JSW Vijayanagar Metallics Ltd., a wholly-owned subsidiary of JSW Steel Ltd., is a leader in the steel production industry and the largest steel producer in India. Located in Toranagallu, Karnataka, the company's Vijayanagar Works is the largest single-location iron and steel plant in India and the sixth largest globally by production volume. To meet the increasing demand for high-quality steel products, JSW is enhancing its production capabilities with the installation of two new 2-strand slab casters. Supplied by Primetals Technologies, these state-of-the-art casters are designed to optimize production efficiency and quality, contributing to JSW is capacity expansion plan to reach 28 million tons per year by 2023.
Challenge
The steel industry demands continuous innovation to improve production efficiency, product quality, and operational flexibility. At JSW Vijayanagar, the challenge was to enhance production capacity while maintaining high-quality standards across a diverse range of products, including deep drawing steels, structural steel, and various high-strength grades. Additionally, minimizing downtime and optimizing resource utilization were critical to achieving the desired production targets. The integration of new technology had to be seamless with existing operations, requiring solutions compatible with Industry 4.0 advancements and capable of accommodating future expansions.
Solution
Primetals Technologies provided a comprehensive solution by installing two 2-strand slab casters equipped with cutting-edge technology. These casters feature DynaGap Soft Reduction 3D and Dynacs 3D spray cooling systems, ensuring superior slab quality with precise thickness control and temperature management. The inclusion of DynaPhase modeling further optimizes the casting process by analyzing phase transformations, enhancing product consistency. Advanced breakout prevention with Mold Expert, LevCon mold level control, DynaFlex mold oscillation, and Quality Expert for real-time quality assessment demonstrate the commitment to maximizing slab quality and operational efficiency. These technologies prepare the casters for Industry 4.0, ensuring they meet current and future production demands.
Results
The caster is capable of producing slabs with thicknesses ranging from 220 millimeters to 260 millimeters, widths from 900 millimeters to 1,650 millimeters, and slab lengths from 5.5 meters to 11.0 meters. It features a 9-meter radius, straight mold, and a patented continuous bending and straightening process, ensuring consistent production quality across various steel grades.
Benefits
- Maximized product quality and production start-up efficiency through advanced Connect & Cast features
- Industry 4.0 readiness ensuring technological compatibility and future-proof operations
- Minimized spare parts and operational exchange requirements thanks to largely identical caster designs
- Improved operator efficiency with reduced training needs
- Enhanced slab quality with precise control and monitoring technologies
Conclusion
- Installation of two new 2-strand slab casters at JSW Vijayanagar strengthens production capacity
- Advanced technologies ensure high-quality output and operational efficiency
- Project supports JSW Steel's strategic expansion to achieve 28 Mtpy capacity by 2023
- Primetals Technologies delivers comprehensive support with global and local expertise
- Seamless integration with existing operations positions JSW to address future industry challenges
