Continuous Steel Casting
Steel producer ArcelorMittal operates a vast production facility in the Port of Ghent. One of the key stages in the manufacturing process is the continuous casting of steel slabs, during which molten steel is transformed into a solid form. These steel slabs are 220 mm thick, can be up to 2,670 mm wide and 11 metres long, and can be produced in a wide range of dimensions. They serve as the starting point for subsequent processes such as hot rolling.
To carry out the continuous casting process, an enormous casting installation is used (see diagram). At the top of the machine, molten steel is poured into a mould. The steel then travels through a curved strand consisting of up to 15 segments and spanning a total length of 36 metres. Along the way, water-cooled rollers and spray nozzles gradually cool and solidify the steel. At the bottom of the installation, the slabs are cut to lengths of up to 11 metres.
As with many industrial processes, the installation is only as strong as its weakest link. That is why every single component, no matter how small must be kept in optimal condition at all times.
Arcelor Mittal Ghent and De Meyer NV: A Partnership Forged in Steel Since 2015!
"Our collaboration with De Meyer goes far beyond a traditional customer–supplier relationship. We operate as true partners, continuously challenging and inspiring each other to do better. De Meyer's expertise and unwavering commitment are what truly make the difference. Based on our experience with partners around the world, we can only be proud that such an exceptional company is based here in Flanders."
Preventive Maintenance: The Key to an Optimised Process
Arcelor Mittal Ghent operates two continuous casting machines. Since 2015, De Meyer has been responsible for the maintenance of one of these installations: the continuous caster. Naturally, all maintenance activities are carried out in close cooperation with the ArcelorMittal Ghent maintenance team.
Considering that this machine casts approximately 2.5 million tonnes of steel every year, it is no surprise that its components are subjected to extreme loads. To ensure maximum reliability and performance, each segment is periodically dismantled, overhauled and rebuilt according to a rigorous maintenance and refurbishment schedule. Particular attention is paid to the rollers and bearings within these segments, which are essential for transporting and solidifying the steel slabs. Operating under exceptionally harsh conditions including extremely high temperatures, constant moisture and continuous production these components are among the most critical wear parts of the installation.
With the right expertise, specialised equipment and, above all, highly skilled people, De Meyer has been a trusted maintenance partner for the past 11 years, carrying out these complex activities in close collaboration with the customer. Together, we continuously pursue improvements across every aspect of the operation, from technical performance to organisation and reporting.
Over the past decade, the machine has been subjected to increasingly demanding operating conditions due to evolving steel grades and changing production requirements. Our partnership has not only enabled the continuous caster to meet these challenges successfully, but has also contributed to extending the service life of its critical components and increasing maintenance intervals.
One Dedicated Team Delivering Flawless Service
More than a decade into this partnership, De Meyer has built a dedicated, highly experienced team responsible for these maintenance activities. At our workshop, we have also established a permanent, purpose-designed work area where the refurbishment process can be carried out safely and efficiently.
The combination of strong project management, mechanical expertise, specialised tooling and equipment, in-house laser measurement capabilities, and the in-depth knowledge gained over many years of working on this installation enables De Meyer to deliver these services consistently to the customer's satisfaction.
Open communication, complete transparency and close collaboration with our counterparts at ArcelorMittal Ghent have been instrumental to the success of this long-term cooperation. Together, they form the foundation of a partnership that is, quite literally, forged in steel.
