Izmir Demir Celik Sanayi A.S. (IDC), a leading Turkish producer of reinforcing steel and profiles, has significantly expanded its steel production capabilities with the installation of a Concast seven-strand continuous caster at its Aliaga plant in Izmir.
This major upgrade has doubled IDC’s annual steel production capacity from 1.55 mln tons to approximately 3.1 mln tons. The new caster not only increases output but also enhances product quality, improves operational efficiency, and reduces the company’s dependence on imported semi-finished materials. With the ability to produce billets and small blooms in six different section sizes, ranging from 150×150 mm to 220×280 mm, IDC is now better equipped to adapt to shifting market demands.
The caster features a 10.25-meter casting radius and operates at speeds between 0.6 and 4.0 meters per minute, allowing for stable and efficient production across various scenarios. It incorporates advanced technologies that optimize process control and ensure high product standards. Innovations such as tundish flow control, monobloc submerged entry nozzles, and an optimized refractory design contribute to superior steel cleanliness. A convex mold design, along with mold level control and remote-controlled oscillators, helps to deliver consistent surface quality, while insulation tunnels maintain high surface temperatures during the unbending phase.
Internal steel quality is enhanced through electromagnetic stirring and modular wave stirring, which ensure a homogeneous structure. The integration of automated powder feeding, accurate cooling spray alignment, and a sophisticated three-zone secondary cooling system further contribute to product uniformity and process stability.
Operational since April 2024, this investment marks a significant milestone for IDC, strengthening its position in the steel industry. The new continuous casting plant enables the company to meet diverse customer needs with greater flexibility, while optimizing production efficiency and reducing overall operational costs.