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Billet casting

CCM-Continuous Casting Machine

Learn about the process of billet casting through CCM
Contact us

CCM - Continuous Casting Machine

Revolutionizing Steel Production.

An introduction to Continuous Casting Machine

Continuous Casting Machines (CCM) have become the backbone of modern steel manufacturing, enabling the direct production of billets from molten metal with remarkable efficiency and quality control. Specifically designed to streamline the steel production process, CCM for billets has replaced traditional ingot casting methods, resulting in better quality, reduced energy consumption, and minimized waste. For consultations, reach out to us!

How does a Continuous Casting Machine (CCM) work?

In essence, CCM for billets is a process that pours molten steel into a casting mold, rapidly solidifies it, and shapes it into long strands that are cut into manageable lengths. This process minimizes the number of steps required in traditional casting, creating a highly efficient way to produce uniform, high-quality billets ideal for further processing into various steel products. The operation of CCM for billets can be broken down into several precise stages, each optimized to produce high-quality billets.

1. Preparation of Molten Steel

The journey begins with molten steel prepared in a ladle from the primary steelmaking furnace. Once ready, the molten steel is transferred to the CCM, usually via a tundish – a refractory-lined vessel that maintains a steady flow and controls the temperature and flow rate.

2. Mold Insertion and Cooling

The molten steel then flows into a water-cooled copper mold tubes that shapes it into the desired billet cross-section (usually square or rectangular for billets). The mold cools the outer layer of steel and creates a thin solid shell while keeping the inner core in a molten state.

Copper mold tubes used in billet casting through CCM continuous casting machine

3. Strand Formation and Withdrawal

As the steel solidifies, the partially solidified billet (also known as a strand) is gently withdrawn from the mold by rollers. This withdrawal is continuous, keeping the molten steel inside the mold constantly replenished.

4. Secondary Cooling Zone

The billet passes through a secondary cooling zone, where it’s sprayed with water or mist, through spray nozzles, to facilitate even cooling and solidification from the outer shell inward. So this step is critical in ensuring that the billet maintains structural integrity without internal or external defects.

5. Straightening and Cutting

Once the billet has fully solidified, it is straightened and cut to the desired lengths by a billet shearing machine. This precise cutting is essential for uniformity in the final product, ensuring that each billet is ready for use or further processing in the rolling mill.

6. Quality Control and Inspection

Automated systems that inspect billets for any surface or structural defects, ensuring only high-quality billets reach the next stage in the manufacturing process.

Key services for Continuous Casting Machines

Design
Layout
Commissioning

Our approach to the design of Continuous Casting Machines (CCMs) centers on precision engineering and adaptability.

With a focus on efficiency and durability, we incorporate advanced materials and technology, ensuring each machine meets the rigorous demands of modern steel production. Our expert team works closely with clients to understand their operational goals, resulting in custom designs that optimize productivity, reduce energy consumption, and ensure seamless integration within existing setups. From casting speed to billet quality, our designs are crafted to deliver exceptional performance at every stage.

An efficient layout is critical for maximizing the effectiveness of any Continuous Casting Machine.

Unisons Steel Solutions services include detailed layout planning that considers spatial constraints, workflow optimization, and safety standards. We create layouts that facilitate smooth material flow, reduce bottlenecks, and support maintenance accessibility. Whether you're upgrading an existing facility or constructing a new one, our strategic layouts ensure the CCM operates at peak efficiency, enhancing productivity and operational safety.

Successful commissioning is the key to bringing your Continuous Casting Machine to life.

Our commissioning services cover every aspect of startup, from meticulous equipment checks to cold commissioning and calibration. We ensure that your machine operates according to specifications, providing full training for operators and maintenance teams. Our commitment extends beyond initial commissioning with post-installation support, helping you maintain reliable, high-quality production and minimize downtime.

Billet passing through billet shearing machine

Key components for Continuous Casting Machines (CCM)

To ensure smooth operations and high-quality billet production, several essential equipment are required.

Mold Assembly for CCM continuous casting machines used in billet casting
Mold Assembly
Tundish that is used to hold molten metal before billet casting process in CCM Continuous Casting Machine
Tundish
Withdrawal for CCM Continuous Casting Machine
Withdrawal
Brass Spray Nozzle for CCM Continuous Casting Machine used for cooling of billet
Brass Spray Nozzles
copper mould tubes used in continuous casting
Copper Mould Tube
Casting Powders for Continuous Casting Machines in steelmaking
Casting Powder

Advantages of Continuous Casting Machine (CCM)

Enhanced Efficiency

Continuous casting drastically reduces production time and the number of production steps, streamlining the entire process. This direct-to-billet approach is far more efficient than traditional casting, saving time, labor, and energy.

Improved Quality Control

By casting billets directly from molten steel, CCM minimizes the chances of contamination or defects associated with ingot casting. Additionally, the precise temperature and speed controls of CCM produce billets with uniform grain structure and better mechanical properties.

Energy and Cost Savings

Compared to older methods, this is highly energy-efficient, using cooling systems that reduce the need for reheating. This reduction in energy translates into cost savings, allowing steel manufacturers to offer competitively priced products.

Environmental Impact

CCM processes are inherently less wasteful and produce fewer by-products, making them a more environmentally friendly option in the steel industry.

CCM from Bolong Machinery, a business partner of Unisons Steel Solutions in Pakistan

Continuous Casting Services

Unisons Steel Solutions is staffed with industry experts and capable engineers to provide the complete Design for your CCM, develop optimal Layout according to your Steel Mill and execute the commissioning for your CCM.

Yes, Unisons Steel Solutions has partnered with leading global manufacturers to supply complete end-to-end equipment and solutions to our customers for CCMs.

Our team of experts and consultants will analyze your requirements and your Steel Mill to offer you the most cost-efficient and optimal solutions for your CCM.

Contact us via email unisons@unisons.com.pk or salespk@unisons.com.pk with your requirements to receive a fresh quotation for your next CCM project.

Continuous Casting Projects

CCM Continous Casting Machine at FF Steel commissioning executed by Unisons Steel Solutions

FF Steel 3 Strand 6000R
CCM Continous Casting Machine 3rd Strand at Naveena Steel commissioning executed by Unisons Steel Solutions

Naveena Steel 3rd Strand Commissioning

CCM Continous Casting Machine at Naveena Steel commissioning executed by Unisons Steel Solutions

Naveena Steel
CCM Continous Casting Machine at Madina Steel commissioning executed by Unisons Steel Solutions

Madina Steel 3 Strand 6x11R
CCM Continous Casting Machine at Union Steel Industries commissioning executed by Unisons Steel Solutions

USL
CCM Continous Casting Machine at Etihad Alloys commissioning to be executed by Unisons Steel Solutions

Etihad Alloys