ArcelorMittal Dofasco Caster No 1 celebrates 30 years of turning molten steel into slabs
Steel News - Published on Mon, 30 Apr 2018
On December 13, 1987, a huge ladle poured the initial heat of molten steel into the reservoir at the top of Dofasco's first ever slab caster. And with it, the company was transformed. It only took minutes for the caster to turn molten steel into slabs, replacing the traditional steps of producing ingots, reheating them in the soaking pits and then rolling them into coils. The two-strand No. 1 Caster was the heart of an integrated system aimed to improve quality and produce more sophisticated grades of steel.
At the time, the CAD 750-million investment was the largest ever by Dofasco and also included the KOBM blowing process, Ladle Metallurgy, the Reheat Furnaces and a two-stand and re-coiler expansion of the Hot Mill. At the press conference announcing the investment, then President and CEO Paul Phoenix said, “This capital programme will enable Dofasco to continue with two of its major objectives – to be a leading supplier of flat rolled steel to the domestic market and to expand product capabilities to meet the more demanding end uses for steel in the future.”
The first slabs’ excellent internal and surface quality exceeded expectations. At the time, leaders attributed the smooth start-up to the hard work of hundreds of people testing, planning and training to prepare for the project during its three years of construction. This included plant-wide training programs, as well as specialized instruction for some employees on equipment at Dofasco and other plants around the world.
Bob Savage, now retired and former vice president of Manufacturing, was caster foreman at the time. He remembers the huge amount of coordination required between Engineering, Operations, Maintenance, Human Resources and Metallurgy, outside consultants, as well as the vast scope of the project, including training and learning new processes. He said “Don McFarlane was the superintendent. Trevor Wright was the assistant superintendent. Doug Watson was general foreman No 2 and Brian Mullen was general foreman No 1. Doug had the main operational responsibility and was really hands on and played a big role in design.”
Source : Strategic Research Institute