Well-equipped for future tasks
Renovated continuous casting plant in Georgsmarienhütte
The sustainability of the renovated continuous casting plant in Georgsmarienhütte can be summed up in an impressive picture, with six rigid dummy bars extending at the beginning of the casting process right up to the ceiling. These rigid dummy bars not only improve the attitude of the billets during casting, they also reduce the auxiliary process times of the continuous casting plant.
On the modernised continuous casting plant blooms with a premium surface quality and outstanding degree of metallurgical purity are manufactured. The upgraded and newly installed technologies, e.g. a mechanical soft reduction, primarily help to minimise segregations as well as potential porosities and cracks.
Consequently the new plant will enable Georgsmarienhütte GmbH, a company of GMH Gruppe, to satisfy customer requirements for the next 20 years and beyond with a punctual, premium-quality service.
Pinpoint precision with the latest technology
With an investment volume of over 60 million euros, the new continuous casting plant at Georgsmarienhütte GmbH features a wide variety of new innovations. The entire control of the continuous casting plant has been thoroughly modernised. This is particularly evident in connection with the burner control panel which has not only been fitted with additional new control panels – state-of-the-art camera technology also makes it possible to keep the warm cast billets permanently in view.
Besides the cold casting compensators, the largest components are the basic driver frames. Weighing over 50 tonnes, these are positioned to the tenth of a millimetre with the help of a crane. In order to be able to adhere to these narrow tolerances, the plant was not only subjected to a complete laser scanning prior to the renovation work – a team of surveyors were also constantly on site throughout the entire conversion phase to ensure that it was completed with extreme precision.
A logistical masterpiece
The eight-strong project team, employees of the steel plant, were also expected to deliver outstanding results. Even coordinating each of the sub-projects with their respective schedules proved a logistical challenge, but the team always had everything under control. Thanks to effective communication and straightforward coordination processes, the renovation of the Georgsmarienhütte site was completed in no time at all. The 30-year-old plant was partially dismantled immediately after the final batch on 17 July 2017. And, after just one week, work began on installing new components. The actual renovation and construction work could then be carried out during the four-week company close-down.
Even the initial casting runs proved that the immense effort and intensive workload have paid off and all of the plant technology functions as it should.
The result of intensive preparations
It is thanks to the careful preparatory work that went into this project that it was able to run so smoothly. This not only involved countless components being pre-installed but also the installation of a prototype system by experts at GMH Gruppe in Georgsmarienhütte years before. The knowledge gained from this prototype was channelled directly into perfecting the six new casting systems. A number of crucial units that do not directly impact ongoing production were able to be installed prior to the company close-down, including the new water management system upstream of the steel plant hall, and the new product cooling system.
Integration tests were carried out by the manufacturers to eliminate any potential sources of error.
A Greenfield project would have been easier,” explains Oliver Brune, Head of New Development, Planning & Construction. “But that just wouldn’t have been possible at this site. The available space has been exploited to maximum effect down to the last six centimetres. A truly bespoke solution.”