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Metals
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Advances in Continuous Casting and Refining of Steel
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Advances in Continuous Casting and Refining of Steel

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Extractive Metallurgy".

Deadline for manuscript submissions: 10 August 2026 | Viewed by 7371

Special Issue Editor

Prof. Dr. Heng Cui

E-Mail Website
Guest Editor
Collaborative Innovation Center of Steel Technology, University of Science and Technology Beijing, Beijing 100083, China
Interests: continuous casting; secondary refining; non-metallic inclusion; casting defects; physical and numerical modeling

Special Issue Information

Dear Colleagues,

Continuous casting and refining play a crucial role in steel production. Continuous casting enables the efficient solidification of molten steel into semi-finished products, enhancing productivity. Refining processes, such as LF and RH, precisely control chemical compositions and remove inclusions. Their combined application ensures the production of high-quality steel with enhanced mechanical properties and reduced defects, meeting the stringent demands of modern industries. Consequently, with the increasing demand for high-quality products, the improvement of equipment, and the advancement of automation and digitalization, metallurgical researchers have developed novel technologies, processes, and mechanisms for continuous casting and refining.

This Special issue aims to present new technologies, processes, and trends regarding the application of continuous casting and refining. Original research articles and reviews from academia and industry are welcome. The scope of this Special Issue includes, but is not limited to, the following topics: innovative casting techniques, the optimization of the refining process, clean steel technologies, improvements in the quality of cast products, digital and intelligent applications, and the impact of novel refractory materials. I look forward to receiving your contributions.

Prof. Dr. Heng Cui
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • continuous casting
  • secondary refining
  • non-metallic inclusion
  • clean steel
  • casting defects
  • solidification
  • physical modeling
  • numerical modeling
  • big data
  • machine learning

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Published Papers (6 papers)

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Research

18 pages, 3357 KB  
Article
Mathematical Simulation and Industrial Application of a Process Control Model for Converter Double-Slag Steelmaking Based on Dephosphorization Slag Discharge and Decarburization Slag Recycling
by Jie Wang, Libin Yang, Jiaqing Zeng, Shengtao Qiu and Yong Yang
Metals 2026, 16(4), 421; https://doi.org/10.3390/met16040421 - 13 Apr 2026
Viewed by 314
Abstract
Converter steelmaking remains the dominant route for global steel production, and the double-slag process is an important refining method that merits further study. In this work, a MATLAB-based mathematical model was developed for the double-slag process under a fixed dephosphorization rate, focusing on [...] Read more.
Converter steelmaking remains the dominant route for global steel production, and the double-slag process is an important refining method that merits further study. In this work, a MATLAB-based mathematical model was developed for the double-slag process under a fixed dephosphorization rate, focusing on slag control during the low-temperature dephosphorization stage (1360–1400 °C) and the subsequent decarburization stage. The model was used to guide industrial trials and analyze the effect of the deslagging ratio (Rds) on slag control and process behavior. The results show that: (1) under a given Rds, the double-slag process can theoretically approach stable slag control and slag volume with increasing decarburization slag recycling cycles; (2) at a fixed dephosphorization rate, changes in Rds affect both the total amount of slag-forming materials and their distribution between refining stages; (3) although the double-slag process reduces slag-forming material consumption compared with the single-slag process and conventional low-slag practice, it does not necessarily guarantee low-slag smelting; and (4) an optimal Rds exists under specific conditions, indicating that a higher deslagging ratio is not always beneficial and must be balanced with effective phosphorus removal. Industrial trials showed that the compliance rate of key slag parameters exceeded 60%, the dephosphorization rate during the dephosphorization stage was above 60%, and the overall dephosphorization rate exceeded 90% on average. The recycling of decarburization slag also showed complex effects on phosphorus removal in subsequent heats, indicating that its influence should be evaluated over multiple cycles rather than from isolated heats. Therefore, ideal stability predicted by the model cannot be fully achieved in industrial practice, and controlled recycling combined with timely slag renewal is required for process optimization. Full article
(This article belongs to the Special Issue Advances in Continuous Casting and Refining of Steel)
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16 pages, 1835 KB  
Article
A Kinetic Model for the Quantitative Estimation of Carryover Slag During BOF Tapping Using Computational Thermodynamics
by Puhong Cheng, Christian Bernhard, Daniel Kavić and Qing Zheng
Metals 2026, 16(3), 334; https://doi.org/10.3390/met16030334 - 17 Mar 2026
Viewed by 313
Abstract
Carryover slag (COS) entrained from the basic oxygen furnace (BOF) during tapping is highly oxidizing and affects secondary steelmaking by increasing deoxidizer consumption, refractory wear, P reversion, and decreasing steel cleanliness. A kinetic COS amount estimation model was developed by using the effective [...] Read more.
Carryover slag (COS) entrained from the basic oxygen furnace (BOF) during tapping is highly oxidizing and affects secondary steelmaking by increasing deoxidizer consumption, refractory wear, P reversion, and decreasing steel cleanliness. A kinetic COS amount estimation model was developed by using the effective equilibrium reaction zone (EERZ) method. The amount of COS was determined by iteratively adjusting the carryover slag coefficient (CSC) until predicted steel and slag compositions approached industrial measurements. Validation with four industrial heats confirmed that the model effectively predicts COS under both complete and incomplete deoxidation conditions. Further simulation results show that increasing the CSC from 2 to 4 kg per tonne of steel leads to 9.3 ppm P reversion. The calculations also confirmed that larger COS amounts accelerate refractory wear due to the higher input of readily reducible components, particularly FeO and MnO. Full article
(This article belongs to the Special Issue Advances in Continuous Casting and Refining of Steel)
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20 pages, 3921 KB  
Article
Temporal Evolution of Inclusions in Pipeline Steel: An Industrial Study via Robotic Sampling During Vacuum Degassing
by Shuai Zhao, Jixin Li, Shuhuan Wang and Dingguo Zhao
Metals 2026, 16(2), 208; https://doi.org/10.3390/met16020208 - 11 Feb 2026
Viewed by 457
Abstract
This study investigates the evolution and influencing factors of non-metallic inclusions in industrial pipeline steel during the vacuum degassing (VD) process. Steel and slag samples were systematically collected at multiple intervals throughout the vacuum treatment using an automated robotic sampler, which integrated temperature [...] Read more.
This study investigates the evolution and influencing factors of non-metallic inclusions in industrial pipeline steel during the vacuum degassing (VD) process. Steel and slag samples were systematically collected at multiple intervals throughout the vacuum treatment using an automated robotic sampler, which integrated temperature measurement and sampling functions. The results indicate that the molten steel temperature and the concentrations of nitrogen, oxygen, and sulfur exhibited an overall decreasing trend, with removal kinetics characterized by a rapid initial reduction followed by a gradual stabilization. The dominant inclusion phases were identified as Mg-Al spinel and calcium aluminates. Specifically, the top slag composition was distributed within the C3A phase field, trending toward the liquid C12A7 region, while the endogenous inclusions transitioned from CA2 toward CA. With prolonged vacuum treatment, the relative fraction of calcium aluminates progressively increased at the expense of Mg-Al spinel due to continuous slag-metal reactions. Furthermore, quantitative analysis reveals that the population density of small equivalent circular diameter (ECD) inclusions continuously decreased, while the average inclusion size increased, indicating that the VD process promotes the collision and coalescence of inclusions. Full article
(This article belongs to the Special Issue Advances in Continuous Casting and Refining of Steel)
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Graphical abstract

23 pages, 1869 KB  
Article
Multi-Dimensional Uniform Cooling Process for Ship Plate Steel Continuous Casting
by Xiaodong Yang, Zhenyao Chen, Jianchao Guan, Xin Xie, Chun He, Hao Hu, Mujun Long, Jianhua Liu and Dengfu Chen
Metals 2025, 15(10), 1137; https://doi.org/10.3390/met15101137 - 13 Oct 2025
Viewed by 900
Abstract
In slab continuous casting, achieving uniform cooling in the secondary cooling zone is essential for ensuring both surface integrity and internal quality. To optimize the process for ship plate steel, a solidification heat transfer model was developed, incorporating radiation, water film evaporation, spray [...] Read more.
In slab continuous casting, achieving uniform cooling in the secondary cooling zone is essential for ensuring both surface integrity and internal quality. To optimize the process for ship plate steel, a solidification heat transfer model was developed, incorporating radiation, water film evaporation, spray impingement, and roll contact. The influence of secondary cooling water flow on slab temperature distribution was systematically investigated from multiple perspectives. The results show that a weak cooling strategy is crucial for maintaining higher surface temperatures and aligning the solidification endpoint with the soft reduction zone. Along the casting direction, a “strong-to-weak” cooling pattern effectively prevents abrupt temperature fluctuations, while reducing the inner-to-outer arc water ratio from 1.0 to 0.74 mitigates transverse thermal gradients. In addition, shutting off selected nozzles in the later stage of secondary cooling at medium and low casting speeds increases the slab corner temperature in the straightening zone by approximately 50 °C, thereby avoiding brittle temperature ranges. Overall, the proposed multi-dimensional uniform cooling strategy reduces temperature fluctuations and significantly improves slab quality, demonstrating strong potential for industrial application. Full article
(This article belongs to the Special Issue Advances in Continuous Casting and Refining of Steel)
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17 pages, 4291 KB  
Article
The Research on Carbon Deoxygenation of Molten Steel and Its Application in the Converter Steelmaking Process
by Fang Gao and Yanping Bao
Metals 2025, 15(6), 648; https://doi.org/10.3390/met15060648 - 10 Jun 2025
Cited by 1 | Viewed by 2207
Abstract
At the steelmaking temperature, carbon has a strong deoxidation ability. Under the vacuum condition, its deoxidation ability can be further improved, and it can become a stronger deoxidation element than aluminum. The product of carbon deoxygenation is CO, which floats up and detaches [...] Read more.
At the steelmaking temperature, carbon has a strong deoxidation ability. Under the vacuum condition, its deoxidation ability can be further improved, and it can become a stronger deoxidation element than aluminum. The product of carbon deoxygenation is CO, which floats up and detaches from the molten steel in the form of bubbles and does not produce oxide inclusions. Under normal pressure, replacing aluminum with carbon to complete partial deoxidation tasks can not only reduce the generation of inclusions and alleviate the pressure of removing inclusions, but also reduce the consumption of aluminum and save deoxidation costs. In this study, the carbon deoxidation process after the converter was investigated. Firstly, the timing of carbon addition was determined through thermodynamic calculations, and it was found that, in oxygen-enriched molten steel, the priority of the reaction of the deoxidation element was [Al] > [Si] > [C] > [Mn]. Through the carbon and oxygen balance calculation, it is known that the carbon deoxidation effect is greatly affected by the carbon content of the molten steel; for low-carbon steel, carbon can be used for pre-deoxygenation, whereas for medium-carbon and high-carbon steel, carbon can complete most of the deoxidation tasks. Finally, with 45 steel as the research object, the carbon deoxidation process was designed and tested in industry. The results showed that, compared with the aluminum deoxidation process, the number of inclusions in the billet casting of the carbon deoxidation process was reduced by 68.8%, and the carbon deoxidation process had fewer large-sized inclusions in the billet casting. In addition, the carbon deoxidation process uses carbon powder instead of the aluminum block for deoxidation during steel tapping from the converter. The deoxidant cost is reduced by CNY 15.47/ton of steel. From a comprehensive point of view, the application of carbon deoxidation after the converter can reduce aluminum consumption and improve the cleanliness of steel, which is an important way for enterprises to reduce costs and increase efficiency. Full article
(This article belongs to the Special Issue Advances in Continuous Casting and Refining of Steel)
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20 pages, 13253 KB  
Article
Numerical Simulation of Effects of Mold Cavity and Submerged Entry Nozzle on Flow, Heat Transfer and Solidification in Funnel-Type Molds for Thin Slab Casting
by Zhaoyang Li, Yao Lu, Rudong Wang, Gengyang Li and Heng Cui
Metals 2025, 15(2), 183; https://doi.org/10.3390/met15020183 - 11 Feb 2025
Cited by 2 | Viewed by 2099
Abstract
As the third generation of thin slab continuous casting and rolling technology, endless strip production (ESP) has been widely used in the steelmaking industry. The key equipment in this process, the funnel-type mold, is prone to accidents such as slag entrainment, surface cracks [...] Read more.
As the third generation of thin slab continuous casting and rolling technology, endless strip production (ESP) has been widely used in the steelmaking industry. The key equipment in this process, the funnel-type mold, is prone to accidents such as slag entrainment, surface cracks and steel leakage under high casting speed conditions. To reduce the incidence of the above accidents, the numerical model of flow, heat transfer and solidification in the funnel-type mold is established by using the k-ε model, enthalpy–porosity method and magnetohydrodynamics (MHD), and the influence mechanism of the mold cavity and submerged entry nozzle (SEN) on the molten steel is studied, providing a new solution for optimizing the ESP process. The results show that compared with the type-I mold, the influence of the geometric disturbance of the top cavity on the flow state of the middle and lower body is localized, while the type-II funnel mold increases the thickness of the solidified shell at the outlet of mold; the marked enhancement in solidified shell thickness and uniformity at the mold exit achieved through the type-II SEN due to the distribution of temperature and velocity are more reasonable, reducing the risk of surface cracks and steel leakage. Full article
(This article belongs to the Special Issue Advances in Continuous Casting and Refining of Steel)
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