New Steelmaking System Sets 10,035-Ton Daily Output Record

A Benchmark for High-Efficiency, Stable, and Intelligent Steel Production

Introduction: A Milestone in Modern Steelmaking

The company’s new-generation steelmaking system has achieved a record-breaking daily steel output of 10,035 tons, marking a historic milestone in operational performance. This achievement demonstrates that the system has reached advanced domestic standards in process stability, equipment integration, production organization efficiency, and end-to-end process coordination.

More importantly, this breakthrough confirms that the new steelmaking system has successfully transitioned from commissioning to sustained, high-volume, and stable industrial operation, laying a solid foundation for long-term mass production and cost competitiveness.

Since the successful hot commissioning and entry into stable operation, the company has consistently focused on its core objective: “improving quality, increasing efficiency, and achieving full production targets.” By addressing system bottlenecks through data-driven optimization and refined management, the overall operational level of the steelmaking system has achieved a qualitative leap.

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I. Refined Metal Material Management: The Foundation of High Output

In a modern steelmaking system, metallic materials flow continuously through converter steelmaking, secondary refining, and continuous casting. The efficiency of this flow directly determines production capacity, metal yield, and cost performance.

To optimize metal balance, the company established a full-process refined metal management system, covering molten iron, scrap, alloys, and recycled materials.

Key Measures Implemented:

• Digital tracking of metal composition, weight, and destination throughout the entire process

• Closed-loop management from furnace charging to finished billet

• Real-time analysis of key indicators such as:

  • Converter steel yield

  • Molten steel loss

  • Continuous casting head and tail losses

By leveraging the Manufacturing Execution System (MES) and process databases, production parameters are dynamically adjusted to minimize unplanned losses.

As a result, molten iron supply intensity is precisely matched with steelmaking rhythm, effectively avoiding heat loss, waiting time, and metal accumulation. The system now maintains a consistently high metal yield, providing a robust material foundation for daily production exceeding 10,000 tons.

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II. Converter Steelmaking Process Optimization: Stabilizing Yield and Reducing Blowing Loss

Converter steelmaking remains a critical bottleneck in high-capacity steel production. During the early operation of the new system, issues such as high blowing loss rates and process fluctuations limited output stability.

To address this, a dedicated process optimization team carried out multiple rounds of targeted trials focusing on:

• Oxygen supply system design

• Bottom-blowing configuration

• Temperature control strategy

• End-point accuracy

Key Technical Improvements:

• Re-optimized oxygen lance nozzle structure to match flow intensity

• Segmented oxygen supply strategy:

  • Early stage: rapid decarburization

  • Middle stage: enhanced bath stirring

  • Final stage: precise temperature and composition correction

These measures stabilized in-furnace reactions, significantly reduced metal splashing, and minimized secondary oxidation losses.

In parallel, bottom-blowing gas flow rates and distribution ratios were optimized, improving molten steel homogeneity and reducing localized overheating risks.

With improved end-point models and online detection systems, temperature and composition control accuracy increased substantially. As a result, the converter blowing loss rate is now stably controlled below 7%, continuously improving metal yield and supporting high-output operation.

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III. Continuous Casting Process Optimization: Unlocking System Capacity

The continuous casting stage represents the final constraint in achieving high daily steel output. The company optimized both process parameters and operational discipline to stabilize casting speed and reduce losses.

Key Improvements:

• Refined secondary cooling curves for different steel grades and slab sizes

• Optimized nozzle layout and water distribution

• Enhanced monitoring of cooling water pressure, temperature, and flow

These measures significantly improved slab surface and internal quality, creating the conditions necessary for higher casting speeds.

At the operational level, stricter process monitoring reduced unplanned speed reductions and shutdowns caused by molten steel fluctuations or mold level instability. The continuous casting machines now operate at high and stable speeds, releasing the full capacity potential of the steelmaking system.

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IV. Shortening the Smelting Cycle: A Key Breakthrough for Daily Output Growth

A long smelting cycle had previously constrained production increases. To overcome this, the company launched a multi-disciplinary optimization initiative targeting technology, organization, and operation.

• Process optimization: Enhanced reaction efficiency through oxygen supply and slag formation improvements

• Production coordination: Improved rhythm matching among converter, refining, and casting

• Operational standardization: Reduced auxiliary time and eliminated non-value-added activities

Through continuous execution of these measures, the converter smelting cycle was significantly shortened, enabling faster system turnover and supporting daily output beyond 10,000 tons.

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V. Equipment Reliability and System Coordination: Ensuring Stable High-Load Operation

Sustained high production places extreme demands on equipment stability. The company strengthened its equipment assurance system through:

• Enhanced routine inspection and maintenance

• Optimized spare parts management

• Preventive maintenance for critical equipment

Simultaneously, cross-process collaboration mechanisms were reinforced, forming a highly integrated and fast-responsive production organization model. This ensures stable and orderly system operation even under long-term high-load conditions.

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VI. Strategic Significance of the 10,000-Ton Breakthrough and Future Outlook

Achieving a daily steel output of 10,035 tons is more than a numerical milestone—it is a comprehensive validation of the company’s:

• Process control capability

• Production organization efficiency

• Equipment reliability

• Cross-team collaboration strength

This achievement confirms the advanced design philosophy and operational feasibility of the new steelmaking system.

Looking ahead, the company will further deepen refined management, accelerate the adoption of digitalization and intelligent steelmaking technologies, and continuously promote higher efficiency, lower emissions, and smarter production models. These efforts will provide strong technical momentum for building a world-class green new materials enterprise.