Breaking New Ground in Casting Technology: The World's Largest Φ1600mm Vertical Semi-Continuous Casting Machine Successfully Commissioned
In October 2024, the world’s largest vertical semi-continuous casting machine (VSCC), capable of producing ultra-large round billets with a maximum cross-section of Φ1600mm, successfully completed its hot trial. Equipped with core equipment and key process technologies provided by Danieli, this milestone marks a significant achievement in the global steel industry.
Commissioned by a leading customer in northern China, the two-strand VSCC will be used to produce ultra-large special steel billets for special forgings. Quality, productivity, and competitiveness form the foundation of the customer’s strategy for producing Φ1600mm maximum cross-section billets.
A Breakthrough in Vertical Semi-Continuous Casting Technology
This project represents the latest application of vertical semi-continuous casting technology in the Chinese market and follows the successful implementation of vertical casting and semi-continuous casting machines by Danieli in Korea’s Seah Steel. In the field of round billets and ultra-large billets, Danieli has been continuously pushing the boundaries of casting process innovation, quality control, and equipment development.
In recent years, Danieli has successfully commissioned arc-shaped continuous casting machines capable of producing billets with diameters exceeding Φ1000mm at renowned Chinese enterprises such as Jiangsu Yonggang, Jianlong Group, Maanshan Steel, and Jiyuan Steel. These successes have continuously redefined the upper limits of billet sizes made possible through continuous casting technology.
The newly commissioned VSCC further pushes these limits, offering flexible production capabilities based on ladle capacities, with billet weights ranging from 100 tons to 200 tons. More notably, it enables the production of round billets with diameters of up to Φ1600mm, setting a new global benchmark.
The Shift from Traditional Ingot Casting to Continuous Casting
In steel production, there are two primary methods for solidifying molten steel: traditional ingot casting and continuous casting. For large-scale special steel billets, such as those required for nuclear power plant forgings, hydropower turbine rotors, and massive ship propeller shafts, traditional ingot casting has long been the standard. However, this process involves multiple time-consuming steps—mold stripping, mold preparation, soaking, and billet breakdown—that result in low production efficiency and poor material yield.
By contrast, adopting continuous casting technology offers several significant advantages:
- Simplified production processes that improve efficiency and flexibility.
- Reduced land requirements, lowering infrastructure investment.
- Lower operating costs and reduced refractory material consumption.
- Improved billet quality through automation and enhanced process control.
Additionally, since billets solidify without the mechanical stress caused by bending and straightening during casting, continuous casting minimizes the risk of crack-related defects. This is particularly beneficial for producing high-quality alloy steels and materials with high sensitivity to cracking.
Advanced Technologies in the New Vertical Semi-Continuous Casting Machine
The VSCC is equipped with Danieli’s latest proprietary technologies:
- PM Mold: Ensures precise billet shaping and enhanced heat transfer.
- Hydraulic Oscillator: Provides smooth and consistent casting flow.
- Rotoflex EMS and EMH Systems: Enhance billet quality by improving solidification and reducing segregation.
- L1/L2 Automation Systems: Offer advanced process control and monitoring through Danieli’s proprietary process models.
These state-of-the-art technologies allow the customer to produce billets with high internal structural stability and exceptional surface quality, while ensuring higher productivity and safety.
Danieli’s Legacy in Special Steel Casting
Danieli has been a pioneer in the field of special steel casting. Back in 2007, Danieli commissioned a Φ700mm round billet continuous caster at its own ABS special steel plant in Italy. After an upgrade in 2014, the caster’s capabilities were expanded to produce Φ850mm billets, replacing traditional ingot casting methods.
Today, the ABS plant remains the largest supplier of round billets in the European and American markets, with its products widely used in industries such as energy, transportation, automotive, and heavy machinery.
A Collaborative Success in the Chinese Market
The successful commissioning of the Φ1600mm VSCC in China was made possible through Danieli China’s efficient local management, its experienced on-site commissioning team, and the strong support from the customer and project partners. This collaboration highlights Danieli’s ability to deliver cutting-edge solutions tailored to the needs of the Chinese market while maintaining international standards of excellence.
A New Era for Large-Specification Billet Production
The commissioning of the Φ1600mm vertical semi-continuous casting machine not only sets a new global benchmark for billet sizes but also represents a significant step forward in the evolution of casting technology. By combining flexibility, efficiency, and superior quality, Danieli’s advanced VSCC technology is unlocking new possibilities for the production of ultra-large special steel billets.
This achievement further solidifies Danieli’s position as a global leader in special steel casting and opens the door for steel manufacturers to explore new levels of capability and competitiveness. HARRIS LEE, FUSHUN METAL
Tags:
#SteelIndustry #CastingTechnology #SpecialSteel #Danieli #InnovationInManufacturing #ContinuousCasting #BilletProduction #EngineeringExcellence #ChinaManufacturing #GlobalSteel
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