Continuous casting is a process that solidifies molten metal into a semi-finished billet, bloom, or slab for subsequent rolling. It involves pouring molten metal from a ladle into a tundish, then through a nozzle into a mold where it solidifies into a continuous strand. As the strand exits the mold, it passes through primary and secondary cooling zones before being bent and cut into final pieces. Continuous casting is now the dominant production method for metals like steel due to benefits like improved yield, quality, and energy efficiency compared to batch casting.

1. Continuous
Casting of
Billets

2. What is Casting
• A manufacturing process
• Types of casting
• Sand casting
• Die casting
• Permanent casting
• Centrifugal casting
• Permanent mold casting

3. CONTINUES CASTING
• Continuous casting, also called strand casting, is the process
whereby molten metal is solidified into a semifinished billet,
bloom, or slab for subsequent rolling in the finishing mills.

4. • Most basic metals are mass-produced using a continuous casting
process, including over 500 million tons of steel, 20 million tons
of aluminum, and 1 million tons of copper, nickel, and other
metals in the world each year

5. • The continuous casting has several configurations to produce
the steel as vertical, vertical with curved type, horizontal and
strip casting.

6. • Curved machines are used for the majority of steel casting and
require bending and / or unbending of the solidifying strand.

8. EQUIPMENTS
• Ladle
• Tundish
• Mold
• Dummy bar
• Roller apron
• Withdrawal rolls
• Bending and straightening rolls
• Cooling sprays
• Cutting devices
• Auxiliary electrical and/or mechanical gears to help run the machine
smoothly.

9. TUNDISHVIEW

10. The tundish holds enough metal to provide a continuous flow to
the mold, even during an exchange of ladles, which are
supplied periodically from the steelmaking process

11. THE IMPORTANCE OFTUNDISH
• The metal remains in the tundish for a relatively short time, reflecting the
continuous nature of tundish operation
• Thus, the major refining reactions such as deoxidation and desulfurization are
carried out in the ladle.
• Enhances oxide inclusion separation
• Provides a continuous flow of liquid steel to the mold during ladle exchanges
• Maintains a steady metal height above the nozzles to the molds, thereby
keeping steel flow constant
• Provides more stable stream patterns to the mold
• The goals of a tundish are to minimize heat loss, deliver the melt evenly into
molds, minimize the formation of macro inclusions, and maximize their
removal.

12. THE PROCESS OF CONTINUOUS CASTING OF
BILLETS
• Continuous casting transforms molten metal into solid on a continuous
basis and includes a variety of important commercial process.
• These processes are the most efficient way to solidify large volumes of
metal into simple shapes for subsequent processing.
• To preheat the tundish before starting the process is that will contribute
about reducing of the cracks over the working living in the tundish.

13. PREHEATING OFTUNDISH

14. Procedure of continuous casting
of billets.
• 1)The liquid steel comes
from the steel plant in a ladle
• 2) From ladle it is tapped
in a tundish

15. 3) Liquid Steel is flowed through the nozzle to mould from
tundish.The flow rate through the nozzle into the mold can be
controlled by a stopper in the tundish
4) HeatTransfer in continuous casting by mist spray
5)The outer shell is being ’grabbed’ by a driven roll just beneath
the mold, pulling a strand of steel out of the mold.
6)The core of the strand, as it exits, is still liquid; because of that,
the strand proceeds through a secondary cooling section
7)The strand is bent from the vertical plane to horizontal plane
using rolls

16. HEATTRANSFER
1) Primary cooling zone
2) Secondary cooling zone

18. THE BENEFITS OF CONTINOUS CASTING
• Considerable energy savings
• less scrap produced, i.e. improved yield
• Improved labor productivity
• Improved quality of steel
• Reduced pollution
• Reduced capital costs
• increased use of purchased scrap when output is maximized

19. DISADVANTAGES
• Not suitable for small quantity production.
• Continuous and efficient cooling of mold is required, else, center line
shrinkage develops.
• Requires large floor space.

20. Conclusion
• Continuous casting has evolved from a batch process into a
sophisticated continuous process.This transformation has occurred
through understanding principle of mechanical design , heat
transfer , steel metallurgical properties and stress strain
relationships, to produce a product with excellent shape and
quality.
• In recent year the process has been optimized through careful
integration of electro-mechanical sensors, computer-controls, &
planning to provide a highly automated system designed for new
millennia.

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ATTENTION