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Ferroalloys Continuous Casting Machine


Development and Demonstration of New Machine for Continuous Casting of Ferroalloys with Water Cooled Rotor Crystallizer Supplied with the Device for Cutting of Cast Products

Tech Area / Field

  • CHE-IND/Industrial Chemistry and Chemical Process Engineering/Chemistry
  • MAN-MCH/Machinery and Tools/Manufacturing Technology

3 Approved without Funding

Registration date

Leading Institute
Institute of Metallurgy, Georgia, Tbilisi


  • Siemens VAI Metals Technologies GmbH, Germany, Berlin\nEconomy Industrial Corporation, USA, PA, Ambridge

Project summary


Decrease of casting machine dimensions, combination of casting process with cutting of foundries for the set sizes, decrease of metal losses at casting, cutting and transportation of Ferroalloys, improving of Ferroalloys quality, prevention of danger of formation of gaseous hydrogen and it compounds (at transportation of Siliceous Alloys), improving of ecological working conditions of the attendants and decrease of industrial expenses.

State of the art in the field

At present in all leading world companies, as for example, Perry Videx and Union Carbide Metals (USA), Ferro-Alloys and Metals LTD (EU – UK), Elkem ACA (Norway), Tokushima Hokurika Hidaka (Japan), Jilin Ferro-Alloy Co LTD (China), Tata Steel and Electro Ferroalloys Private LTD (India), Cerro Matoso (Colombia), etc., casting of ferroalloys realizing by conveyer type Machines. The basic demerits of these Machines are their unhanliness, big losses of metal at casting, crushing and transportation, and also in extreme conditions danger of formation of gaseous hydrogen and it compositions (at transportation of siliceous alloys). In practice there are such cases (for example, in the autumn 2006 ignition in the Russian port Simferopol at transportation of Ferro-Silicon).

Despite of numerous researches and some successes achieved recently in improvement of designs of conveyer type Machines, considerably improving situation is failed and casting process still remains the weakest part in a technological cycle of ferroalloys manufacturing. Therefore conveyer type machines have exhausted own opportunities and investigation of principally new technological decisions is necessary.

Such decision is using of a method of continuous casting. Some researchers believed, that application of a method of continuous casting for ferroalloys is impossible on account of full absence of plasticity at ferroalloys, however experimental researches carried out in Georgian Institute of Metallurgy and Materials Science, have allowed to develop principles of new technology of ferroalloys casting by method of continuous casting. This technology has been modeling on large-scale pilot laboratory two profiled installation and serviceability and expediency of a new design and its indisputable advantage above existing of conveyer type Machines have been proved.

Realization of the submitted project will give possibility to develop and accomplish of development of above mentioned new Machine and to create an industrial sample of five profiled Machine, carrying out of demonstration tests and thereby to achieve a level of developments commercialization. For this purpose it is necessary to complete technological and design parameters of the Machine, in particular to define necessary section of carrying channels of a crystallizer, quantity of chutes of an internal crystallizer, a principle of an arrangement of basic rollers and cutting knifes, a degree of necessity of application of cross-section ribs in chutes.

The importance of project developments is not limited only to national interests of one country and will promote progress of ferroalloys industry at the international level.

Novelty of the project

Novelty of the project consists in development of the unique machine for continuous casting of ferroalloys which will be characterized by significant decreases of dimensions with preservation of productivity and will provide combination of casting process with cutting of billet for the necessary sizes, improving of quality of ferroalloys, prevention of danger of formation of gaseous hydrogen and it compounds (at transportation of siliceous alloys) and improving of ecological working conditions of the attendants.

Expected results and their application

As a result of realization of project developments the industrial sample of five profiled machine for continuous casting of ferroalloys with diameter of an internal crystallizer 2 m and productivity 35 – 40 т/hour will be created. Demonstration tests of the new Machine will be carrying out.

Expected advantages of the new Machine in comparison with conveyer types:

  1. Overall dimensions of the machine are decrease in 8 – 10 times without reduction of productivity;
  2. Losses of metal at casting are reduced with 1,5 – 2 % up to 0,1 – 0,15 % on weight;
  3. Segregation in foundries decreases with 10 – 6 % up to 2 – 1,5 %;
  4. Cracking of Alloys at transportation and in extreme conditions development of process of formation of gaseous hydrogen and it compounds (for Siliceous Alloys) are prevented;
  5. Ecological working conditions of the attendants improve;
  6. Casting process is fully automated;
  7. Expenses for manufacturing and operation of the Machine are reduced in 5 – 6 times.

Project developments will be complete up to commercialization level

Competence of the project team

Project participants are high-skilled specialists in the area of research engineering and development activity in metallurgy. In the Former SU they were involved mainly in defenses programs. For the recent 12-15 years these scientists participated in the conversion programs. During the above mentioned period by them have been published more than 40 scientific works, among them 11 works were published in the area of project technology. E.g.: 1. Mathematical model of steel continuous casting. Bulletin of the Georgian Academy of Sciences, v. 158, # 3, Tbilisi, Georgia, 1998 (G. Kevkhishvili, I. Zhordania, V. Shengelaya); 2. Influence of temperature of a surface of a crystallizer and of a gap for speed of solidification of an edge of continuously cast billet. Bulletin of the Georgian Academy of Sciences, v. 161, # 3, Tbilisi, Georgia, 2000 (G. Kevkhishvili, I. Zhordania, V. Shengelaya); 3. The analysis of dynamics of a chain line of a drive of briquetting rolls. Steel, № 9, Moscow, Russia, 2000 (M. Mikautadze, S. Mebonia); 4. Rotor type machine of continuous casting of ferroalloys. Problems of welding, metallurgy and related technologies, v. VIII, GWA, Tbilisi, Georgia, 2003 (G. Kevkhishvili, I. Zhordania, T. Chubinidze); 5. Definition of design parameters of the internal crystallizer used at casting of hollow billets. Problems of welding, metallurgy and related technologies, v. X, GWA, Tbilisi, Georgia, 2005 (G. Kevkhishvili, I. Zhordania); 6. Automation of process of continuously casting of hollow billets. Problems of welding, metallurgy and related technologies, v. XI, GWA, Tbilisi, Georgia 2006 (G. Kevkhishvili, I. Zhordania);

Meeting ISTC goals and objectives

The scientific employees that earlier carried out military orders of the Ministries of a Defensive structure of former USSR will be involved in the realization of the project. The support of the project will allow to direct scientific potential of these scientists on realization of researches for the peace purposes on development of new technology in the area of the metallurgical engineering. The Project developments will be realized with the minimum expenses if compared with world costs.

The project goals and tasks completely meet national interests of Georgia and also provisional for solving the problems of science and technology on the international level.

Role of foreign collaborators

Role of foreign collaborators will consist in mutual discussion of reports, comments on the technology development, joints workshops and publications, promote on development application.


The International Science and Technology Center (ISTC) is an intergovernmental organization connecting scientists from Kazakhstan, Armenia, Tajikistan, Kyrgyzstan, and Georgia with their peers and research organizations in the EU, Japan, Republic of Korea, Norway and the United States.


ISTC facilitates international science projects and assists the global scientific and business community to source and engage with CIS and Georgian institutes that develop or possess an excellence of scientific know-how.

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