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Steel is the heart of modern industry.
Every structure, every machine, every infrastructure system is built on steel in one way or another.
But producing steel isn’t just about melting it at high temperatures and shaping it.
It’s a matter of engineering and efficiency on its own.
And this is exactly where technology steps in: Continuous Casting.
It enhances both efficiency and quality.
In this article, we will explore what continuous casting is, how it works, why it’s preferred, and how Hasçelik sets itself apart in this field.
But that’s not all.
You’ll also learn about the advantages of this process, the equipment used, the critical parameters to consider, and much more.
If you're ready, let’s take you to the very heart of the steel world.
The high-tech journey shaped by continuous casting starts now.
Meet one of the technologies that has revolutionized the manufacturing industry:
Continuous Casting.
Compared to traditional methods, continuous casting offers a much faster, more efficient, and higher-quality production process.
But how exactly?
Let’s start with a definition:
Continuous casting is the process of continuously pouring molten metal into a mold of a specific shape while simultaneously solidifying it to produce a semi-finished product.
In other words, molten steel is solidified within a continuously flowing system in a specific cross-section (e.g., square, rectangular, or round).
The result?
Seamless, standardized, high-quality steel billets, slabs, blooms, and more.
Thanks to this uninterrupted nature, the method is also known as “strip casting.”
Because steel flows from the production line like a continuous strip.
So what lies at the core of this system?
Here’s the key point:
In continuous casting, processes such as heat transfer, speed control, and cooling are managed with extreme precision.
Molten steel is transferred from the casting ladle to a tundish (intermediate vessel), and from there, it flows through a specially designed water-cooled mold (called a copper mold) where solidification begins at the surface.
As the process continues, the product fully solidifies through controlled cooling and is cut to the desired length for shipment.
There’s no "fill – wait – release" downtime throughout the process.
The keyword here is continuity.
Steel constantly flows through the mold, takes shape, and is released.
What does this mean?
• Production speed increases
• Quality standards improve
• Waste and costs decrease
• Energy efficiency is achieved
In short, continuous casting is a game-changing approach in industrial production.
And as we dive deeper into the details of this system, you’ll understand exactly why the world’s largest steel producers choose this method.
Though continuous casting may seem like a cutting-edge part of modern technology, it's actually the product of a long-standing pursuit in engineering.
So how was this technology born?
How did it evolve?
Let’s take a brief journey through time.
It all began with an idea.
By the late 19th century, there were serious debates in the metallurgy world about how to make steel production faster and more economical.
Traditional casting methods were both slow and expensive.
At that point, in 1856, British inventor Sir Henry Bessemer sparked the first idea of continuous casting.
However, the technological infrastructure of the time was not yet advanced enough to implement this idea.
It would take nearly another 100 years for it to become reality.
The first industrial continuous casting line was developed in the early 1950s by the Swiss engineering company Concast AG.
This innovation marked a turning point in steel production.
Until then, steel was poured into individual molds. Now, it could be produced continuously.
And as you might guess...
This method quickly spread across the globe.
During the 1970s and 1980s, industrialized nations like Japan, Germany, the United States, and South Korea rapidly adopted continuous casting technology and integrated it into their production lines.
These countries experienced significant improvements in both steel quality and production efficiency.
So much so that today, approximately 95% of global steel production is carried out using continuous casting methods.
In other words, traditional casting methods have been almost completely replaced by this advanced technology.
High quality, low cost, and uninterrupted production...
There is one production method that can offer all three: Continuous Casting.
So why is continuous casting preferred?
Which industries benefit from this technology?
And what needs does it meet?
Let’s take a closer look:
Unlike traditional casting, continuous casting is a modern method where molten metal is solidified into the desired shape continuously.
As a result, production time loss is minimized, efficiency increases, and material quality becomes more uniform.
That’s why…
For steel producers, continuous casting is not just a choice – it's a strategic necessity.
Higher quality products, lower costs, more sustainable production.
So, what does this technology change?
• Creates a revolution in efficiency
• Provides energy savings
• Ensures uniform quality
• Reduces scrap and waste rates
• Compatibility with automation and integrated production
• Less processing, lower costs
• A more sustainable future
Imagine a steel production line;
In that critical phase where molten metal is transformed into solid steel, every component must work in perfect harmony.
The continuous casting line is essentially an engineering symphony.
In this symphony, each structural component has a clear role and a significant impact.
Let’s explore the backbone of this system together:
Molten steel is first transferred from the converter or electric arc furnace to the ladle.
Function:
• Temporarily transport and direct the molten metal
• Maintain the temperature and chemical composition of the liquid metal
The ladle is usually lined with refractory (heat-resistant) materials.
An intermediate vessel through which the molten steel passes before being poured into the mold.
It acts as a kind of “flow regulator.”
Advantages:
• Controls casting speed
• Maintains temperature thanks to its refractory lining
• Prevents impurities like slag from flowing downward
This is one of the most critical points determining casting quality.
Provides the transition between the tundish and the mold.
By extending below the surface of the molten metal, it ensures that steel enters the mold without contacting air.
As a result:
• Oxidation risk is reduced
• Quality increases
• Surface defects are prevented
The section where molten steel begins to solidify for the first time.
Consists of water-cooled metal molds.
Functions:
• Rapidly solidify the outer surface of the molten steel
• Define the cross-sectional shape of the product (square, rectangular, slab, bloom, etc.)
• Provide controlled cooling
The solidified shell forms here, while the inner part solidifies in the next phase.
Allow the semi-solid steel to move downward in a controlled manner.
This system:
• Prevents breakage
• Maintains correct geometry
• Enhances surface quality of the product
The positioning of these rollers is especially critical for wide sections like slabs.
Spray water onto the steel that hasn’t fully solidified, ensuring rapid and controlled cooling.
Usually activated after the mold exit.
Advantages:
• Regulates cooling rate
• Prevents surface cracks
• Optimizes production speed
Ensures thermal balance throughout the entire system.
Especially:
• Molds
• Rollers
• Hydraulic systems
...are continuously cooled by this circuit.
Benefits:
• Solidification remains controlled
• Equipment lifespan is extended
• Production stability is ensured
Cuts the produced semi-finished products (billet, bloom, slab) to the desired length.
The system generally uses:
• Mechanical shears (cold cutting)
• Oxygen torches (hot cutting)
The cut products are transported to storage areas via conveyors or cranes.
During this process, products are carefully guided to prevent surface deformation.
Continuous casting differs not only in what is produced, but also how it is produced.
Based on the orientation of the production line, the flow direction of the material, and the layout of the facility, there are three main types: vertical, horizontal, and inclined.
So what are the differences between these systems?
When is each one preferred?
Let’s discover together:
In this system, molten steel is poured vertically from top to bottom.
Commonly used for the production of small-diameter round or special alloy products.
Advantages:
• High homogeneity
• Simple flow direction
• Easier quality control
Applications:
• Special alloys
• Stainless steel production
• Lab-scale or niche productions
As the name suggests, molten metal exits the mold in a horizontal direction.
Mostly used in the production of non-ferrous metals such as copper, bronze, and brass.
Advantages:
• Requires less vertical space
• Saves space in the facility
• Ideal for small and medium-sized plants
Applications:
• Wire rods
• Tubes and thin-section profiles
• Non-ferrous metals post-refinement
Combines the advantages of both vertical and horizontal systems.
The casting line is positioned at a specific angle.
Today, this is the most widely used system in the steel industry.
Advantages:
• Ergonomic plant layout
• Increased production speed
• Lower investment cost
Applications:
• Slab, billet, and bloom production
• High-volume steel production
• Compatibility with automation systems
In summary:
| Type | Description | Application Area |
|---|---|---|
| Vertical | Vertical casting from top down | Special alloys |
| Horizontal | Horizontal casting flow | Non-ferrous metals |
| Inclined | Casting with angled flow | Mass steel production |
Although it may seem like a complex system from the outside, continuous casting is actually a highly logical and orderly process.
So, how does this cycle begin?
How does molten steel transform into a smooth, homogeneous, and uninterrupted billet?
Let’s take it step by step.
The process begins with the production of molten steel in electric arc furnaces or blast furnaces.
This steel is then transferred into ladles (molten metal transport vessels) at high temperatures.
The molten steel in the ladles is carefully transferred into an intermediate vessel called a tundish.
The tundish acts like a “traffic light” in the system.
It directs the molten flow according to the casting line’s speed and production balance.
Molten steel from the tundish is poured into a water-cooled copper mold through a submerged entry nozzle.
Here, the steel begins to solidify from the outside in.
As the steel starts to solidify, it is rapidly cooled with spray nozzles.
Meanwhile, support rollers ensure the steel progresses smoothly along the line.
This stage is critical!
If the cooling is unbalanced, the internal structure may be compromised.
Once the billet has solidified sufficiently, it is cut to the desired length by automatic cutting machines.
The resulting products are generally semi-finished forms such as slabs, blooms, or billets.
The cut products are either sent directly to dispatch or transferred to rolling mills,
where they are shaped into final products like profiles, sheets, or bars.
The shape of the steel to be produced, its intended use, and the target quality determine which continuous casting method is used.
So, what are these methods and how do they differ?
Here are the main forms in which steel takes shape:
Slabs are wide and flat-sectioned products.
They are typically used in the production of hot-rolled sheets, coils, and plates.
Typical dimensions:
• Width: 600 – 2,500 mm
• Thickness: 200 – 300 mm
Application areas:
• Automotive
• White goods
• Shipbuilding
• Construction industry
It offers high efficiency and excellent surface quality.
Blooms are thicker and closer to square in section compared to slabs.
They are generally rolled into rails, profiles, or other large-section products.
Typical dimensions:
• Section: 200×200 mm – 400×400 mm
Application areas:
• Railway rails
• Automotive parts
• Heavy structural profiles
• Steel industry sub-products
Ideal for high-strength components.
Billets are small semi-finished products with square or rectangular cross-sections.
They are used in the production of bars, rebar, wire, and pipes.
Typical dimensions:
• 100×100 mm, 130×130 mm, 150×150 mm, etc.
Application areas:
• Rebar
• Wire rod
• Machine parts
• Free-cutting steel production
It provides precise tolerances and high production speed.
This is a new-generation method.
Instead of traditional shapes like slabs or billets, the products are cast almost in their final form.
It reduces the need for additional processing.
Advantages:
• Reduces machining
• Minimizes material waste
• Saves energy
Application examples:
• Thin strip casting
• Beam blank (profile-section blooms)
Continuous casting is a manufacturing process that combines precision, balance, and engineering discipline.
To ensure everything goes smoothly, some critical parameters must be meticulously controlled.
Here they are and why they matter:
• The temperature of the tundish and ladle is crucial for the steel’s fluidity.
• Excessive temperature → surface defects, bubbles
• Low temperature → solidification problems, flow irregularities
Solution: Real-time temperature sensors and automatic control systems
• The casting speed must match the solidification rate.
• Too fast → insufficient cooling, risk of cracks
• Too slow → inefficiency, increased costs
Solution: Adjust speed according to cooling capacity and continuously monitor it
• Spray nozzle cooling is critical for proper solidification.
• Uneven cooling → structural defects, microstructural issues
Solution: Optimize nozzle distribution and maintain balanced water pressure
• Uneven distribution of elements like carbon, manganese, and sulfur harms mechanical properties.
Solution: Proper alloy mixing during steel production and validation through analyses
• A stable molten level in the tundish is essential for uniform casting.
• Level fluctuations → surface defects, flow interruptions
Solution: Level sensors and automatic nozzle positioning
• The inner surface of the mold must provide adequate cooling.
• Uneven mold temperatures → inconsistent shell thickness
Solution: Continuous monitoring of mold temperatures and controlled water flow rate
• Rollers, cutters, and drive systems must operate in full sync.
• Poor synchronization → product shape deformations
Solution: Fully integrated management through digital control systems
• Oxidation and bubble formation during casting can degrade the surface.
Solution: Inert atmosphere (argon use), slag removal systems, and surface cleaning
When quality, efficiency, and sustainability come together in steel production, a strong vision emerges.
Hasçelik operates with exactly this vision, leading the industry through its investments in continuous casting technology.
So, how does Hasçelik create this difference?
Let’s take a look together.
Hasçelik’s production facilities are equipped with high-tech steelmaking infrastructure.
This ensures quality and consistency at every stage of the continuous casting process.
Key equipment includes:
• Advanced Electric Arc Furnaces (EAF)
• Tundish systems integrated with automation
• Online analysis and process monitoring systems
• High-precision cooling control circuits
In short, steel is not just poured — it is meticulously managed and shaped to perfection.
Hasçelik doesn’t just produce — it integrates technology into every aspect of its processes:
• Real-time data monitoring systems
• Industry 4.0-compliant production lines
• Digital quality control infrastructure ensuring traceability
• Sensor-supported automation systems that predict and prevent potential errors
As a result, human error is minimized, and consistent quality in production is achieved.
Another area where Hasçelik stands out is its environmental consciousness and sustainability approach.
With new-generation continuous casting investments:
• Energy-efficient systems are used
• Recycled scrap steel is prioritized in production
• Special filtration and chimney technologies are integrated to reduce emissions
• Closed-loop cooling systems reduce water consumption
And perhaps most importantly, investments in green technologies continue to grow to reduce the carbon footprint.
