Vacuum Ingot Casting in the Modern Era: Plant Concepts, Process Optimization, and Performance

Abstract

Vacuum ingot casting is experiencing a strong revival driven by rising demand for large, high-integrity forged components in critical applications such as power generation and heavy machinery. This paper outlines the metallurgical principles and modern technological developments of the process to enhance degassing and minimize reoxidation. Focus is placed on current plant concepts, such as direct ladle casting and pony ladle configurations, and their impact on process stability, cleanliness, and operational flexibility. Recent innovations—ranging from automated casting rate control to advanced vacuum pump systems—are presented as key enablers for improved efficiency, safety, and sustainability. Special attention is given to achieving ultra-low hydrogen levels and high cleanliness standards required for demanding steel grades. The contribution also includes selected recent operational results from a modern vacuum ingot casting plant, demonstrating achievable performance levels under industrial conditions, and highlighting the technology’s relevance for future steel production.