Continuous casting is a metallurgical process used in the downstream stages of metal production — most notably in gold and iron ore processing — in which molten metal is solidified into a continuous strand or semi-finished shape such as billets, slabs, or ingots, which are then cut to the required length for further processing or sale. In gold refining, continuous casting machines pour refined molten gold into water-cooled moulds to produce gold bars of consistent size and purity, which are then stamped and certified for the international bullion market. In the iron and steel industry, continuous casting of molten steel (derived from iron ore via blast furnaces or electric arc furnaces) replaces the older ingot-casting method, delivering major improvements in yield, surface quality, energy efficiency, and throughput. The process requires precise temperature control, mould oscillation, secondary cooling with water sprays, and careful management of casting speed to prevent defects such as centreline segregation, surface cracks, or breakouts. Continuous casting has become the dominant method for steel production globally, with more than 96% of steel now produced by this method. The technology is fundamental to converting iron ore value chains from primary extraction to value-added finished products.
