A reduced-order model of mould heat transfer in the continuous casting of steel

Hibbeler, Lance C.; See, Melody M. Chin; Iwasaki, Junya; Swartz, Kenneth E.; O’Malley, Ronald J.; Thomas, Brian G.

doi:10.1016/j.apm.2016.04.002

Cited by 19 publications

(9 citation statements)

References 59 publications

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“…Calibration of solidification heat‐transfer models in the mold can exploit measurements such as cooling‐water heatup for a global energy balance, thermocouple temperatures in the mold walls for the heat‐flux profile, and shell thickness measurements from breakout shells or composition profiles after trace‐metal injection . This can be accomplished using trial and error or an inverse model, with either a full 3D model or an accurate reduced‐order model of the mold wall geometry . An example is shown in Figure , where interfacial parameters in the model were calibrated to match mold temperatures, and then comparison with the breakout shell profile represents model validation .…”

Section: Heat Transfer and Solidificationmentioning

confidence: 99%

Review on Modeling and Simulation of Continuous Casting

Thomas

2017

steel research int.

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183

115

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Continuous casting is a mature, sophisticated technological process, used to produce most of the world's steel, so is worthy of fundamentally-based computational modeling. It involves many interacting phenomena including heat transfer, solidification, multiphase turbulent flow, clogging, electromagnetic effects, complex interfacial behavior, particle entrapment, thermal-mechanical distortion, stress, cracks, segregation, and microstructure formation. Furthermore, these phenomena are transient, three-dimensional, and operate over wide length and time scales. This paper reviews the current state of the art in modeling these phenomena, focusing on practical applications to the formation of defects. It emphasizes model verification and validation of model predictions. The models reviewed range from fast and simple for implementation into online model-based control systems to sophisticated multiphysics simulations that incorporate many coupled phenomena. Both the accomplishments and remaining challenges are discussed.

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Section: Heat Transfer and Solidificationmentioning

confidence: 99%

Review on Modeling and Simulation of Continuous Casting

Thomas

2017

steel research int.

Self Cite

183

115

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“…Mathematical modelling aids in proper design and operating practices [17][18][19][20]. Several numerical models have been developed for the contact problem and air gap formation [20][21][22][23]. Deformation models coupled with the fluid flow, heat transfer, and solidification have been described elsewhere [24][25][26][27][28][29].…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, focus has been limited to local regions of interest. To speed-up the coupled problem simulation, reduced order models have been continuously developed [23,65,66]. The recently proposed recurrence methodology (rCFD) reported in [67] uses collected statistics to extrapolate simulation results for the steady-state processes and (partially) the transient processes [68][69][70][71][72].…”

Section: Introductionmentioning

confidence: 99%

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On Modelling Parasitic Solidification Due to Heat Loss at Submerged Entry Nozzle Region of Continuous Casting Mold

Vakhrushev

Kharicha

et al. 2021

Metals

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Continuous casting (CC) is one of the most important processes of steel production; it features a high production rate and close to the net shape. The quality improvement of final CC products is an important goal of scientific research. One of the defining issues of this goal is the stability of the casting process. The clogging of submerged entry nozzles (SENs) typically results in asymmetric mold flow, uneven solidification, meniscus fluctuations, and possible slag entrapment. Analyses of retained SENs have evidenced the solidification of entrapped melt inside clog material. The experimental study of these phenomena has significant difficulties that make numerical simulation a perfect investigation tool. In the present study, verified 2D simulations were performed with an advanced multi-material model based on a newly presented single mesh approach for the liquid and solid regions. Implemented as an in-house code using the OpenFOAM finite volume method libraries, it aggregated the liquid melt flow, solidification of the steel, and heat transfer through the refractory SENs, copper mold plates, and the slag layer, including its convection. The introduced novel technique dynamically couples the momentum at the steel/slag interface without complex multi-phase interface tracking. The following scenarios were studied: (i) SEN with proper fiber insulation, (ii) partial damage of SEN insulation, and (iii) complete damage of SEN insulation. A uniform 12 mm clog layer with 45% entrapped liquid steel was additionally considered. The simulations showed that parasitic solidification occurred inside an SEN bore with partially or completely absent insulation. SEN clogging was found to promote the solidification of the entrapped melt; without SEN insulation, it could overgrow the clogged region. The jet flow was shown to be accelerated due to the combined effect of the clogging and parasitic solidification; simultaneously, the superheat transport was impaired inside the mold cavity.

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“…For this reason, the behaviour of liquid slag layer on the liquid steel surface in mould is an important and often investigated problem of modern continuous steel casting process. The research take different forms, including plant measurements [4,5], investigations -basing on the similarity numbers: Webber (We), Froude (Fr), Reynolds (Re) and Capillary (Ca) -using the oil-water physical models [6,7] and also numerical simulations [8,9].…”

Section: Introductionmentioning

confidence: 99%

Physical and Numerical Investigations of Mould Flux Entrainment into Liquid Steel

Jowsa

Bielnicki

Cwudziński

2016

Archives of Metallurgy and Materials

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This paper presents results of model tests, performed in order to analyze phenomenon of slag droplets entrainment into steel in mould, during continuous casting process. The carried out studies took the form of laboratory experiments using physical model, in which -using similarity criteria -the behaviour of interfacial boundary liquid steel-liquid slag has been simulated using water and silicon oils, differing in physicochemical properties. Additionally, based on PIV (Particle Image Velocimetry) measurements and numerical simulations, vector flow field and values of critical velocities, at which observed the occurrence of interfacial boundary silicon oil-water instability have been identified. Based on the carried out investigations, results, that illustrate relationship between critical entrainment velocity and physicochemical properties of oils have been presented.

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A reduced-order model of mould heat transfer in the continuous casting of steel

Cited by 19 publications

References 59 publications

Review on Modeling and Simulation of Continuous Casting

Review on Modeling and Simulation of Continuous Casting

On Modelling Parasitic Solidification Due to Heat Loss at Submerged Entry Nozzle Region of Continuous Casting Mold

Physical and Numerical Investigations of Mould Flux Entrainment into Liquid Steel

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