Essar Steel has commissioned India's most modern slab caster at its Hazira steel plant. The caster has an annual production capacity of 1.8 million tonnes. This caster will augment Essar Steel's annual capacity to 4.6 million tonnes and is part of the expansion of capacity of the steel plant from 2.4 mmtpa to 4.6 mmtpa.
The Caster has been designed by SMS-Demag who are a world renowned equipment supplier in this field. They have also supplied basic engineering and the critical equipments, Level II automation and provided support in commissioning. Essar Constructions, an Essar group company undertook complete engineering, civil, structural, construction, equipment erection, piping, electrical and automation jobs on single point responsibility basis in record time of 14 months. The caster is designed to cast slabs of upto 2000 mm width, 220/260 mm thickness and cut length from 4.6 metres to 10.2 metres.
With the commissioning of the third caster, Essar Steel will be able to offer more sophisticated grades of steel required for specialized requirements like Interstitial Free (IF) Steel, Ultra Low Carbon (ULC) Steel, plate grade upto API x 80 line steel and many more critical applications.
The Caster is equipped with the latest technologies such as Vertical Mould of special copper alloy, Hydraulic Mould Oscillator with dynamic control, Mould width adjustment, Automatic Mould Level Controller, Sticker Detection System, Segments with Dynamic soft reduction etc.
It is also equipped with the latest state-of-the-art electrical and automation system, some of which is being introduced for the first time in any Caster in India. These are designed to ensure precise control of grain structure, surface quality, internal soundness and defect-free slabs.
Essar Steel expects to complete the expansion of the steel plant capacity during the current year at an estimated cost of Rs. 2000 crores. The expansion also involves raising capacity of its sponge iron, steel making, casting. and rolling units along with connected utilities.