Danieli has successfully completed the modernisation of a billet caster at JSW Salem Works, with the project receiving final acceptance after achieving production targets within a week of commissioning. The upgrade marks another milestone in the long-standing partnership between Danieli and JSW, while making all three continuous casting machines at the Salem facility part of Danieli’s technology portfolio.
The project involved replacing an existing billet caster supplied by another manufacturer with a new three-strand Danieli billet caster designed to improve production efficiency, operational reliability and product quality. The modernised caster has been developed to support the production of multiple steel grades and billet sizes required by the plant.
As part of the revamp, the existing continuous caster with a nominal 9-metre radius and 1,300 mm strand spacing was upgraded with advanced casting equipment and automation technologies. Danieli supplied new moulds capable of producing 160 mm and 200 mm square billets, along with oscillators equipped with the company’s Hy Power actuators to improve casting precision and operational performance.
The scope of the project also included the installation of Danieli Rotelec electromagnetic mould stirrers and final electromagnetic stirrers, helping improve internal steel quality and consistency during the casting process. In addition, new withdrawal and straightening units, roller tables and a modern discharge system were installed to streamline material handling throughout the production line.
The upgraded discharge section includes a lateral transfer car, a walking-beam cooling bed and collecting tables, enabling smoother billet movement and improved handling after casting. These enhancements are expected to increase operational efficiency while supporting higher production reliability. Following commissioning, the caster resumed commercial production and achieved its planned output within one week, demonstrating the effectiveness of the upgraded equipment and the smooth execution of the modernisation project.
The new caster has been designed to meet the production requirements of JSW Salem Works by supporting the manufacture of 160 mm and 200 mm square billets across a wide range of steel grades. The combination of advanced electromagnetic stirring technology, upgraded mechanical equipment and improved process control is expected to deliver better metallurgical quality, stable production and consistent operating performance.
The successful completion of the project further strengthens the long-standing relationship between Danieli and JSW Steel while reinforcing Danieli’s position as a technology partner for modern steel manufacturing facilities. The modernisation also highlights the growing adoption of advanced continuous casting technologies aimed at improving productivity, product quality and operational efficiency in India’s steel industry.
Danieli is a global supplier of equipment and technology for the metals industry, providing complete solutions for steelmaking, rolling mills, continuous casting, aluminium production and automation systems. The company designs, manufactures and installs advanced plants and machinery that help steel and metal producers improve productivity, product quality and energy efficiency. With operations and projects across the world, Danieli continues to support customers through engineering expertise, innovative technologies and comprehensive lifecycle services for modern metal production.
