Direct Rolling (Integrated Casting and Rolling)

When applying direct rolling, the casted slab is rolled directly in the hot strip mill, saving handling and energy costs. Direct production of hot-rolled strip by connecting the thin slab caster with the hot-rolling process was introduced around 1990. In existing integrated plants this option may be difficult to implement, as the rolling stands need to be located directly next to the continuous caster. This leads to high retrofit costs.

Development Status Products

Direct Rolling (Integrated Casting and Rolling)Costs & Benefits

Parent Process: Casting
Energy Savings Potential

The specific energy consumption should be 40% lower than that needed for a traditional rolling mill. Energy savings of 60% with regard to the traditional cycle are possible.

CO2 Emission Reduction Potential

In an application in Japan equipment and construction costs were approximately ¥200 million and ¥50 million, respectively (NEDO, 2008).

Direct Rolling (Integrated Casting and Rolling) Publications

Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry

The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry, discusses energy efficiency practices and technologies that can be implemented in iron and steel manufacturing plants. This guide provides current real world examples of iron and steel plants saving energy and reducing cost and carbon dioxide emissions.

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Global Warming Countermeasures: Japanese Technologies for Energy Savings / GHG Emissions Reduction

This revised 2008 version of the publication from New Energy and Industrial Technology Development of Japan includes information on innovative Japanese technologies for energy efficiency and for the reduction of COemissions.  

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