BAGR Berliner Aluminiumwerk GmbH, Europe's leading independent secondary aluminium slab producer, has announced on Tuesday, September 1, that it has started a fully-automated continuous casting line to manufacture high-quality rolling ingots in large widths.
On commissioning of the new casting line, Mustafa Güngör, Managing Director of BAGR, said: "Our customers have indicated to us that they would like to purchase high-quality rolling ingots in larger dimensions than we have previously been able to produce. Due to the spatial limitations in our foundry, the planning and construction of the new continuous casting line was extremely complex in terms of technology and organisation. We are therefore proud to have successfully implemented this investment together with our partners. This enables us to secure valuable jobs at the Berlin location, especially in light of the major current challenges."
For the new continuous casting plant, GT Projekt, Poland, delivered outstanding precision work in the design and preparation of the casting pit as well as the entire constructional infrastructure. Oleg Hoffman, Operations Manager at BAGR, commented: "We were very impressed by the organisation, the quality of the execution and the adherence to deadlines."
The plant is fully automated, designed by Wagstaff Inc, using the proven Wagstaff® EpsilonTM moulds. BAGR also chose a Wagstaff® ShurCastTM casting system in conjunction with the Wagstaff® AutoCastTM automated casting control system, as this equipment uses SCADA technology for system monitoring and data storage.
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The new plant is being designed in such a way that it is able to cast four large-format blocks per drop. So, to provide sufficient liquid metal for the casting of four large-format slabs, Jasper Gesellschaft für Energietechnik and Kybernetik mbH were requested to supply a hydraulically tilting and casting furnace for a capacity of 75t liquid metal. "Our long-standing technology partner met the structural conditions in the hall with remarkable creativity," stated Oleg Hoffmann.
Ensuring high process stability and occupational safety, the plant has fully adapted the cooling, transport, and lifting technology to be able to cast the large rolling ingot formats.
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