feature: The ladle turret with its maximum capacity of 2 x 535 t is the world's largest S-shaped ladle turret designed and built by SMS Siemag. The first 300 mm slab produced by MMK's continuous caster. The caster will be equipped with several ISC modules (Intelligent Slab Casting) which determine quality and production. The resonance oscillation system with variable oscillation frequency, oscillation height and curve shape warrants consistently good slab surfaces. In addition, the unit is equipped with the Mold Monitor- ing System and hydraulically adjusted CyberLink segments as well as air-mist cooling. The technology packages of Breakout Prediction System, Dynamic Soft Reduction and the dynamic cooling model complete the caster equipment. This equipment allows the production of high-quality slabs and makes the caster extremely reliable and flexible. The scope of supply also included the entire X-Pact electrical and as well as the drive system. The complete was set up at the test field beforehand and tested and optimized according to the proven Plug & Work method. Following installation at the customer, this allowed production to be started directly after a short commissioning phase. Also "We have fulfilled our investment program completely", said Viktor included in the supply scope were Rashnikow at the press conference held on the occasion of the the mechanical equipment includ- commissioning of the slab caster, taking stock of the results of the year "With the commissioning of the slab caster we can now produce the full line of slabs for the heavy-plate rolling mill." ing the slab removal facilities as well as the electrical and hydraulic components. The slabs produced by the caster are all ed in the new heavyplate mill which was also supplied by SMS Siemag. The combination of these two units makes it possible to produce high-quality heavy plates for the most exacting requirements, for example for oil and natural gas companies. Viktor Raschnikow is Chairman of the Board of Directors of OAO MMK. Technical data Magnitogorsk Iron and Steel Works 2009 Continuous casting 1 x 1-strand vertical bending caster Ladle contents 380 t Annual production 1,650,000 tpy Slab dimensions 190 / 250 / 300 mm 1,400 to 2,700 mm primary 4.1 to 12 m, secondary 2.5 to 4.1 m Metallurgical length 34.2 m Machine radius 11.0 m Vertical length 2.7 m Number of segments

30 MAANSHAN IRON AND STEEL COMPANY China Modernization SMS-know-how: LCR plus dynamic online thickness reduction of 35 mm. Economic: Increased plant availability Large variety of products Two single-strand CSP casters with Liquid Core Reduction LCR plus In 2003, SMS Siemag installed two single-strand CSP casters at Maanshan Iron & Steel. The production capacity in the years between 2007 and 2008 was each around 2.3 million t of hot-rolled wide strip for the production of hot and cold strip. In 2009, the two single-strand CSP casters were successfully modernized and are now equipped with LCR plus. This technology provides an extended thickness range from 90 to 60 mm (formerly 90 to 72 mm) as well as a high utilization of the strand guide length (metallurgical length) of 9,705 mm. LCR plus is the result of research and Ladle turrets of the two single-strand CSP plants. development work as well as industrial-scale testing in close collaboration between SMS Siemag and Maanshan Iron & Steel. CSP casters no. 1 and no. 2 The two casters are of identical design. The strand guide length of 9.7 m allows a maximum casting speed of 7.0 meters per minute. There are two moulds with a starting thickness of 90 and 72 mm, which in operation with use of LCR Gao Hai Cao, Director of steelworks and rolling mill "With LCR, Maanshan Iron & Steel is now in a position to flexibly roll all steel grades within one sequence", explains Chen You Gen, Senior Technical Manager of the steelworks and rolling mill no.1 Gao Hai Cao, director of the steelworks and rolling mill: "This makes the CSP caster of Maanshan Iron & Steel the world's first unit to realize a 30 mm liquid core reduction. cover a final thickness range from 90 to 50 mm. LCR and Thermal Segment Tapering are performed by four hydraulically positioncontrolled segments which are infinitely variable. Liquid Core Reduction (LCR plus) The aim of cost-effectively producing hot-rolled strip leads to ever new sequences. Production stoppages to set the caster to a different thickness must be minimized. Since all strand guide segments are equipped with infinitely variable position-controlled hydraulic cylinders, LRC plus, depending on the steel grade and hot-strip final gauge, allows an individual adjustment of the slab thickness. LCR plus allows the operator or production planning department to preselect a dynamic thickness reduction from 1 to 35 mm. This allows minor thickness changes of 1 to 20 mm to be set via segment 1 and thickness changes up to 35 mm via segments 1 and 2. The rolling schedule thus becomes a great deal more varied. In both cases the thermal shrinkage of the strand that corresponds to the steel grade is also automatically taken into account in segment setting. During casting with dynamic LCR plus, the positions of the segments are monitored and controlled online. Flexible adaptations of thickness over the length of a slab can thus be precisely regulated and communicated to the HSM computer. Position control of the segment takes into account the current cylinder loads. In position control mode, the cylinder loads are maintained at exactly adjusted minimum and maximum levels, so as to provide a permanent contact between the roller and strand and to thereby protect the segment from overloads. The special travel algorithm of the position-controlled segments 1 to 4 makes it possible to roll down the transition pieces produced during the thickness reduction, without output and quality losses. Technical data Maanshan Iron and Steel Company 2009 Continuous casting Ladle contents Annual production Slab dimensions Metallurgical length Machine radius 2 x 1-strand vertical bending caster 120 t 2,300,000 tpy 88 to 60 / 70 to 50 mm 900 to 1,600 mm infinitely variable with LCR plus 9.7 m 3.25 m Number of segments 4 Bending points continuous straightening 60 61

31 WUHAN IRON AND STEEL (GROUP) CORP. China Extract from Wisco's Large variety of products Economic: High production right from the start thank-you letter Two-strand CSP caster for 2.5 million t of hot strip On 7 March 2009, the first strip was rolled by the new CSP caster at Wuhan Iron & Steel Corp. (Wisco) in Wuhan in the Chinese province of Hubei. For the two-strand CSP caster SMS Siemag supplied the mechanical equipment and the automation system. At 10,000 t and 70,000 t, the production targets set for the first two months were clearly exceeded. The Plug & Work concept is intensively used to prepare commissioning. All components of the are set up and tested under near-real conditions before commissioning. Depending on the required final gauge, the steel grade and casting speed, the slab thickness is infinitely variable from 90 to 70 and 70 to 52 mm by means of Liquid Core Reduction. The production of the new plant focuses on strip made from highquality steel grades, including steels for the automotive industry, weathering-resistant steels, pipe and multiphase steels as well as silicon steels. the slabs upon their entry in the furnace, undesired precipitations are avoided. On entering the rolling mill, the thin slab exhibit a virtually constant temperature over its width, thickness and length. These conditions allow a stable, trouble-free rolling even in case of materials that are difficult to roll, with the mechanical and geometrical properties thus lying within close tolerances. At 14:00 o clock, 7th March, 2009, the divisional hot commissioning of Wisco CSP project successfully produced its first coil with only one trial. This great event is unprecedented in Wisco s history. It s a proved dedication from all SMS project team and it can meanwhile be dubbed as a symbol of SMS s mature technology. Hereby we would like to extend our congratulatory attitude and appreciation to your company. Technical data Wuhan Iron and Steel (Group) Corp Continuous casting Ladle contents Annual production Slab dimensions Metallurgical length Machine radius 2 x 1-strand vertical bending caster 150 t 2,500,000 tpy 70 to 52 / 90 to 70 mm 900 to 1,600 mm infinitely variable with LCR m 3.25 m Number of segments 5 Bending points continuous straightening Wisco is one of China's major producers of silicon steels. With respect to the involved, CSP casters provide good conditions for the production of these steels. This starts with the casting : The thin slab solidifies at an early stage and has a particularly homogeneous microstructure with finely distributed precipitations. Due to the relatively high temperatures of Thin slab entering the rolling mill. A glimpse of the casting floor

32 JINDAL STAINLESS HISAR India Continuous caster for stainless steel grades SMS-know-how: Resonance oscillation to improve the surface quality Successful modernization with hydraulic resonance oscillator At Jindal Stainless in Hisar, province of Haryana, SMS Siemag has modernized a singlestrand continuous slab caster and successfully re-commissioned it at the end of The caster was equipped with a hydraulic resonance oscillator for the mould and the relating technological control system. In addition, SMS Siemag supplied the detail design for a new segment 0. The resonance oscillator, with variable oscillation frequency, stroke length and curve shape, guarantees that the slab surface will be of consistently excellent quality. This represents a considerable cost benefit, above all when casting stainless steels. In the resonance oscillator, the moulds weighing around 30 to 40 t oscillate at a frequency of 1 to 7 Hz during casting, to avoid that the steel sticks to the cooled walls of the mould. In addition, this allows the specific placement of casting flux between the hot strand and the mould's copper wall. Basic data JSL Stainless Ltd Resonance oscillator with leaf springs. Continuous casting 1 x 1-strand bow-type caster Ladle contents 50 t Annual production 600,000 to 720,000 tpy Slab dimensions 140 / 160 / 200 mm 620 to 1,280 mm 6 to 8 m Metallurgical length 11.8 m Machine radius 8.5 m Number of segments