Continuous casting and rolling are essential processes in steel production. The continuous casting process involves pouring liquid steel into a mould to form a semi-solidified shape, which is then subjected to a rolling process to form the desired product shape.
In the continuous casting process, liquid steel is poured into a horizontal, rectangular mould known as a tundish, from which it is uniformly distributed over the entire mould. The mould is filled with an inert gas, such as nitrogen or argon, to protect the steel from oxidation. Different types of moulds are available for casting different shapes, such as flat, round, and square.
Once the steel is in the mould, it begins to solidify and form a solid shell. As this happens, the mould is passed through a series of rollers that shape the solidified shell into a uniform, continuous strip. During this process, the ingot shape may be changed by adjusting the speed of the rollers and the shape of the mould.
Once the strip has been formed, it is cut into the desired length to form a semi-finished product. This semi-finished product can then be subjected to a further rolling process, depending on the desired end product. Flat products, such as sheets and plates, are usually rolled using pairs of rollers to reduce the thickness of the material. Profile sections, such as rail and angle sections, are usually rolled using a single set of rollers to roll the shape and thickness of the section.
The rolling process also has other benefits such as improving the surface finish of the product, increasing the strength of the product and eliminating internal defects. Rolling also improves the accuracy of the product, as it can be done to very close tolerances.
Continuous casting and rolling have revolutionized steel production, by significantly increasing the efficiency and cost-effectiveness of the production process. They have enabled high quality steel products to be produced in much larger quantities, more quickly and without compromising on quality. This has allowed steel production facilities to be more competitive in the global steel market.
