Thin Slab Casting - Near Net Shape Casting

In near net shape casting the metal is cast to a form and dimensions that is close to the what required for the finished product. This reduces the processing needed to finish the product. In other words, this technology integrates the casting and hot rolling of steel into one process step, thereby reducing the need to reheat the steel before rolling (Worrell et al., 2010. p. 93). Thin Slab Casting (TSC) and Strip Casting (SC) are two main types of near net shape casting and they are both continuous processes.   

In the case of TSC, the steel is cast directly to slabs with a thickness between 30 and 60 mm – instead of slabs with a thickness of 120–300 mm. This technology has been a success in the US mini–mills producing flat products. TSC offers significant energy savings.

Thin strip casting, near net shape casting technologies hold a high applicability potential for China, India and the US.  However, these technologies require major changes in the plant and may not be applicable to many plants where flexibility in production is required. 

Development Status Products
Commercial
Thin sheet steel

Thin Slab Casting - Near Net Shape CastingCosts & Benefits

Parent Process: Casting
Energy Savings Potential

TSC is estimated to reduce energy consumption by 4.9 GJ/t-crude steel.
TSC with a tunnel furnace offers an energy savings 1.08 GJ/t-steel cast (US EPA, 2010. p. 24)

CO2 Emission Reduction Potential

TCS is estimated to reduce CO2 emissions by 779 kg per ton of product. 

Costs

Investment costs for a large-scale plant were estimated to range from $234.9/t-product with a resultant cost savings of approximately $31/t-crude steel.
TSC is estimated to have a payback time of 3.3 years (US EPA, 2010. p. 24). 

Parent Process: Rolling Mills
Energy Savings Potential

TSC is estimated to reduce energy consumption by 4.9 GJ/t-crude steel.
TSC with a tunnel furnace offers an energy savings 1.08 GJ/t-steel cast (US EPA, 2010. p. 24)

CO2 Emission Reduction Potential

Thins slab casting is estimated to reduce CO2 emissions by 779 kg per ton of product. 

Costs

Investment costs for a large-scale plant were estimated to range from $234.9/t-product with a resultant cost savings of approximately $31/t-crude steel.
TSC is estimated to have a payback time of 3.3 years (US EPA, 2010. p. 24). 

Thin Slab Casting - Near Net Shape Casting Publications