Hot metal rejuvenates steelmaking
BOS and casters pumping and pushing product out the door
If the blast furnace is the beating heart of the Whyalla Steelworks, then it stands to reason the Basic Oxygen Steel (BOS) and Caster plants are similarly vital organs.
For these ‘organs’ to stay healthy, they need a good supply of blood (hot metal) from the heart. That is now the case with BOS and Casters (billet and combi) pumping out saleable product in the form of blooms and billets.
Steelmaking Technology Manager, Larisa White, is witnessing the benefits of that blast furnace performance as the BOS goes about its oxygen blowing process to make-ready the steel for the casting operations.
“When the blast furnace is able to achieve consistent high quality raw product for the BOS, we are better placed to consistently convert that iron into steel,” Larisa said.
“The good chemical stability allows us to charge into our furnace and run our processes in a more stable manner.
“Better chemical consistency means less silicon, less slopping out the top of the vessels, a better stream of metal to the casters and things like our refractories last longer.”
Casting Operations Manager, George Rossouw, said that stream has allowed the combi and billet casters to operate simultaneously in recent times, something that hasn’t been achieved for a couple of years.
“If the hot metal quality is good from the blast furnace, the BOS is able to send more steel consistently to the casters and the more product we pump out,” George said.
“This machinery performs better when it can run constantly so we just want to keep it running.
“Everyone wants to dual cast and it’s actually easier when you get it going.”
Both Larisa and George said the morale at the BOS and Caster plants was on the up with funding provided by the Federal and State governments resulting in more maintenance, repairs and staff.
“It is certainly better to be producing steel than doing nothing,” Larisa said. “We have brought a lot of new people on board which is another positive sign, we’re getting things fixed, getting new people and we’re making big steps to get back to where we should be … where can all do our jobs.”
George said the return to normal operations had made it more enjoyable for everyone involved in casting.
“Things got pretty low when we had big shuts because everyone just wants to cast,” George said. “We all want to come in casting and go home casting … we don’t want stop-start, and we don’t want to be sitting idle.”
“It definitely gives us peace of mind knowing we are pushing steel out of the building, people are getting paid and everyone is busy.”
