Strategic Expansion Doubles ProductionCapacity
İzmir Demir Çelik Sanayi A.Ş (IDC), a leading Turkishmanufacturer of reinforcing steel and profiles, has completed a transformativeexpansion at its Aliağa facility near İzmir. The centerpiece of this ambitiousproject is a state-of-the-art seven-strand continuous caster supplied by SMS,which has catapulted the company's annual steel production capacity from 1.55million metric tons to approximately 3.1 million metric tons. This remarkabledoubling of output positions IDC to respond more effectively to growing marketdemands across the region while simultaneously reducing its historicaldependence on imported semi-finished products. The strategic investmentstrengthens IDC's vertical integration and enhances its competitive position inboth domestic and international markets during a period of significantvolatility in global steel supply chains.
Technical Sophistication Enables ProductionVersatility
The newly installed continuous casting plant incorporatescutting-edge design features that provide IDC with unprecedented manufacturingflexibility. With a casting radius of 10.25 meters and operational speedsranging from 0.6 to 4.0 meters per minute, the system delivers optimalperformance across diverse production scenarios. Perhaps most significantly,the caster's versatility allows IDC to produce billets and small blooms in sixdistinct section sizes, spanning from 150x150 millimeters to 220x280 millimeters.This dimensional flexibility enables the company to rapidly pivot betweendifferent product specifications in response to shifting market demands,optimizing production efficiency while maintaining consistent qualitystandards. The ability to cast multiple product dimensions on a single machinerepresents a significant competitive advantage in today's dynamic steelmarketplace.
AdvancedTechnologies Elevate Product Quality
The new continuous casting plant integrates a comprehensivesuite of advanced technologies specifically designed to enhance product qualityand optimize process control. Superior cleanliness and minimal inclusions areachieved through a combination of advanced tundish flow control, optimizedrefractory design, and monobloc submerged entry nozzles (SEN). The largecasting radius facilitates inclusion flotation, while precise mold levelcontrol ensures consistent production parameters. Surface quality receivesparticular attention through the implementation of a convex mold design,optimized secondary cooling systems, and a remotely controlled mold oscillator.Insulation tunnels maintain elevated surface temperatures before unbending,while the automated CONFEED powder feeding system creates a stable mold powderlayer that contributes to consistent quality outcomes across production runs.
Electromagnetic Stirring Enhances InternalStructure
Internal quality control represents a critical focus areain the new casting installation, with electromagnetic stirring (M-EMS) andmodular wave stirring (MWS) technologies playing central roles. Thesesophisticated systems generate controlled electromagnetic fields that inducefluid movement within the solidifying steel, promoting a homogeneous internalstructure by preventing segregation and ensuring uniform distribution ofalloying elements. The implementation of precise strand guidance, accurate coolingspray alignment, and a three-zone secondary cooling system further enhancesbillet and bloom quality by maintaining optimal thermal conditions throughoutthe solidification process. These technological advancements enable IDC toproduce steel products with exceptional internal and external characteristics,meeting stringent quality requirements for demanding applications.
OperationalEfficiencies Drive Cost Reduction
Beyond expanding production capacity and enhancing productquality, the new continuous casting plant delivers significant operationalefficiencies that translate directly to cost advantages. The integrated designoptimizes production processes, reducing energy consumption, minimizingmaterial waste, and decreasing labor requirements per ton of output. Advancedautomation systems throughout the installation minimize downtime and maximizeequipment utilization rates, contributing to overall operational excellence.The plant's ability to rapidly transition between different product dimensionsreduces changeover times and associated production losses, further enhancingmanufacturing efficiency. These operational improvements position IDC tomaintain competitive pricing while delivering superior products, strengtheningthe company's market position in an increasingly challenging global steellandscape.
Strategic Partnership Strengthens RegionalPresence
The successful implementation of this ambitious projectunderscores the strategic partnership between SMS, a global leader inmetallurgical equipment and technology, and IDC, one of Türkiye's most dynamicsteel producers. The installation serves as a key reference project for SMS inthe Turkish market, highlighting the company's ability to deliver complex,high-performance systems tailored to specific customer requirements. For IDC,the investment represents a significant vote of confidence in the future ofTurkish steel manufacturing and the company's growth trajectory. Thecollaborative approach between equipment supplier and steel producer ensuredsmooth project execution despite the technical complexity involved, with thenew continuous casting plant successfully entering operation in April 2024 andreceiving final acceptance in October of the same year.
MarketPositioning Strengthened Through Technological Leadership
The completion of this major capital investment strengthensIDC's position within the competitive Turkish steel industry and broaderMediterranean market. By embracing technological leadership through theimplementation of advanced casting technologies, IDC has positioned itself as aforward-thinking producer capable of meeting increasingly stringent qualityrequirements while maintaining cost competitiveness. The enhanced productionflexibility provided by the new caster allows IDC to rapidly respond to changingmarket conditions, targeting high-value market segments that demand superiormetallurgical properties. This strategic positioning is particularly valuablein the current global steel environment, characterized by volatile raw materialcosts, evolving quality standards, and intense international competition. Theinvestment demonstrates IDC's long-term commitment to maintaining technologicalleadership while expanding its market presence.
KeyTakeaways:
• İzmir Demir Çelik Sanayi A.Ş (IDC) has doubled its annualsteel production capacity from 1.55 million to 3.1 million metric tons with anew seven-strand continuous caster at its Aliağa plant, reducing dependence onimported semi-finished products while enhancing manufacturing flexibility.
• The advanced continuous casting plant features a10.25-meter casting radius and produces six different section sizes rangingfrom 150x150mm to 220x280mm, incorporating electromagnetic stirring (M-EMS) andmodular wave stirring (MWS) technologies to ensure superior internal andsurface quality.
• Successfully commissioned in April 2024 with finalacceptance in October, the SMS-supplied installation optimizes productionprocesses, reduces operational costs, and strengthens IDC's competitiveposition in both domestic and international markets through enhanced productquality and manufacturing flexibility.
