STRANGGIESSEN
Der Stranggießen wurde in den letzten Jahrzehnten zum führenden Verfahren für die Produktion von hoch-qualitativem Halbzeug aus Stahl. Die kontinuierliche Steigerung der durch Strangguss produzierten Produkte ist auf die deutliche Senkung der Produktionskosten bei gleichzeitiger Erhöhung der Qualität der gegossenen Produkte zurückzuführen. Aufgrund der Tatsache, dass bezogen auf die Rohstahlerzeugung derzeit rund 95% der weltweit produzierten Stähle im kontinuierlichen Stranggussverfahren hergestellt werden, hat dieses Verfahren auch für INTECO und seine Marktpositionierung große Bedeutung.
Mit der schrittweisen Integration der Firma TBR, mit seiner mehr als 30-jährigen Erfahrung im Stranggussbereich gepaart mit Fachwissen von INTECOs Ingenieuren, wurde vor mittlerweile knapp 15 Jahren ein Kompetenzzentrum im Stranggussbereich ins Leben gerufen.
Diese Sparte repräsentiert heutzutage einen wichtigen Teil der INTECO-Gruppe. INTECO ist stolz, industriell etablierte Stranggusstechnologien im Bereich der Vorblock-, Knüppel- und Beam-Blank-Anlagen liefern zu können.
Stranggussanlagen für Spezialanwendungen, wie Horizontal- oder Vertikalstranggießanlagen vervollständigen das Produktportfolio.
- Vorblock- und Knüppelstranggießanlagen
- Beam-Blank-Anlagen
- Horizontalanlagen
- Vertikale Anlagen / Segment Caster
- Tundish Inertisierung
- Speziell entwickelte Gießspiegelregelung (MLM – Mould Level Master)
- Hydraulik- oder Servo-Oszillator
- Dynamisch regulierbare Sprühkühlung gekoppelt an ein Online-Erstarrungsmodell
- Kontinuierliches Abbiegen/Richten
- Dynamische Soft Reduction (MSR – Mechanical Soft Reduction)
- Flexible elektromagnetische Rührsysteme
- Robuste Kühlbetten für kontrollierte Abkühlung
- Level2/ Erstarrungs- und „Soft Reduction“-Modell
Digitalisierung und Smart Production sind die treibenden Kräfte für Entwicklung und Veränderung in der Stahlbranche. Bei INTECO bieten wir Ihnen nicht nur erstklassiges Engineering im Anlagenbau, sondern auch maßgeschneiderte digitale Lösungen, die den anspruchsvollen Anforderungen unserer Kunden gerecht werden. Überwachen Sie Ihre Produktion effizienter und nutzen Sie die gesammelten Informationen für Anpassungen und Fortschritt.
1) INTECO heating controller for EPH and ESH
for optimal automated tundish heating
The INTECO heating controller for EPH and ESH is a sophisticated solution for tundish heating. The basic design offers a cascaded control function for temperature control based on a fixed value or a temperature profile. It features automatic slag melting, immersion depth control and detection of stirring problems. Optionally, a temperature and prediction model can be applied using tundish condition and history as well as data of successful heat levels for predicting and controlling the temperature and making the system independent from a temperature signal.
2) INTECO's Oscillation Master
for optimal surface
The INTECO Oscillation Master uses a universal platform for all section sizes that can be used for hydraulic cylinders and servo drive oscillation systems. The servo drive oscillation’s eccentric drive is powered by a backlash free servo-drive, while the oscillating movement is achieved by alternating the servo-drive’s rotation direction. The frequency, stroke and shape of the oscillation movement can be adjusted online using the variable rotation angle. The actuator is exchangeable for flexibility and maintenance. With a servo-drive, high accelerations are feasible.
3) INTECO’s mould width adjustment system
for online adjustment of the mould width during casting
INTECO’s mould width adjustment system allows online adjustment of the mould width during casting and works with both INTECO mould designs as well as existing moulds with electromechanical or hydraulic cylinders. It features non-parallel adjustment to reduce stress on the strand shell and to minimize the transition length.
4) INTECO's Break Out Prevention System (IBOPS)
to automatically detect and prevent liquid breakouts during casting
INTECO’s Break Out Prevention System (IBOPS) automatically detects and prevents liquid breakouts during the casting process which helps to reduce costly shutdowns. The system is based on classical algorithms and combines it with an AI-based system to improve the detection rate and to decrease false positives. Additionally, the AI-based system improves its effectiveness over time by utilizing historic trend data.
5) Dynamic final stirrer
for segregation and porosity reduction in cast products
INTECO’s advanced online solidification model allows precise adjustment of the dynamic final stirrer’s position during the casting process and provides real-time data. It defines thermo-physical properties of steel according to the chemical composition and calculates temperature profiles along the entire solidifying strand. This allows to change input parameters such as casting speed, water flow, tundish heat, steel grade composition and many more. As a result, it ensures highest final product quality, guaranteeing high level of soundness, low segregation and defect-free center structure.
6) INTECO's Tundish Level Master (TLM)
for automatic level control of the tundish filling level
The Tundish Level Master is used for automatic level control of the filling level in the tundish at a defined set point by monitoring the tundish gross weight (through the related weighing system) and controlling the ladle slide gate.
7) INTECO's Mould Level Master
to ensure exact mould level control
A stable mould level is essential for casting high-quality steel grades. The INTECO Mould Level Master is an advanced control system which uses a patented detection system to ensure exact mould level control throughout the entire continuous casting process, regardless of the conditions, variations and disturbances. It reduces the risk of overflow, which results in better casting stability and a safe and reliable operation. The included flushing function removes clogging (alumina build-up). The system is sensor-independent and can be connected to various measuring systems such as radiometric, ultra-sonic, or eddy-current systems.
8) Soft reduction model
for segregation and porosity reduction in cast products
The soft reduction model can be easily linked to the solidification model to determine the optimal reduction amount depending on the solid fraction. Additionally, our secondary cooling optimization model uses the temperature data from the solidification model to control each cooling zone according to a defined temperature profile.
9) Solidification model
to calculate the temparature profile during solidification
Our micro-segregation model defines thermo-physical properties of steel according to the chemical composition such as liquidus/solidus temperature, density and thermal conductivity. The solidification model calculates the temperature profiles along the entire solidifying strand, taking the thermal boundary conditions and relevant process variables like casting speed and water flow into consideration. The model provides real-time data on surface temperature, internal gradients and shell thickness as a function of solid fraction.
10) IMAS process automation
IMAS-PA-CC provides advanced top-down process guidance through dynamic or static treatment planning and integrated optimization tools. Process supervision is massively improved by the cockpit view and integrated real-time process models. IMAS provides instant real-time information and alerts, based on which the operators can control and steer the process just-in-time. The heat-based data recording stores sensor data, including complex information such as video streams, allowing observation of real-time data for quality assurance and process improvement.
The INTECO heating controller for EPH and ESH is a sophisticated solution for tundish heating. The basic design offers a cascaded control function for temperature control based on a fixed value or a temperature profile. It features automatic slag melting, immersion depth control and detection of stirring problems. Optionally, a temperature and prediction model can be applied using tundish condition and history as well as data of successful heat levels for predicting and controlling the temperature and making the system independent from a temperature signal.
The INTECO Oscillation Master uses a universal platform for all section sizes that can be used for hydraulic cylinders and servo drive oscillation systems. The servo drive oscillation’s eccentric drive is powered by a backlash free servo-drive, while the oscillating movement is achieved by alternating the servo-drive’s rotation direction. The frequency, stroke and shape of the oscillation movement can be adjusted online using the variable rotation angle. The actuator is exchangeable for flexibility and maintenance. With a servo-drive, high accelerations are feasible.
INTECO’s mould width adjustment system allows online adjustment of the mould width during casting and works with both INTECO mould designs as well as existing moulds with electromechanical or hydraulic cylinders. It features non-parallel adjustment to reduce stress on the strand shell and to minimize the transition length.
INTECO’s Break Out Prevention System (IBOPS) automatically detects and prevents liquid breakouts during the casting process which helps to reduce costly shutdowns. The system is based on classical algorithms and combines it with an AI-based system to improve the detection rate and to decrease false positives. Additionally, the AI-based system improves its effectiveness over time by utilizing historic trend data.
INTECO’s advanced online solidification model allows precise adjustment of the dynamic final stirrer’s position during the casting process and provides real-time data. It defines thermo-physical properties of steel according to the chemical composition and calculates temperature profiles along the entire solidifying strand. This allows to change input parameters such as casting speed, water flow, tundish heat, steel grade composition and many more. As a result, it ensures highest final product quality, guaranteeing high level of soundness, low segregation and defect-free center structure.
The Tundish Level Master is used for automatic level control of the filling level in the tundish at a defined set point by monitoring the tundish gross weight (through the related weighing system) and controlling the ladle slide gate.
A stable mould level is essential for casting high-quality steel grades. The INTECO Mould Level Master is an advanced control system which uses a patented detection system to ensure exact mould level control throughout the entire continuous casting process, regardless of the conditions, variations and disturbances. It reduces the risk of overflow, which results in better casting stability and a safe and reliable operation. The included flushing function removes clogging (alumina build-up). The system is sensor-independent and can be connected to various measuring systems such as radiometric, ultra-sonic, or eddy-current systems.
The soft reduction model can be easily linked to the solidification model to determine the optimal reduction amount depending on the solid fraction. Additionally, our secondary cooling optimization model uses the temperature data from the solidification model to control each cooling zone according to a defined temperature profile.
Our micro-segregation model defines thermo-physical properties of steel according to the chemical composition such as liquidus/solidus temperature, density and thermal conductivity. The solidification model calculates the temperature profiles along the entire solidifying strand, taking the thermal boundary conditions and relevant process variables like casting speed and water flow into consideration. The model provides real-time data on surface temperature, internal gradients and shell thickness as a function of solid fraction.
IMAS-PA-CC provides advanced top-down process guidance through dynamic or static treatment planning and integrated optimization tools. Process supervision is massively improved by the cockpit view and integrated real-time process models. IMAS provides instant real-time information and alerts, based on which the operators can control and steer the process just-in-time. The heat-based data recording stores sensor data, including complex information such as video streams, allowing observation of real-time data for quality assurance and process improvement.
Projekte
Shagang Group
Arcelor Mittal Belval
vertraulicher Kunde
