ECO POWER MOULD

Power Mould™ is the innovative, patented cartridge-type mold developed by Danieli to increase the casting speeds up to 50% in comparison to the use of a conventional mold.

It's unique design of drilled channels inside the copper tube helps to reduce off-corner cracks and, therefore, increases the sub-surface quality.

• Running for 23 hours at an average speed of 6.2 mpm in endless mode;
• Casting above 45 tph per strand in a billet caster in open stream, and 76 tph per strand in submerged casting (designed up to 115 t/h);
• Up to 60,000 t service life for the copper tube;
• 30% less media consumption, compared to a conventional mould.

In order to reach the above figures, we went through a learning curve of mould design.

The first trial was a new mould that consisted of four thick copper plates with drilled longitudinal holes. The contact joints between the copper plates along the corners have been improved and overseed introducing a monolithic tube: the well-known Power Mould that is freestanding, and does not require additional back plates or water jackets for alignment.

The thickness of Cu tube and the longitudinal cooling drill holes give the possibility to applying different cooling strategies by changing the numbers of holes, as well as distances between them and distance from the steel. This solution ensures the most appropriate temperature distribution around the product section, which is an essential condition for uniform shell growth along the mould.

The consistency of performances and operations achieved with Power Mould focuses our attention on the construction techniques to further improve the competitiveness of the product cost, and the result is the Eco Power Mould.

The latest update of this technology considers the enhancement of copper effectiveness by employing a lower thickness tube and a new design of the water cooling channels, which lead to a lower meniscus temperature and lower media consumption of the mould.

Power Mould evolved to Eco-Power Mould to confirm productivity, quality and energy savings.