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INTECO

INGOT CASTING

ATS, the Advanced Teeming System by INTECO, represents the cutting-edge solution for achieving automated, high-performance ingot casting with minimal manual involvement. INTECO’s innovative teeming system revolves around the concept of semi- to fully automated circulation and handling of casting sets. It incorporates a substantial level of automation and robotics, enhancing safety and ergonomics for operators. Key benefits include reproducible production processes and higher product yield.

Reference projects:

  • Metal Ravne
  • Buderus Edelstahl
  • Daye Special Steel
  • Gloria Materials Technology
  • Variations:

    • Sections: round, polygonal, rectangular, hollow
    • Sizes up to Ø1500 or comparable for other geometries
    • Length up to 13–15m with cutting to final product size
    • No limitations to steel grades

     

    Process variations:

    • Semi-continuous (SC) to ingots from 1 to 4 strands in parallel and subsequent offline cutting
    • Continuous (VCC) in sequences of multiple ladles with inline cutting and subsequent ingot manipulation

     

    Features

    • Inductive feeder for maximum hot top yield
    • Dynamic electromagnetic stirring system (EMS)
    • Retractable heat insulation system
    • EPH system for ladle heating at ultra-low casting speeds
    • Liquid steel protection from ladle to mould
    • Servo drive oscillation
    • Fully automatic dummy bar system
    • Fully automatic discharge system
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Plate cleaning station

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Bottom plate preparation

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Mould preparation

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Mould cleaning unit

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Trumpet erection

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Stripping

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Hot-top cleaning

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Ingot casting car

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Ingot casting car

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Casting station

Bodenplattenreinigungsstation
Bodenplattenvorbereitung
Kokillenvorbereitung
Kokillenwaschanlage
Trichterbaustation
Strippstation
Gießpulverabsaugung
Blockgusswagen
Gießwagen
Gießplatz

Vacuum ingot casting is the technology of choice for very large ingots. The largest systems supplied by INTECO worldwide allow production of ingots exceeding 700t.

Casting under vacuum enables attainment of the lowest hydrogen content, since there is no hydrogen absorption during casting, thus preventing flake formation.

INTECO provides customized plant solutions for all ingot weight and throughput requirements. Both conventional steam jet pumps and mechanical vacuum pumps are used as vacuum systems. In addition to engineering and delivering the plants, INTECO provides expertise in mould design, casting parameters, and more.

To produce high-quality ingots, it is nowadays considered state-of-the-art to use an ingot casting car with casting rate control and casting stream protection. The three-dimensional adjustability of the ladle in the car allows easy and perfect positioning of the ladle slide gate over the trumpet. The casting stream protection guarantees shielded casting during the whole process for increased steel quality and avoidance of re-oxidation. INTECO’s Casting Rate Controller (ICAST) in combination with an accurate weighing system is essential for pouring rate control (independent of the ferro-static pressure in the ladle) throughout the entire casting process.

Digitalization and smart production are transforming the steel industry, driving development and change. At INTECO, we offer not only first-class engineering in plant construction, but also customized digital solutions tailored to our customers’ demands. Enhance your production with our digital solutions and utilize the collected data to make strategic adjustments and drive continuous progress.

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1) ICAST - INTECO's Casting Rate Controller
for automated casting

ICAST, which stands for INTECO’s Casting Rate Controller, enables automated casting with consistent pouring rates. Specially developed algorithms control the ladle slide gate and, consequently, the fully automated pouring rate for a defined casting profile with multiple process phases. ICAST can be utilized with casting cranes or INTECO’s ingot casting cars, providing the option for semi-automatic ladle positioning. ICAST is not only perfect for new installations but also an ideal solution for modernization projects, enhancing plant operation through seamless installation. A significant advantage of ICAST lies in minimizing the human factor in controlling the casting process.

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2) IMAS Process Automation

IMAS-PA-IC provides advanced top-down process guidance through dynamic or static treatment planning and integrated optimization tools. Process supervision is massively improved by the cockpit view and integrated real-time process models. IMAS provides instant real-time information and alerts, based on which the operators can control and steer the process just-in-time. The heat-based data recording stores sensor data, including complex information such as video streams, allowing observation of real-time data for quality assurance and process improvement.

ICAST - INTECO's Casting Rate Controller

ICAST, which stands for INTECO’s Casting Rate Controller, enables automated casting with consistent pouring rates. Specially developed algorithms control the ladle slide gate and, consequently, the fully automated pouring rate for a defined casting profile with multiple process phases. ICAST can be utilized with casting cranes or INTECO’s ingot casting cars, providing the option for semi-automatic ladle positioning. ICAST is not only perfect for new installations but also an ideal solution for modernization projects, enhancing plant operation through seamless installation. A significant advantage of ICAST lies in minimizing the human factor in controlling the casting process.

IMAS process automation

IMAS-PA-IC provides advanced top-down process guidance through dynamic or static treatment planning and integrated optimization tools. Process supervision is massively improved by the cockpit view and integrated real-time process models. IMAS provides instant real-time information and alerts, based on which the operators can control and steer the process just-in-time. The heat-based data recording stores sensor data, including complex information such as video streams, allowing observation of real-time data for quality assurance and process improvement.

PROJECTS

Ovako

ICAST, highest safety standards
two 100t ingot casting cars

Buderus Edelstahl

Most modern automated casting system
Two 200t ingot casting cars & advanced Teeming System

Breitenfeld Edelstahl

Multiple ladle casting for ingots up to 130t
two 65t ingot casting cars

Taewoong Special Steel

Worlds biggest vacuum ingot caster
700t vacuum ingot casting

Grupo FRISA

Complete ingot casting area
50t ingot casting car, mould washing unit, plate transfer and tilting device

DAYE Special Steel

Advanced Teeming System