This is the first step in designing a continuous caster. Considerations are then made based on desired annual tonnage, liquid steel availability, and anticipated operating hours. Then, the machine design considerations can be made for the number of strands and cast speeds to match the liquid metal supply from the melt shop. This bar prevents liquid steel from flowing out of the mold. The steel poured into the mold is partially solidified, producing a steel strand with a solid outer shell and a liquid core.
Liquid steel continues to pour into the mold to replenish the withdrawn steel at an equal rate.
The withdrawal rate depends on the cross-section, grade and quality of steel being produced, and may vary between 12 and 300 inches per minute. Casting time is typically 1.0 - 1.5 hours per heat to avoid excessive ladle heat losses. This area preserves cast shape integrity and product quality. Once the strand is fully solidified and has passed through the Straightener Withdrawal Units, the dummy bar is disconnected, removed and stored. Billets have cast section sizes up to about 7 inches square.