The concept of continuous casting is a melting cum holding furnace with a graphite crucible heated with highly efficient graphite resistant heating elements furnace with a cooler, together with graphite die and cooler assembly and run out track with withdrawal machine and cut-off device. Molten metal flows from the crucible into the graphite casting die which is cooled with the help of a highly efficient cooling jacket.
Water-cooled graphite dies are attached horizontally to the holding crucible. During the continuous casting operation, the metal flows into the graphite casting die where it solidifies. The solidified strands are intermittently withdrawn in a "pull-pause" sequence by means of withdrawal equipment. After leaving the graphite to die, which is housed within the primary cooler, the cast strands pass through a secondary cooler in the form of water 'sparge' which removes the surplus heat contained in the solidified billet. Water 'sparge cooling' beyond the exit of the die is much more thermally efficient than using a graphite water-cooled sleeve cooler.
The machine is well insulated with a low thermal mass high-temperature zirconia ceramic modules for high thermal efficiency.
The majority of continuous casting installations in use today operate in the horizontal mode. The reason for this is mainly logistic, based on ease of product handling and to some extent safety in operation. There are, of course, inherent problems applying horizontal as opposed to vertical casting mainly to gravity-induced directional cooling. However, in most cases, These difficulties can be accommodated.
The horizontal continuous casting is graphite resistant heated furnace. A graphite crucible and die assembly is heated with a set of graphite heaters. The heaters have specifically been designed for having a balanced three-phase system which makes it easier to operate on A generator. The graphite heaters are placed in the areas where the heating is actually required to have the maximum utilization of the heat & be user-friendly.