Continuous Casting and Direct Rolling System (CCDR)
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Maximum Thermal Integration: Directly feeds hot cast billets into the rolling mill, eliminating traditional cooling and reheating stages to cut fuel consumption by up to 60-80%.
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Minimized Oxidation Scale Loss: Rapid, uninterrupted processing reduces material exposure to oxygen, lowering scale loss from the typical 1.5% down to under 0.5%.
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Accelerated Production Cycle: Compresses the total processing time from liquid steel to finished long or flat products into less than 30 minutes.
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Fully Synchronized Automation: Advanced PLC tracking ensures real-time speed, temperature, and tension coordination between the casting strands and the rolling stands.
1. Product Overview
Continuous Casting Direct Rolling Line (CC-DR) is the core integrated low-carbon complete production line for short-process steel plants. It connects the whole process of EAF/converter steelmaking, molten steel continuous casting and hot billet gap-free direct rolling, completely eliminating procedures including billet cooling, stacking and reheating furnace reheating. After molten steel forms high-temperature billets via caster, hot billets are delivered to rolling mills through fully enclosed heat-preservation roller tables, relying on self-residual solidification heat for rolling. Equipped with intelligent casting-rolling synchronization control system, segmented heat preservation conveying and induction supplementary heating buffer modules, it supports flexible switching of three production modes: pure direct rolling, hot-charge direct rolling and furnace standby rolling.
The whole line can be matched with front-end full-series multi-frequency screens, scrap steel continuous preheating system and plunger type ladle baker, forming a complete green metallurgy solution covering scrap pretreatment, scrap preheating, ladle baking, steelmaking, continuous casting and direct rolling, widely applied in mass production of rebar, round bar, high-speed wire rod, narrow strip and light section steel.
2. Detailed Description
CC-DR cancels offline billet stacking and large gas soaking furnaces in conventional processes. The full-line roller conveyor is divided into two core sections: front sealed smoke hood heat preservation section and middle baking/induction supplementary heating section. High-temperature defect-free square billets from continuous caster first pass through fully closed smoke hoods to lock heat, with multi-point infrared temperature detection for temperature judgment. Low-temperature billets enter the baking supplementary heating unit for temperature equalization, while high-temperature qualified billets directly pass through the heat preservation channel. The inherent sensible heat from molten steel solidification is fully utilized; hot rolling is completed with zero or minimal supplementary heating, including two technical routes: pure direct rolling and supplementary heating direct rolling.
- High-temperature qualified billets (≥960℃): Bypass supplementary heating section via shortcut insulated roller way and directly deliver to mill;
- Medium-temperature billets (880~960℃): Main line into baking supplementary heating section for local heating to eliminate head-tail temperature difference;
- Low-temperature unqualified billets: Automatically switch to spare buffer furnace channel as standby production stock.
The supplementary heating section is equipped with full-oxygen radiant baking devices entirely wrapped by mini heat preservation hoods, matched with independent combustion system and exhaust pipelines. It only performs directional radiant heating on low-temperature edges & segments of billets without overall high-temperature soaking.Working logic: Automatically adjust gas-oxygen ratio and flame power based on temperature data to control integral billet temperature difference ≤50℃. After supplementary heating, billets return to main insulated roller way and are uniformly transported to roughing mill.
Two mainstream heating types:
- Flame radiant baking heating: Full-oxygen combustion of natural gas/converter gas, suitable for billets with large-range temperature drop;
- Electromagnetic induction heating: Eddy current heating via high-frequency coils for rapid local edge temperature equalization with lower energy consumption.
3. Why Choose Us
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Eliminate gas reheating furnace, save 65% energy per ton steel, realize drastic carbon emission reduction: No high gas consumption reheating furnace; save 20~40kg standard coal per ton steel, cut CO₂ emission over 0.1t. Reduce flue gas & dust pollution by 90%, fully compliant with low-carbon steel plant transformation policies.
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Oxidation burning loss reduced to 0.2%~0.3%, metal yield increased by 0.8%~1.5%: Long-time high-temperature soaking in reheating furnace is canceled, less iron scale formed. For 1Mt annual output line, extra 10,000 tons qualified steel produced every year, extra profit 40~50 RMB per ton.
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Integrated compact production line, production cycle shortened from 30h to less than 2h: Seamless connection of steelmaking, casting and rolling; cancel offline billet stacking, transportation and furnace charging. Plant footprint reduced by 30%, lower total investment and faster capital turnover.
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Sealed insulated roller way temperature control, billet head-temp difference ≤50℃ for stable rolling: Full-line high-temp insulated cover retains heat, 12m billet outlet temperature ≥960℃. 3-section online temperature measuring & automatic sorting system, stable direct rolling rate 90%~98%.
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Uniform & refined metal grain structure, stable mechanical performance of finished products: High-temperature direct rolling avoids coarse grain caused by repeated phase transformation, microalloy elements fully precipitated. Less fluctuation on tensile strength & elongation rate, higher product qualification rate for rebar, special steel and wire rod.
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Dual-mode dynamic switch between direct rolling & furnace rolling, non-stop production under variable working conditionsPLC: PLC intelligent linkage system switches production modes automatically when casting speed or billet temperature fluctuates. Cold billets diverted to backup furnace automatically to guarantee 24h stable full-capacity production.
4. Specifications & Technical Data
| Parameter Item | Standard Index |
| Process Model | CC-DR Pure Direct Rolling / CC-HDR Induction Supplementary Heating |
| Applicable Billet Spec. | 120×120mm / 150×150mm / 200×200mm square billet |
| Standard Billet Length | 6~12m customizable |
| Required Billet Outlet Temp | ≥960℃ (CC-DR) / ≥880℃ (CC-HDR) |
| Allowable Head-Tail Temp Difference | ≤50℃ |
| Annual Production Capacity | 300,000 ~ 3,000,000 tons |
| Direct Rolling Stable Rate | 90% ~ 98% |
| Energy Saving Rate vs Traditional Furnace Rolling | 60% ~ 65% |
| Oxidation Burning Loss | 0.2% ~ 0.3% |
| Supporting Control System | PLC touch screen, full-line temperature tracking, automatic billet sorting interlock |
| Insulated Roller Cover Material | 310S stainless steel + aluminum silicate high-temp insulation layer |
| Applicable Products | HRB400/500 rebar, wire rod, special alloy bar |
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