Continuous Casting
Solidifying liquid steel into billet and bloom form by transferring through tundish into copper mold. Spray water cooling and electromagnetic stirring.
Continuous casting is a critical production stage where liquid steel produced in the steelmaking plant is converted into semi-finished products. Liquid steel is transferred from the ladle furnace through the tundish to the copper crystallizer. Through intense water cooling from the copper mold walls, the outer shell of the steel rapidly solidifies.
The Electromagnetic Stirring (EMS) system ensures homogeneous mixing of liquid steel during casting. Thanks to this technology, segregation (element separation) is minimized and internal structure homogeneity is guaranteed. Automatic mold level control is a critical parameter that directly affects casting surface quality.
In the secondary cooling zone, controlled cooling is applied through water spray zones. The cooling rate is optimized according to steel grade and cross-section size. Too rapid cooling can cause internal stresses, while too slow cooling can lead to segregation. Therefore, specific cooling curves are determined for each steel grade.
At the end of casting, billets are cut to desired lengths by the oxygen cutting unit. Cutting length is adjusted between 3 and 12 meters according to customer orders and subsequent process requirements. Each billet is marked with heat number and charge information to ensure full traceability.
This process is carried out at partner mills across our supply network. Aktif Çelik is responsible for grade selection, conformity to specification, inspection documentation (EN 10204) and shipment follow-up.
Technical Parameters
Continuous Casting — Key technical data of the process
Equipment & Facilities
- Tundish – 5 ton capacity
- Copper crystallizer (oscillating mold)
- Secondary cooling – water spray zones
- Electromagnetic Stirrer (EMS)
- Automatic mold level control (mold level sensor)
- Oxygen cutting unit
- Roller apron system
Quality Control Points
- Automatic mold level measurement
- Surface temperature monitoring (pyrometry)
- Macro structure control (Baumann test)
- Segregation analysis
- Ultrasonic internal structure inspection
- Surface defect detection (visual inspection)
Reference Standards
Related Products
Products obtained or used in this production process
Technical Support & Quote
Continuous Casting — For detailed technical information, capacity details and custom production requests, contact our expert team.
What is continuous casting?
Continuous casting solidifies liquid steel into semi-finished shapes (billet, bloom or slab) by passing it without interruption through a water-cooled copper mould. Steel from the ladle is distributed by the tundish, forms a shell in the mould, solidifies fully in the secondary cooling zone and is cut to length. Compared with ingot casting it gives higher yield (~95%+), a more homogeneous structure and lower cost — the standard of modern steelmaking.
Process steps and quality control
The flow: ladle → tundish (flow control, inclusion flotation) → oscillating copper mould (first shell) → secondary cooling (water sprays) → straightening and cutting. Billets (square, ~100–200 mm) feed long products; blooms feed larger sections; slabs feed flat products. Quality keys: mould level control (surface defects), electromagnetic stirring (centre segregation) and the right cooling recipe (internal cracks). Cast billets are inspected for surface and internal soundness; for critical applications segregation is verified by macro-etching.
Frequently Asked Questions
What is the difference between billet, bloom and slab?+
A billet is a small square section (~100–200 mm; for bars/wire), a bloom a larger section (for sections/rails), a slab a wide rectangular section (for plate/sheet).
What does the tundish do?+
It buffers between ladle and mould: stabilizes the flow, distributes it to several strands and gives inclusions time to float out.
Why is continuous casting better than ingot casting?+
Higher yield (~95%+), more homogeneous structure, lower energy and labour; uninterrupted production gives superior cost and quality consistency.
What is centre segregation and how is it reduced?+
Alloying elements concentrating at the section centre during solidification; reduced by electromagnetic stirring, low superheat and soft reduction.
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