Physical and Numerical Modeling of Exposed Slag Eye in Continuous Casting Mold using Euler–Euler Approach

Liu, Zhongqiu; Li, Baokuan; Vakhrushev, Alexander; Wu, Menghuai; Ludwig, Andreas

doi:10.1002/srin.201800117

Cited by 41 publications

(28 citation statements)

References 44 publications

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“…Free surface behavior, slag/gas bubble entrapment issue, etc., are of immense importance [41][42][43]. Both experimental work and advanced model development have been the topics of recent research [44][45][46][47][48].…”

Section: Introductionmentioning

confidence: 99%

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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Section: Introductionmentioning

confidence: 99%

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

Vakhrushev

Kharicha

et al. 2021

Metals

Self Cite

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“…Many factors can influence the quality of the steel in the ingot casting process. For example, the filling rate affects macrosegregation, [ 1 ] a high mass flow rate during the teeming process flushes off small pieces of refractory, [ 2 ] high turbulence can cause mold flux entrapments, [ 3–5 ] and reoxidation during teeming can lead to the formation of inclusions. [ 6 ] In large ingots, gas bottom injection is used to improve the thermal and chemical homogenization.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Study of the Free Surface During the Side Teeming Ingot Casting Process

Yin

Ersson

Jönsson

et al. 2021

steel research int.

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The flow pattern affects the interaction between the mold flux and liquid steel, especially during the initial entry of liquid steel into the mold. Strong turbulence can cause mold flux entrapments during the ingot casting process. If this happens, nonmetallic inclusions are generated, which decreases the quality of the final product. Herein, the side teeming process is introduced as an alternative to the traditional uphill teeming process to decrease mold flux entrapments. Both physical experiments and mathematical modeling are conducted to study the free surface. Specifically, the Weber number is also evaluated to predict the possibility of mold flux entrapments at the free surface. The results show that a calmer free surface is formed in the side teeming process compared with the uphill teeming process. Also, the results show that the Reynolds stress model is more suitable to predict the free surface compared with the realizable k–ε model. The present findings strongly suggest that an implementation of a side teeming process would be an effective way of reducing the risk for mold flux entrapments.

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“…Cho [4] used the 1:3 water model with the aid of a high-speed video camera and analytical models to investigate the gas pressure, initial bubble size, bubble descending velocity, bubble residence time, and bubble size distribution. Meanwhile, mathematical modeling has been developed to accurately simulate the mechanism of various defects, such as inclusions and the formation of oscillation marks [5][6][7][8][9][10]. Wu [7,8] considered the evolution of the solid shell, including a fully solidified strand and a partially solidified dendritic mushy zone, which strongly interacts with the turbulent flow and in the meantime is subject to continuous deformation due to the funnel-type mold.…”

Section: Introductionmentioning

confidence: 99%

Effect of Mold Width on the Flow Field in a Slab Continuous-Casting Mold with High-Temperature Velocity Measurement and Numerical Simulation

Liu

Yang

et al. 2021

Metals

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In this paper, the effects of the width of the mold on the surface velocity, flow field pattern, turbulent kinetic energy distribution, and surface-level fluctuation in the mold were studied with measurement of the flow velocity near the surface of the mold at high temperature with the rod deflection method and numerical calculation with the standard k-ε model coupled with the discrete-phase model (DPM) model for automobile exposed panel production. Under the conditions of low fixed steel throughput of 2.2 ton/min, a nozzle immersion depth of 140 mm, and an argon gas flow rate of 4 L/min, as the width of the mold increases from 880 mm to 1050 mm and 1300 mm, the flow velocity near the surface of the mold decreases. The flow direction changes from the positive velocity with the mold widths of 880 mm and 1050 mm to the unstable velocity with the mold width of 1300 mm. The calculated results are in good agreement with the measured results. The turbulent kinetic energy near the submerged entry nozzle (SEN) gradually increases, and the risk of slag entrainment increases. Under the conditions of high fixed steel throughput of 3.5 ton/min, the SEN immersion depth of 160 mm, and the argon gas flow rate of 10 L/min, as the width of the mold increases from 1600 mm to 1800 mm and 2000 mm, the velocity near the mold surface decreases. The flow velocity at 1/4 of the surface of the mold is positive with the mold width of 1600 mm, while the velocities are negative with the widths of 1800 mm and 2000 mm. The calculated results are basically consistent with the measured results. The high turbulent kinetic energy area near the nozzle expands to a narrow wall, and the risk of slag entrainment is significantly increased. In both cases of low and high fixed steel throughput, the change rules of the flow field in the mold with the width are basically the same. The argon gas flow rate and the immersion depth of SEN should be adjusted reasonably to optimize the flow field in the mold with different widths under the same fixed steel throughput in the practical production.

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Physical and Numerical Modeling of Exposed Slag Eye in Continuous Casting Mold using Euler–Euler Approach

Cited by 41 publications

References 44 publications

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

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

Experimental and Numerical Study of the Free Surface During the Side Teeming Ingot Casting Process

Effect of Mold Width on the Flow Field in a Slab Continuous-Casting Mold with High-Temperature Velocity Measurement and Numerical Simulation

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