Uploaded December 2025 | Updated September 2026, 2 weeks ago
Abstract: Continuous casting moulds have evolved incrementally. We explore here departures from conventional water-cooled copper mould design to enhance energy recovery and improve product quality. We examine heat dissipation in continuous casting moulds for 180 mm round steel billets with 20°C superheat, where conventional systems extract 35-50 kWh/t (approximately 21-30% of total solidification heat) at low-grade temperatures (30-60°C). By challenging two fundamental assumptions—water as the cooling medium and 600-900 mm mould length—we propose liquid tin cooling inspired by the Pilkington float glass process, combined with extended mould geometry enabled by additive manufacturing. Theoretical analysis suggests this approach could increase heat recovery to 170 kWh/t at 600-800°C (69% energy efficiency vs. 7% for water), yielding 117 kWh/t of useful high-grade heat while improving billet quality through near-complete controlled solidification. What prevents us from borrowing proven technologies from other industries? This work aims to stimulate discussion rather than present finished solutions.
Prof. Fabio Miani obtained his PhD in Engineering Metallurgy from the University of Padua in 1994. His PhD dissertation was on mechanochemical synthesis of nanophase metal powders, with emphasis on iron carbide and their characterization with Mössbauer spectroscopy. After completion of PhD, he worked as a process metallurgist at ABS steels company where he was responsible for producing special steels, as well as R&D head of ferrous metal powders. He joined as Assistant Professor at Udine in 1995, and has been Professor of metallurgy since 2003. During the last 30 years, he has been working/collaborating with several academic or industrial entities, chiefly in Italy. Prof. Fabio Miani has been the mentor of several hundreds of master thesis works which have been developed mainly in collaboration with local industries Danieli, ABS Acciai, Ferriere Nord Pittini etc.
Abstract: Continuous casting moulds have evolved incrementally. We explore here departures from conventional water-cooled copper mould design to enhance energy recovery and improve product quality. We examine heat dissipation in continuous casting moulds for 180 mm round steel billets with 20°C superheat, where conventional systems extract 35-50 kWh/t (approximately 21-30% of total solidification heat) at low-grade temperatures (30-60°C). By challenging two fundamental assumptions—water as the cooling medium and 600-900 mm mould length—we propose liquid tin cooling inspired by the Pilkington float glass process, combined with extended mould geometry enabled by additive manufacturing. Theoretical analysis suggests this approach could increase heat recovery to 170 kWh/t at 600-800°C (69% energy efficiency vs. 7% for water), yielding 117 kWh/t of useful high-grade heat while improving billet quality through near-complete controlled solidification. What prevents us from borrowing proven technologies from other industries? This work aims to stimulate discussion rather than present finished solutions.
Prof. Fabio Miani obtained his PhD in Engineering Metallurgy from the University of Padua in 1994. His PhD dissertation was on mechanochemical synthesis of nanophase metal powders, with emphasis on iron carbide and their characterization with Mössbauer spectroscopy. After completion of PhD, he worked as a process metallurgist at ABS steels company where he was responsible for producing special steels, as well as R&D head of ferrous metal powders. He joined as Assistant Professor at Udine in 1995, and has been Professor of metallurgy since 2003. During the last 30 years, he has been working/collaborating with several academic or industrial entities, chiefly in Italy. Prof. Fabio Miani has been the mentor of several hundreds of master thesis works which have been developed mainly in collaboration with local industries Danieli, ABS Acciai, Ferriere Nord Pittini etc.
