Curved continuous casting process flow:
Qualified molten steel from steel refining furnace will be poured into steel ladle, then it will be delivered to the position above the CCM after external refining processing, and molten steel will be poured into the tundish from ladle bottom outlet. Tundish nozzle shall be adjusted to match with the lower mold in advance.
After opening the tundish stopper or sliding nozzle (or sizing nozzle), molten steel will flow into forced water-cooled copper mold. The mold has no bottom, so the drop bottom is required before filling with molten steel, meanwhile the drop bottom play a role in drawing out the casting billet and it is called dummy bar.
The molten steel inside the mold will be quickly cooled into crystals, meanwhile molten steel front will be solidified together with the head of dummy bar at the bottom of mold.
The rear end of dummy bar is clamped in the withdrawal roller of billet withdrawing machine, and billet withdrawing machine and mold oscillating unit will be started simultaneously when molten steel inside the mold reach to required height and solidified shell, at the mold lower outlet, reach to a certain thickness.
Withdrawal and straightening machine will pull out the dummy bar (with dummy bar) from the mold at a certain speed. To prevent the solidified shell from cracking breakout and reduce the withdrawal resistance of the mold, mold inner wall lubrication and up-down reciprocating movement are required.
After pulling out from the mold, the casting billet shall be cooled by spaying water, and this is called secondary cooling, meanwhile casting billet liquid-core will be gradually solidified by the secondary cooling.
The casting billet is continuously pulled out and molten steel is continuously poured into the mold, forming into the continuous casting process.
After passing through the billet withdrawing machine and straightening machine (straightening is not required for vertical type and horizontal type continuous casting), the casting billet will be removed from dummy bar.
The completely solidified straight billet will be cut into required size by cutting equipment, and transported to subsequent process by conveying roller.
The equipment used for continuous casting steel production is actually the complete set of mechanical equipment in the continuous casting production line.
In the continuous casting production, one complete set of continuous casting equipment that share with one ladle and capable of one strand or multiple strand casting billet production is called one set of CCM.
One set CCM can be of multiple units or single unit, the unit at here means the independent driving system and work system in one set of CCM.
For each set of CCM, the total quantity of the casting billet that is casted at the same time is called CCM strand quantity.
If one set of CCM has only one unit and is capable of one casting billet production, it is called one unit one strand; if one set of CCM has one unit and is capable of more than two casting billets production at the same time, it is called one unit multiple strands; if one set of CCM has multiple units and capable of multiple casting billet production, called multiple units multiple strands.
AE Electric can provide
1) Small Square billet (100mm-200mm) continuous casting production line equipment;
2) Rectangular billet (200mm-400mm) continuous production line equipment;
3) Continuous casting slab (thickness: 120mm above, width: 800mm-2000mm) production line equipment.
AE continuous casting technology:
1)Curved mold technology, and mold hydraulic oscillation technology;
2)Liquid level automatic detection and breakout prediction technology;
3)Electromagnetic stirring technology, and mold automatic width control technology;
4)Secondary cooling zone vaporization cooling technology, segment multipoint straightening and soft reduction technology, etc.
Description
Advanced Integration for Steel Production Lines
The Continuous Casting Machine (CCM) is engineered for comprehensive steel billet manufacturing, targeting metallurgical plants that utilize metal smelting furnace systems. Designed for operators and engineers seeking seamless integration between ladle refining, tundish delivery, and casting molds, the CCM enables uninterrupted throughput with reliable billet quality. This system suits facilities requiring flexible configurations, from single-strand to multi-strand casting, meeting varied volume demands. Its capacity to interface smoothly with existing furnace for smelting setups supports optimized workflow and material handling efficiencies, catering to industrial-scale steelmaking operations.
Precision Engineering Features and Specifications
Equipped with curved mold technology and hydraulic oscillation, the CCM employs sophisticated control systems including liquid level automatic detection and breakout prediction to maintain shell integrity during solidification. The secondary cooling zone utilizes vaporization cooling techniques, complemented by electromagnetic stirring and automatic mold width control to enhance billet surface quality and dimensional accuracy. The system supports billet sizes from 100-200 mm square to rectangular billets of 200-400 mm, plus continuous casting slabs up to 120 mm thick and 800-2000 mm wide. These robust technical features position the CCM as a leading option among industrial furnace manufacturers seeking to maximize casting precision and yield.
Industrial Applications and Operational Value
The CCM serves diverse steel production environments where durability and consistency of billets are paramount. Its capabilities align with large-scale smelting furnace operations requiring continuous and reliable casting processes, supporting production planning and capacity expansion targets. Implementation includes integration with refining furnaces, ensuring coordinated metal flow and solidification. The CCM’s adaptability to multi-unit multi-strand configurations facilitates enhanced throughput, critical for competitive steelworks focusing on cost-effective, high-output billet production. This makes it an indispensable asset for metallurgical industries prioritizing quality control and efficient resource utilization.
Advantages
Modular Design and Structural Innovation
The CCM features a modular design philosophy that enables tailored configurations to fit different production scales and billet dimensions. Its structural system integrates a hydraulic mold oscillation unit, curved mold technology, and segment multipoint straightening mechanisms, providing precise control over casting parameters. These components, combined with automatic liquid level detection and breakout prediction, deliver improved reliability and safety during continuous casting within large smelting furnace facilities. The adaptability of the CCM extends to single or multiple strand layouts, enabling metallurgical plants to optimize their casting lines with a system designed for seamless installation and maintenance.
Enhanced Operational Performance and Usability
From a performance perspective, the CCM offers advanced process control capabilities that simplify operator interventions while maintaining billet consistency and reducing downtime. Its automated systems for mold width control and secondary cooling optimization ensure stable shell formation and uniform billet quality. Users benefit from improved process predictability, reduced scrap rates, and enhanced throughput, contributing to a better return on investment. The ergonomic design and integrated controls align with industry compliance standards, making the CCM a practical choice for industrial furnace manufacturers and steel producers aiming for operational efficiency and sustained performance.
Use Scenarios
Design and Commissioning of Continuous Casting Lines in Steel Plants
In steel production facilities with integrated metal smelting furnace infrastructure, the CCM plays a critical role in the design and validation phase of continuous casting lines. Positioned after the refining furnace and tundish, the machine is tasked with precise billet formation and quality assurance. Its technical features like breakout prediction and hydraulic oscillation ensure smooth casting during commissioning, supporting the startup of multi-strand configurations to meet planned steel output targets. The CCM’s compatibility with existing metallurgy systems facilitates seamless workflow integration and process optimization, vital for meeting industry standards and production reliability demands.
Quality Control and Process Optimization in Industrial Smelting Environments
During ongoing operations at facilities employing industrial melting furnace technologies, the CCM supports quality control by regulating temperature gradients and solidification fronts with advanced sensing and electromagnetic stirring. Its liquid level detection system and secondary cooling zone management contribute to maintaining billet shell continuity, essential for downstream processing and mechanical property consistency. These technical advantages enable operators to optimize the casting process in response to real-time data, enhancing efficiency and minimizing defects, hence improving overall furnace throughput and product uniformity in high-capacity industrial environments.
About Us
Professional manufacturer of metallurgical equipment Xi'an Abundance Metallurgical Equipment Co., Ltd. is located in Xi'an High-tech Development Zone. After 20 years of development, it has become a leading manufacturer in China's electric furnace industry, integrating design, manufacturing, installation, commissioning and technical services. Currently, more than 200 sets of our electric furnaces are operating safely around the world. 60% of the company's products are exported to more than 30 countries and regions around the world, and its electric furnace export performance has ranked among the top in the electric furnace industry for three consecutive years. We have successfully completed the EPC of the medium and low carbon ferrochromium project in South Africa, the copper casting project in Mexico, the aluminum smelting project in Egypt, the silicomanganese smelting project in Gabon, the EPC steelmaking wire and bar project in Mongolia, and the brown corundum project in India. We have an expert team of more than 30 people, more than 200 engineers and professional technicians, and have more than 20 years of rich experience in the field of green steelmaking and ferroalloy smelting. It has more than 200 successful project experiences around the world, involving green steelmaking production lines, ferroalloy smelting (metal silicon smelting furnace, calcium carbide furnace projects, ferrochromium furnace smelting furnaces, etc.), petroleum coke calcination system projects, etc. We have electric arc furnace (EAF), ladle refining furnace (LF), submerged arc furnace (SAF), argon oxygen decarburization furnace (AOD), converter (BOF), titanium slag furnace, vacuum consumable electric arc furnace, white corundum furnace, brown corundum furnace, CCM continuous casting hot rolling mill, Titanium slag smelting furnace, Vacuum Arc Remelting Furnace (VAR/RVAR) and other equipment manufacturing experience, welcome global customers to cooperate sincerely. We always insist on our principle of optimizing our product features, saving our customer’s cost and assuring the high quality of the product. Consequently, we have won the customers’ favor and ratification on our products and after-sale service. Xi'an Abundance Metallurgical Equipment Co., Ltd. has passed ISO9000 authentication of international quality management system. We have got 6 national patent certifications in the professional field. With our strong economy, scientific and technological strength, strict attitude, advanced way of designing, integrity of business ideas and perfect after-sale services, we sincerely serve the world's metallurgy, forging, casting, military, automotive, agricultural machinery, motorcycle, aerospace, marine, hardware tools, general machinery, heat treatment and other industries. Mission: Your expectation is our destination. We develop and provide metallurgical Equipment and thus helping Customers achieve their business objectives through innovative latest Technology with international standards however, at favorable cost. Vision: With innovative ideas for plant construction, we believe in trendsetting technology, adapting to business dynamic changing, which is cost efficiency and leads to improve customer services. Core Values: • Customer Centric Technology • Business Ethics • Professional Pride • Meeting the planned targets through close monitoring • Excellence in engineering and services.
FAQ
1.What billet sizes are compatible with the Continuous Casting Machine (CCM)?
The CCM supports square billets sized 100-200 mm, rectangular billets from 200-400 mm, and slabs with a thickness of 120 mm and widths between 800 and 2000 mm. This accommodates a broad range of steel billet production needs for industrial applications.
2.Can the CCM be customized for different production capacities and configurations?
Yes, the CCM offers versatile system configurations including single unit single strand, single unit multiple strands, and multiple units with multiple strands. This flexibility enables various production capacities and billet sizes to meet diverse manufacturing requirements.
3.What are the core technologies integrated into this industrial furnace system?
The CCM incorporates curved mold technology with hydraulic oscillation, liquid level automatic detection and breakout prediction, electromagnetic stirring, mold width control, secondary cooling with vaporization technology, and segment multipoint straightening with soft reduction, optimizing steel billet quality and process control.
4.How does Xi’an Abundance support installation and maintenance of the smelting furnace systems?
Xi’an Abundance Metallurgical Equipment Co., Ltd. offers comprehensive technical services including design, manufacturing, installation, commissioning, and operator training. Their expertise ensures reliable setup and maintenance of large smelting furnace and CCM systems to maximize operational efficiency and quality control.
