ABB Flow Control Mold to improve quality, control and productivity at new US plate steel mill

Latest electromagnetic stirring and braking technology will help Nucor Steel Brandenburg produce cleaner steel faster, with reduced maintenance and at lower cost

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ABB has been selected to supply its Flow Control Mold (FC Mold) electromagnetic stirring and braking solution for one of the world’s widest thick slab continuous casters at the new Nucor Corporation steel plate mill at Brandenburg, Kentucky, USA.

With capacity for slabs of up to 305mm thick by 3,150mm wide, the caster is the widest ever to be equipped with FC Mold. The order - placed by caster supplier, SMS Group will be operational by 2022.

In continuous slab casting, conditions in the meniscus area of the solidifying steel are crucial to determining end product quality and have a major impact on productivity and overall operating costs. Integrated with the caster, FC Mold uses electromagnetic fields to control meniscus flow speed and fluctuations, while helping prevent gas bubbles and impurities from becoming trapped in the solidifying steel.

Results from more than 40 installations worldwide have proven that FC Mold delivers higher productivity and quality, and lower operating costs for casters operating at all speeds. Typically, installation of FC Mold results in a significant reduction in defects, rejects and downgraded products. In addition, FC Mold can allow for a higher casting speed.

Anders Lehman, Vice President of ABB Metallurgy Products

“Having enjoyed a productive relationship with SMS Group for many years, this is our first order for Nucor Brandenburg and our first US order for FC Mold. The facility’s very wide casting format is challenging, but in addition to improving slab quality, FC Mold will also help optimize its operation significantly. We are looking forward to demonstrating the many benefits of our latest electromagnetic stirring and braking technology at this greenfield site.”

Your Challenges

  • Improve conditions in the near-meniscus area which are crucial to determining end-product quality and have a significant effect on overall productivity and operating costs
Our Solution

  • FC Mold offers simultaneous stirring and braking in the mold from one fixed position via three independent magnetic fields to control meniscus flow speed and dampen fluctuations, and minimize downward flow to allow gas bubbles to float to the surface instead of being trapped in the solidifying steel. 

    • Automatic, adaptable process control

    • Automatic quick connectors shorten mold change time

    • Very low maintenance and long lifespan 

    • Achieve up to 50% less surface surface and internal defects
    • Reduce your reject ratio by up to 80%
    • Improve productivity with a higher casting speed

    •  Lower operating costs with less rejects and downgrades

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