voestalpine Stahl Donawitz, located in Donawitz, Austria, has set a new benchmark in steel production with the installation of the bloom continuous caster CC4. This state-of-the-art plant is renowned for its cutting-edge digitalization and environmental standards, making it the most advanced bloom caster worldwide. The installation of the CC4 caster, which began operations in the summer of 2020, replaces its decades-old CC2 caster. Not only does this upgrade mark a milestone in production capability, but it also sets the stage for future expansion with the possibility of adding a fifth strand.
Challenge
The initial idea to build the new CC4 as a replacement for the CC2 (startup 1980) at voestalpine Stahl Donawitz GmbH came in the third quarter of 2014. Before the involvement of Primetals Technologies in the second quarter of 2017, plenty of various planning efforts already took place. Due to the tight space situation in the existing casting bay, an alternative erection place for the CC4 had to be found. The identification of the new erection area enabled the machine to also have a future provision for a 5th strand, as well as the possibility to cast bigger section sizes.
Four stand Bloom caster with provision for a 5th strand
Solution
The successful realization of the CC4 project was anchored in advanced digitalization, with a focus on Through-Process Quality Control (TPQC). This system integrates data collection across all production stages, ensuring consistent high-quality output. The TPQC system is pivotal for adhering to stringent automotive standards like the IATF 16949:2016. The Level 2 models, including Dynacs 3D and DynaGap, dynamically control and optimize the casting process, ensuring precise bloom solidification and surface quality. Additionally, the CC4 features a fully automatic crane system that efficiently manages bloom handling and storage, enhancing operational efficiency and product quality. These technological advancements have enabled voestalpine Stahl Donawitz to produce blooms with exceptional internal and surface quality, free from defects.
Continuous Casting Main control room
Continuous Casting Level 1 and Level 2 Automation
Fully automatic crane system
Fully automatic crane system
Results
Since its commissioning, the bloom casting machine CC4 has consistently delivered outstanding results, aligning with the highest quality standards in steel production. The implementation of advanced digital models such as Dynacs 3D and DynaGap has led to precise control over the casting process, resulting in blooms with exceptional internal and surface quality. The innovative electromagnetic stirring and soft reduction techniques have minimized carbon segregation, achieving segregation index values as low as 1.01 to 1.05 for the 330x440 mm² section in steel grade 100Cr6. Moreover, the automated systems have ensured that the production process remains efficient and reliable, with no internal or surface cracks reported. The enhanced macroscopic cleanliness of the blooms has significantly reduced rejection rates, particularly in rail production, underscoring the effectiveness of the digital quality control and process optimization strategies employed at the plant.
High Quality Blooms
High Quality Rounds
Continuous Casting
The Most Innovative Bloom Caster Worldwide at voestalpine Donawitz CC4
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Benefits
Enhanced product quality and reduced rejection rates in steel production
- Expanded product portfolio with up to 9% alloy content
- Fully automated production and handling processes increase efficiency
- Advanced digitalization supports stringent quality control and compliance
- Future-proofed design allows for expansion and adaptation
Conclusion
- Replacement of the outdated CC2 with the state-of-the-art 4-strand bloom caster CC4, with the potential for a fifth strand
- Production capacity of up to 0.95 million tons per year with a heat size of 67 tons
- Capability to produce a wide range of steel grades, including rail steels and seamless pipe steels
- Maximum casting speed of 1.7 meters per minute
- Comprehensive role of Primetals Technologies in engineering, manufacturing, installation, and commissioning
