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Baowu Zhongnan Iron & Steel Smart One-Click Casting Platform Project

Case Introduction

Baowu Zhongnan Iron & Steel Smart One-Click Casting Platform Project

  • One-Click Casting
  • Higher Productivity
  • RMB 450,000 Labor Cost Savings
  • Reduced Energy Consumption
  • Improved Product Quality

Continuous Casting Machine No. 4 of the Steelmaking Plant was commissioned on October 9, 2008. As the only slab continuous casting machine of Zhongnan Iron & Steel, it has an annual billet production capacity of 1.65 million tons.

The production line is capable of manufacturing more than 200 steel grades across nine major product categories, including carbon structural steel, low-alloy structural steel, shipbuilding steel, alloy tool steel, high-quality carbon structural steel, high-strength steel, bridge steel, pressure vessel steel, and pipeline steel.

2008
Commissioned
1.65Million Tons
Annual Production Capacity
Solution

The existing eddy-current mold level control system suffered from poor operational stability, high spare-parts costs, and aging equipment that was difficult to maintain.

In addition, several high-intensity manual operations remained in place, resulting in significant labor demands.

Frequent mold replacement shutdowns also led to low equipment utilization and increased maintenance workload.

Project Benefits
  • 01

    Additional Benefits

    Safety Benefits: Robotic operations replace manual work in hazardous areas, significantly reducing safety risks and creating a safer working environment.

    Social and Brand Benefits: Intelligent production line equipment reduces energy consumption, improves slab quality, and enhances corporate brand value.

  • 02

    Electromagnetic Induction Slag Detection System

    Improved ladle slag detection sensitivity reduces residual steel by approximately 100 kg per heat, generating annual cost savings of RMB 1.46 million.

  • 03

    Intelligent Mold Width Adjustment System

    Generates annual economic benefits of RMB 2.75 million by improving continuous casting efficiency, reducing auxiliary material consumption, and minimizing head and tail slab losses.

  • 04

    Continuous Casting Platform Robot System

    The system enables unmanned casting platform operations and optimized workforce allocation. By reducing one operator per shift across four shifts, it saves RMB 450,000 in annual labor costs while significantly reducing manual workload. Current platform operations are remotely monitored by one operator from the central control room.

  • 05

    Electromagnetic Stopper Rod Automatic Start-of-Casting System

    ① Improved Quality and Production Efficiency

    The system features high-precision molten steel level detection, fast response, and strong anti-interference capability.

    It improves slab quality, reduces downgraded slabs, and achieves a ±3 mm level control accuracy hit rate of over 99%, improving accuracy by 2%.

    By reducing downgraded slab production, the system can generate annual economic benefits of approximately RMB 2.592 million.

    ② Reduced Head Slab Scrap Loss

    During the automatic casting start process, the system rapidly stabilizes molten steel level control, reducing the length of transitional slabs by more than 0.5 meters per casting sequence.

    Based on 593 automatic casting starts per year, the system can reduce transitional slab waste and generate economic benefits of approximately RMB 1.838 million annually.