ABB has been awarded a contract to provide its advanced electromagnetic stirring technology, the Flow Control Mold Generation 3 (FC Mold G3), for a new thick slab caster at the Hazira steel plant in Gujarat, operated by ArcelorMittal Nippon Steel India (AM/NS India). The Hazira plant is expanding its production capacity from 9 million tons to 15 million tons annually.
The new technology will be integrated into a two-strand slab caster, supplied by Danieli. ABB will deliver two FC Mold G3 coil units, designed to manage the flow of molten steel inside the mold during the continuous casting process. This technology controls the behavior of the steel near the surface, reducing defects and enhancing the final quality of the slabs.
Unlike conventional methods, the FC Mold G3 utilizes three magnetic fields from a single unit to stir the molten steel. This process reduces turbulence and slows down downward flow, allowing gas bubbles to rise to the surface rather than being trapped inside the solidifying steel.
Zaeim Mehraban, ABB’s Global Head of Sales for Metallurgy, explained, “The FC Mold G3 is a reliable system for improving product quality and minimizing waste. By controlling the flow conditions near the steel surface, manufacturers experience fewer surface defects, less internal cracking, and better overall outcomes.”
ABB’s electromagnetic stirring technology has been implemented in over 40 slab casting installations worldwide. Reports from plants using FC Mold indicate up to 50% fewer surface and internal defects and an 80% reduction in rejected material. Many customers have seen a full return on investment in less than a year.
ABB is a global leader in engineering, automation, and electrification, with operations in more than 100 countries and a workforce of around 110,000 employees. The company’s Process Automation division develops technologies that improve the efficiency and sustainability of industries such as energy, water, manufacturing, and shipping.
