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ORGANIZER;CN=ESTAD 2023:mailto:info@metec-estad.com
LOCATION:Room 18b
SUMMARY:The new billet caster S1 at Saarstahl
DESCRIPTION:The new billet caster S1 at Saarstahl AG

Saarstahl is one of the world leading suppliers of long products for demanding steel grades of special bar quality. The product portfolio includes a wide range of unalloyed and high-alloyed steel grades with a carbon content from 0.01 up to 1.0 wt.-%C, which are mainly utilized in the automotive sector.

To underline its forefront technology position and to achieve further quality improvements, as well as production flexibility and capacity, Saarstahl ordered a new 5-strand billet caster named “S1” in 2017. Designed by SMS Concast AG, the caster produces 180x180mm2 billets. After the successful commissioning of caster “S0” and revamping of caster “S3”, this is already the third cooperation between both parties on a major caster project since 2005.

The caster is equipped with Convex Mould Technology, consecutive stirring in mould (MEMS) and strand (SEMS) position, AirMist soft secondary cooling, Dynamic Mechanical Soft Reduction (D-MSR), automatic deburring, marking and sampling machines, speed and temperature measurements as well as an extended discharge concept including 4 silent turn over cooling beds. 

Among the technological equipment, the installation of the 12 MSR units, which are comprised by six double modules, must be highlighted. Each reduction roll is capable to apply up to 1000kN of force to ensure intense soft and hard reduction. The optimum steel grade specific reduction pattern are adjusted online automatically based on the process conditions and casting parameter to ensure lowest segregation and porosity levels and therefore highest internal quality. 

24 months after awarding the contract to build the new “S1”, the caster had its first cast in November 2019.
This paper shall outline the main technological features in detail and reflect the quality results that could already be achieved in standard production after an intensive hot commissioning and testing period. 


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