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Clogging problems at Caster A in

GG MID

Presenter:
Paulo Carvalho Fernandes

Título da Apresentação 1

refractory and Team Moral. This problems become more severe in Jan/2011 causing many losses in Power off.Opening / Introduction • Gerdau Midlothian had experienced problems during the Continuous Casting of Al Killed heats treated with CaSi wire and minimum Sulphur required for the Grade. Metallic yield. alloys. Clogging problems at Caster A in GG MID 2 .

1035I. mold level can be seen online at Active Factory. Clogging problems at Caster A in GG MID 3 . 4140I. 4130I. casting tons.1018MI • Caster: A caster – Heat Size:150 Ton – Tundish Size: 15 Ton – Nozzle: slide gate with usually 22 mm – Gate opening Target: 76%. • Grades : – 8620I. gate opening. – Sequence of 5 or 6 heats.1017MI.Details • Problem: Clogging in Majority of Al Killed grades. 8630I. – Casting Time: 85 min • All the trends/graphic(speed.

LADLE STOPPER TUNDISH MOLD STRAND CUT BILLET Clogging problems at Caster A in GG MID .

Example of a Bad Campaign with clogging Gate Opening Cast Tons LOST ALL STRAND DUE TO THE CLOGGING Clogging problems at Caster A in GG MID 6 .

– Tom White – Joe Malchar – Carlos Berlini Filho Título da Apresentação 7 .Brainstorming with Knowledge Management • Posted on: 5/19/2011 • Answers from: – Paulo Carvalho Fernandes.

• Change the sequence Addition – KM suggestion. • Reduction in the CaSi wire addition. • Change the slag composition: V ratio reduced – KM suggestion. • Defined time between wire addition/ bubbling in the end of Heat – KM suggestion Clogging problems at Caster A in GG MID 8 .Actions Implemented • Divide the grades by Sulphur range.

010 or less Sulphur.010 %S – Reduced the Pour backs in 80% for these grades. – Reduced Missing chemistry for these Grades in 100%. – Great Improvement in Clogging and chemistry stabilization in grades with more than 0.Solution Overview • How long the solution took to be implemented: 35 days • Improvements: – Any Clogging problems in heats with 0. Clogging problems at Caster A in GG MID 9 .

Current Casting Trend Gate Opening Cast Tons Example of a good 5 heats campaign Clogging problems at Caster A in GG MID 11 .

less changeovers.7 lbs/ton – Savings: USD 43.430.4 lbs/ton in tundish and ladle lifetime – Savings: USD 296.7 kwh/ton – Savings: USD 53.423 • Refractory Consumption: Reduced 0.397 • Metallic Losses: Reduced 0. Clogging problems at Caster A in GG MID 12 .528 • Safety: Less Pour backs.8 min/heat – Savings: USD 1.2 lbs/ton – Savings: USD 175.000 • Electrical Energy: Reduced 0.Savings • Power Off: Reduced in 0.000 • Alloys Consumption: Reduced 0.

Clogging problems at Caster A in GG MID 13 . • Do not be ashamed to ask for suggestions. • The KM is a very powerful tool and should be used and spread at Gerdau Worldwide.Conclusion • Do not fight Thermodynamics.

GG ACO Clogging problems at Caster A in GG MID 14 . GG MID • Paulo Carvalho Fernandes – Consultant. GG MID • David Wiggins – Furnace Foreman. GG MID • David Usry – QE Manager. GG MID • Tom White – Improvement Facilitator. GG KNX • Carlos Berlini – Process Engineer.Team Members • Darciso Castilho – Process Engineer. GG Brazil • Joe Malchar – Refractory Foreman.

malchar@gerdau.castilho@gerdau.com 15 .com David Usry Metallurgist Manager Contact: Telephone: +01-972-779-1870 e-mail: David.usry@gerdau.Questions and Answers? Darciso Castilho Process Engineer MS Contact: Telephone: +01-804-896-3415 e-mail: Darciso.com Joseph Malchar Improve Facilitator Contact: Telephone: +01-817-723-8684 e-mail: Joe.

fernandes@gerdau.br Carlos Berlini Process Engineer.White@gerdau.Questions and Answers? Paulo C. GG ACO Contact: Telephone: +55-31-3749-2943 | +55-31-9622-0598 e-mail: carlos.br Tom White Improve Facilitator Contact: Telephone: +01-865-546-0102 ext 458 | +01-865-850-3380 e-mail: Charles. Fernandes Ladle Furnace Community Moderator GSB Technical Consultant Contact: Telephone: +55-51-93488332 e-mail: paulo.com.com.com 16 .filho@gerdau.

Thank you for your attention! Clogging problems at Caster A in GG MID 17 .