Tata Steel and SMS group commission third slab caster at Kalinganagar

Tata Steel has commissioned a third two-strand continuous slab caster at its Kalinganagar steelworks in India, further expanding the production capabilities of Steel Melting Shop No. 1. Supplied by SMS group, the new facility has an annual production capacity of 3.1 million tonnes and is designed to manufacture a broad range of high-quality steel grades.

According to SMS group, the caster reached its target production capacity within a few months of the first heat, demonstrating stable operating conditions and high casting speeds.

Advanced technology for high-quality steel production

The vertical bending caster produces slabs with a nominal thickness of 230 mm, with alternative thicknesses of 210 and 250 mm, and widths ranging from 1,000 to 2,150 mm.

The facility can achieve casting speeds of up to 1.9 metres per minute on both strands, including at the nominal slab thickness of 230 mm.

Its product range includes interstitial-free (IF) steel, low-carbon grades, microalloyed peritectic steels and medium-carbon steel.

To ensure consistent product quality, the caster incorporates a high-performance copper mould with hydraulically controlled oscillation, precise mould-level regulation and hydraulically adjustable strand guidance.

SMS group's Dynamic Soft Reduction technology and a zone-controlled air-mist secondary cooling system are designed to improve solidification conditions and minimise internal slab defects.

The installation also includes the X-Pact automation system with Level 1 and Level 2 process controls, breakout prevention functions and continuous online monitoring.

Record casting sequence demonstrates operational stability

The commissioning phase was characterised by a rapid production ramp-up and sustained operational performance.

One of the most notable achievements was a continuous casting sequence of 560 heats over 17 consecutive days, highlighting the facility's availability and process stability.

An important contribution comes from the tundish change-on-the-fly system, which allows tundishes to be replaced without interrupting the casting sequence. This reduces downtime and supports longer production campaigns.

According to SMS group, the caster has also reached its maximum design casting speed of 1.9 metres per minute at a slab thickness of 230 mm on both strands.

Further expansion of Kalinganagar steelmaking capacity

The new installation is the third slab caster supplied by SMS group to Tata Steel's Kalinganagar facility.

The first two casters entered operation in 2016 and 2024, respectively. The latest project builds on this existing infrastructure and strengthens the plant's ability to produce demanding steel grades at industrial scale.

With the additional casting capacity, Tata Steel is continuing to develop Kalinganagar as an important production centre for high-quality flat steel products.

The successful commissioning also marks another stage in the long-standing technological cooperation between Tata Steel and SMS group.

Source and Photo: SMS Group