Castrip铸造与轧钢的终极目标

FASTERSMARTERTHINNERBETTERTheLatestDevelopmentswiththeCastrip®ProcessSept2010®ProcessFundamentalsFASTERSMARTERTHINNERBETTERNominalproductionof600,000tpa–50mlinelength15-150m/minuteHotBox20-24toncoil0.8-1.8mmthick50mMillRunouttablecoolingCastripLineBasics•Widthfrom1000mmto1680mm•Smallfootprint-200x200m•CapExis~25%lessthan‘thin-slab’casterpertonofannualcapacity•OpExcost~15%lessthan‘thin-slab’casterpertonforthingaugestrip•LowEnergy–GreenTechnologyFASTERSMARTERTHINNERBETTEREnergyEfficiencyandLowEmissions(ladlethroughcoldrollequivalent)ComparisonofEnergyConsumptionComparisonofGreenHouseEmissionsFASTERSMARTERTHINNERBETTERCastrip®ProcessSchematicFASTERSMARTERTHINNERBETTERTheCastrip®ProcessFASTERSMARTERTHINNERBETTERRoleofHotMillintheCastrip®Process•Ensurenocenterlineporosity•Improvesurfacequality(Ra41.1microns)•Increasegaugeflexibility•Improveproductdimensionaltolerance(1/3ASTM)andflatness(40IU)•Contributiontopropertydevelopment(includingpreservingcoarseaustenitegrainstructure)FASTERSMARTERTHINNERBETTERUniqueChallengesforRollingMill•Lowentrytensiontomill•Stripatmillentryas-castmaterialislessthan2.0mmthickatatemperaturegreaterthan1100ₒCelsius•StripisvirtuallyscalefreeTheimpactofpoorlubricationonthestripsurfacewherethestripweldsontotheworkrollsurfaceFASTERSMARTERTHINNERBETTERKeyRollingMillTechnologiesUsed•ConventionalAGC•Rollbitelubrication•Anti-crimprollatmillentry•Asymmetricworkrollbending•Segmentedworkrollcooling•ExitflatnessmeasurementforcontrolFASTERSMARTERTHINNERBETTERFlatnessControlSystemH(x)Ω(x)H(x)DynamicCrownControlStripCrownBendingStripCrownRollTiltStripCrownCoolingRollForceBendingFeedbackControlFlatnessBendingFlatnessCoolingMonitorControlActuatorSupportBendingCoolingHGCTiltSelectiveRollCoolingControlCoolingDistributionFjCoolingDistributionFjFFlatnessRollBendingControllerIncomingProfileProcessingFlatnessDistributionEstimatorGapTrimθ(x)Θ(x)h(x)BendingTrimSpraySequenceFASTERSMARTERTHINNERBETTERNucorCrawfordsville(IncludesVTD&LadleFce)FASTERSMARTERTHINNERBETTERNucorCastripArkansasFASTERSMARTERTHINNERBETTERStripCasterGeneralSpecificationsCrawfordsvillevs.BlythevillePlantUnitCrawfordsvilleSpecificationBlythevillespecificationCastinglinelength(centreturrettono.2coiler)58.68m49.0mPasslineelevationEL+800mmEL+3680mmLadleheatsize110tonnes(metric)110tonnesTundishweight18tonnes18tonnesCastertype500mmdiametertwinroll500mmdiametertwinrollMaxcasterwidth1345mm1680mmSteelgradeLowcarbonMn/SikilledLowcarbonMn/SikilledwithhighresidualsProductthicknessrange0.76to1.8mm0.7to2.0mmCastingspeed65m/mintypical,120m/minmax65m/mintypical,120m/minmaxMaxcoilsize25tonnes25tonnesInlinerollingmillSinglestand,4highwithhydraulicrollbendingandautomaticflatnesscontrolwithworkrollzonecoolingSinglestand,4highwithhydraulicrollbending,automaticflatnesscontrol,workrollshiftingandzonecontrolcoolingWorkrolldimensions475mmx2050mm560mmx2100mmBackuprolldimensions1550mmx2050mm1350mmx1900mmMaximumrollingforce30MN27.5MNCoolingtable10topandbottomheaders10topandbottomheadersCoilersize2x40tonneswithbeltwrappers2x32tonneswithbeltwrappersCoilermandrel762mm762mmAnnualcapacity540kt/yr674kt/yrFASTERSMARTERTHINNERBETTERCastrip®-CrawfordsvilleProductionHighlights•Record24heatsequencewith4flyingtundishchanges–36hourscasting(75tons/hour)–91%coiledtoliquid•Demonstratedcapabilityof40,000ton/month•Over1MilliontonsproducedFASTERSMARTERTHINNERBETTERCastrip-ArkansasFeaturedImprovements:•1680mmcastwidth,680KTpa•Lowcostscrapmixforhighermargins•EnhancedcoolingonCastingRolls•RevisedLayoutofCastingDeckMechanicalsforhigherproductivity•Elevatedpassline•Spraymistcoolingandashorterrolltable•UpgradedAutomationsystemFirstCast/CoilOct.13,2009FASTERSMARTERTHINNERBETTERMicrostructuralDevelopmentInclusionTransformationStartAllotrimorphicFerriteΑFαWFAcicularFerriteWidmanstattenFerriteFASTERSMARTERTHINNERBETTERMicrostructuralDevelopmentFASTERSMARTERTHINNERBETTERSuperiorFormingHoleExpansionTestUCS380(UltrathinCastStrip)HR360HR3008cmClearanceDie10mmPunchClearanceDie10mmPunchClampingForceClampingForceDie60°ExpanderEdgeBurrClampingForceClampingForceDie60°ExpanderEdgeBurrPunchingFASTERSMARTERTHINNERBETTERHoleExpansionClearanceDie10mmPunchClearanceDie10mmPunchClampingForceClampingForceDie60°ExpanderEdgeBurrClampingForceClampingForceDie60°ExpanderEdgeBurrPunchingHoleExpanding04080120350400450500550TS(MPa)λ(%)IncreasingAcicularFerriteContent275UCS,380UCS200HR,300HR,360HR300CR&CA,350CR&CAMicrostructureKSI5080506070FASTERSMARTERTHINNERBETTERPotentialUCSAlloyStrategiesYieldStrength(ksi)TotalElongation(%)StandardC-MngradesLimitedthicknesswindowathigherstrengthHSLAgradesExpandsthicknesswindowHigheststrengthsonlyingalvRecoveryannealedNballoyedcoldrolledsubstrateHighcopper(~0.35%)StrongerforagivenprocessingrouteSlowcoolingeffectiveforlowerstrength1020Expandsthicknesswindow1050HighMnNothicknesslimits1020304060801001035LowalloyC-MngradesLowerYS,higherelongationFASTERSMARTERTHINNERBETTERCastrip®“UCS