Using the finite element software ProCAST to predict the temperature field, the flow field, the turbulent kinetic energy, and melt-pool outlet temperature of the top side-pouring twin-roll casting (TSTRC) of 6.5 wt.% Si steel process. The effect of different process conditions on the TSTRC process was investigated through numerical simulation, and a processing technic appropriate for the production of 6.5 wt.% Si steel was obtained. Meanwhile, the influence of violent stirring in the melt-pool on the microstructure under different process conditions was evaluated. The results showed that vigorous stirring in the melt-pool was conducive to formate the equiaxed crystal structure. We realized the near-final shape of the metal sheet and achieved the near-final shape of the microstructure. An appropriate process was selected to show good consistency with the experimental results.