Clogging problems at Caster A in

GG MID

Presenter:
Paulo Carvalho Fernandes

Ttulo da Apresentao 1
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.
This problems become more severe in Jan/2011 causing many
losses in Power off, Metallic yield, alloys, refractory and Team
Moral.

Clogging problems at Caster A in GG MID 2

Details

Problem: Clogging in Majority of Al Killed grades;

Grades :
8620I, 4140I, 4130I, 8630I, 1035I,1017MI,1018MI
Caster: A caster
Heat Size:150 Ton
Tundish Size: 15 Ton
Nozzle: slide gate with usually 22 mm
Gate opening Target: 76%;
Sequence of 5 or 6 heats;
Casting Time: 85 min

All the trends/graphic(speed, casting tons, gate opening, mold level

can be seen online at Active Factory;

Clogging problems at Caster A in GG MID 3

 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

Brainstorming with Knowledge Management

Posted on: 5/19/2011

Answers from:
Paulo Carvalho Fernandes;
Tom White
Joe Malchar
Carlos Berlini Filho

Ttulo da Apresentao 7
Actions Implemented

Divide the grades by Sulphur range;

Reduction in the CaSi wire addition;
Change the slag composition: V ratio reduced KM suggestion;
Change the sequence Addition KM suggestion;
Defined time between wire addition/ bubbling in the end of Heat
KM suggestion

Clogging problems at Caster A in GG MID 8

Solution Overview

How long the solution took to be implemented: 35 days

Improvements:
Any Clogging problems in heats with 0.010 or less Sulphur;
Great Improvement in Clogging and chemistry stabilization in grades
with more than 0.010 %S
Reduced the Pour backs in 80% for these grades;
Reduced Missing chemistry for these Grades in 100%;

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

Savings

Power Off: Reduced in 0.8 min/heat

Savings: USD 1,430,423

Refractory Consumption: Reduced 0.4 lbs/ton in tundish and ladle lifetime

Savings: USD 296,397

Metallic Losses: Reduced 0.7 lbs/ton

Savings: USD 43,000

Alloys Consumption: Reduced 0.2 lbs/ton

Savings: USD 175,000

Electrical Energy: Reduced 0.7 kwh/ton

Savings: USD 53,528

Safety: Less Pour backs, less changeovers;

Clogging problems at Caster A in GG MID 12

Conclusion

Do not fight Thermodynamics;

Do not be ashamed to ask for suggestions;
The KM is a very powerful tool and should be used and spread at
Gerdau Worldwide.

Clogging problems at Caster A in GG MID 13

Team Members

Darciso Castilho Process Engineer, GG MID

Paulo Carvalho Fernandes Consultant, GG Brazil
Joe Malchar Refractory Foreman, GG MID
David Wiggins Furnace Foreman, GG MID
David Usry QE Manager, GG MID
Tom White Improvement Facilitator, GG KNX
Carlos Berlini Process Engineer, GG ACO

Clogging problems at Caster A in GG MID 14

Questions and Answers?

Darciso Castilho
Process Engineer MS

Contact:

Telephone: +01-804-896-3415
e-mail: Darciso.castilho@gerdau.com

David Usry
Metallurgist Manager

Contact:

Telephone: +01-972-779-1870
e-mail: David.usry@gerdau.com

Joseph Malchar
Improve Facilitator

Contact:
Telephone: +01-817-723-8684
e-mail: Joe.malchar@gerdau.com

15
Questions and Answers?

Paulo C. Fernandes
Ladle Furnace Community Moderator
GSB Technical Consultant

Contact:

Telephone: +55-51-93488332
e-mail: paulo.fernandes@gerdau.com.br

Carlos Berlini
Process Engineer, GG ACO

Contact:

Telephone: +55-31-3749-2943 | +55-31-9622-0598

e-mail: carlos.filho@gerdau.com.br

Tom White
Improve Facilitator

Contact:
Telephone: +01-865-546-0102 ext 458 | +01-865-850-3380
e-mail: Charles.White@gerdau.com

16
 Thank you for your attention!

Clogging problems at Caster A in GG MID 17