Spread Sheet Model of Continuous Casting

1996 ◽  
Vol 118 (1) ◽  
pp. 37-44 ◽  
Author(s):  
B. G. Thomas ◽  
B. Ho
Keyword(s):  
Continuous Casting ◽  
Programming Languages ◽  
Casting Process ◽  
Transfer Model ◽  
Continuous Casting Mold ◽  
Microsoft Excel ◽  
Spreadsheet Program ◽  
Model Predictions ◽  
Engineering Models ◽  
Spread Sheet

Spreadsheet programs, such as Microsoft Excel, Informix WINGZ, and Lotus 123, provide a framework for very fast and easy development of simple engineering models. The present paper describes a model of the continuous casting process that has been developed using a spreadsheet program, Microsoft Excel, running on a Macintosh II personal computer. The model consists of two-dimensional (2-D) steady-state finite-difference heat conduction calculations within a continuous casting mold coupled to a one-dimensional (1-D) transient solidification heat transfer model of the solidifying shell. The model structure and equations are described and the model predictions are compared with previous solutions. Practical examples using the model are discussed and sample results are provided. Spreadsheet programs running on personal computers are capable of relatively complex calculations that would require extensive effort using conventional programming languages.

scholarly journals Numerical Simulation of Fluid Flow, Heat Transfer, Species Transfer, and Solidification in Billet Continuous Casting Mold with M-EMS

Metals ◽  
2019 ◽  
Vol 9 (1) ◽  
pp. 66 ◽  
Author(s):  
Wenjie Zhang ◽  
Sen Luo ◽  
Yao Chen ◽  
Weiling Wang ◽  
Miaoyong Zhu
Keyword(s):  
Fluid Flow ◽  
Continuous Casting ◽  
Swirling Flow ◽  
Casting Process ◽  
Longitudinal Section ◽  
Current Intensity ◽  
Continuous Casting Mold ◽  
Casting Mold ◽  
Billet Continuous Casting ◽  
Negative Segregation

Electromagnetic stirring in mold (M-EMS) has been widely used in continuous casting process to improve the solidification quality of the steel strand. In the present study, a 3D multi-physical-field mathematical model was developed to predict the macro transport phenomena in continuous casting mold with M-EMS using ANSYS commercial software, and was adopted to investigate the effect of current intensity (0, 150, 200, and 240 A) on the heat, momentum, and species transports in the billet continuous casting mold with a size of 160 mm × 160 mm. The results show that when the M-EMS is on, the horizontal swirling flow appears and shifts the high-temperature zone upward. With the increase of current intensity, two swirling flows form on the longitudinal section of continuous casting mold and become more intensive, and the flow velocity of the molten steel at the solidification front increases. Thus, the wash effects of the fluid flow on the initial solidified shell become intensive, resulting in a thinner shell thickness at the mold exit and a significant negative segregation of carbon at the billet subsurface.

Effect of Bottom Structure of Submerged Entry Nozzle on Flow Field in Ultra-Thick Slab Continuous Casting Mold

2010 ◽  
Vol 154-155 ◽  
pp. 840-845 ◽  
Author(s):  
Xin Xie ◽  
Deng Fu Chen ◽  
Qiang Liu ◽  
Jia Long Shen ◽  
Zheng Peng ◽  
...  
Keyword(s):  
Continuous Casting ◽  
Flow Pattern ◽  
Submerged Entry Nozzle ◽  
Casting Process ◽  
Surface Flow ◽  
Water Model ◽  
Continuous Casting Mold ◽  
Flat Bottom ◽  
Thick Slab ◽  
Flow Intensity

Submerged entry nozzle (SEN) bottom structure plays an important role in determining the flow pattern in continuous casting process. This work applies a water model to evaluate the pointed-bottom, flat-bottom and recessed-bottom nozzle performance in ultra-thick slab mold. The jet properties and surface flow are compared for the three kinds of nozzles quantitatively. The results show that flat-bottom and recessed-bottom nozzles are similar in flow pattern, but the pointed-bottom nozzle has smaller jet angle, thinner flow pattern, larger surface asymmetry rate, and higher surface flow intensity.

Interfacial Heat Flux Estimation in a Funnel Shaped Mould and Analysis of Solidification Characteristics in Thin Slab Continuous Casting

2021 ◽  
Author(s):  
Pedduri Jayakrishna ◽  
Ananda Vaka ◽  
Saurav Chakraborty ◽  
Suvankar Ganguly ◽  
Prabal Talukdar
Keyword(s):  
Heat Flux ◽  
Continuous Casting ◽  
Molten Steel ◽  
High Speed ◽  
Thermal Characteristics ◽  
Submerged Entry Nozzle ◽  
Casting Process ◽  
Transfer Model ◽  
Thin Slab ◽  
Slab Continuous Casting

Abstract An inverse heat transfer model based on Salp Swarm optimization algorithm is developed for prediction of heat flux at the hot faces of a mould in thin slab continuous casting. The industrial mould considered in this work is a funnel-shaped mould having complex arrangement of cooling slots and holes. Significant variations of heat flux along the casting direction, as well as across the width are observed. Subsequently, the obtained heat flux profile estimated by the inverse method is used to analyse the fluid flow and thermal characteristics of the solidifying steel strand inside the mould. Three different recirculatory zones are present due to molten steel flow, affecting the thermal and solidification characteristics significantly. The effect of these recirculatory flows on remelting phenomenon, and consequent formation of thinner shell at the mould outlet leading to quality control issues in the casting process have been discussed. Another practical issue of depression in the wide face shell thickness at the mould outlet has been identified, and its cause has been related to the location of the Submerged Entry Nozzle and the high speed of the molten steel inflow.

scholarly journals The Spontaneous Emulsification of Entrained Inclusions During Casting of High Aluminum Steels

2021 ◽  
Author(s):  
Akalya Raviraj ◽  
Nadia Kourra ◽  
Mark A. Williams ◽  
Gert Abbel ◽  
Claire Davis ◽  
...  
Keyword(s):  
Continuous Casting ◽  
Slag Phase ◽  
Continuous Caster ◽  
Casting Process ◽  
Inclusion Size ◽  
Confocal Scanning Laser Microscopy ◽  
Continuous Casting Mold ◽  
Spontaneous Emulsification ◽  
Mold Slag ◽  
High Aluminum

AbstractMold slag entrainment during the continuous casting process presents a late stage source of non-metallic inclusions (NMI) with a high likelihood of ending up in the final product. The reaction between the entrained slag phase and surrounding liquid steel in the continuous casting mold affects the inclusion morphology and properties. However, there is a lack of information on the kinetics of the NMI-steel reaction. A novel approach, utilizing controlled synthetic inclusion/metal samples, has been developed to study the reactions between free inclusion-slag droplets and steel. The technique combines High-Temperature Confocal Scanning Laser Microscopy (HT-CSLM), X-ray Computed Tomography (XCT) and advanced electron microscopy techniques offering rapid controlled heating performance and extensive characterization of the samples. This method offers the ability to observe the size, shape and composition of an unconstrained reacting inclusion and to investigate the interface between the materials with respect to reaction time. This study interrogates a low aluminum steel (0.04 wt pct) and a high aluminum steel (1 wt pct) in contact with an inclusion-slag phase with a starting composition aligned to a typical mold slag. It was found that the reaction between silica and aluminum across the interface of the two phases provided a driving force for spontaneous emulsification to occur. Products of such emulsification will have a significant effect on the inclusion size distribution and potentially the prevalence of inclusion retention in molten steels solidifying in the continuous caster (for example if emulsified buoyancy forces are reduced to near zero) and hence in the subsequent solid product.

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

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1375
Author(s):  
Alexander Vakhrushev ◽  
Abdellah Kharicha ◽  
Menghuai Wu ◽  
Andreas Ludwig ◽  
Yong Tang ◽  
...  
Keyword(s):  
Continuous Casting ◽  
Steel Slag ◽  
Phase Interface ◽  
Steel Production ◽  
Submerged Entry Nozzle ◽  
Casting Process ◽  
Material Model ◽  
Slag Layer ◽  
Continuous Casting Mold ◽  
High Production Rate

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.

scholarly journals Influence of EMS on Asymmetric Flow with Different SEN Clogging Rates in a Slab Continuous Casting Mold

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1288
Author(s):  
Bin Li ◽  
Haibiao Lu ◽  
Yunbo Zhong ◽  
Zhongming Ren ◽  
Zuosheng Lei
Keyword(s):  
Flow Field ◽  
Continuous Casting ◽  
Submerged Entry Nozzle ◽  
Casting Process ◽  
Continuous Casting Mold ◽  
Continuous Casting Process ◽  
Slab Continuous Casting ◽  
Safe Level ◽  
Mold Flow ◽  
Slag Entrapment

Submerged entry nozzle (SEN) clogging is a troublesome phenomenon in the continuous casting process that can induce the asymmetric mold flow, and thus, lowering the steel product quality. In this paper, a mathematical model coupling the electromagnetic and flow fields, was developed to investigate the influence of the SEN clogging rate on the flow field and the influence of electromagnetic stirring (EMS) on the asymmetric mold flow. Slag entrapment index Rc was introduced to quantify the possibility of slag entrapment, and symmetric index S was introduced to quantify the symmetry of the flow field. The results show that as the SEN clogging rate increased, the slag entrapment index Rc increased, while the symmetric index S decreased. EMS can greatly improve the symmetry of the flow field with SEN clogging, but it cannot remove the asymmetric phenomenon completely because the stirring intensity should be controlled below the safe level to avoid slag entrapment.

A New Non-Sinusoidal Oscillation Waveform for Continuous Casting Mold

2010 ◽  
Vol 154-155 ◽  
pp. 334-337
Author(s):  
Xin Jin ◽  
Ting Zhi Ren
Keyword(s):  
Continuous Casting ◽  
Oscillation Frequency ◽  
Casting Process ◽  
Sinusoidal Oscillation ◽  
Continuous Casting Mold ◽  
Continuous Casting Process ◽  
Advanced Technique ◽  
Continuous Casting Slab ◽  
New Type

A new non-sinusoidal oscillation waveform which is shown by waveform distortional rate was advanced. The amplitude, oscillation frequency, waveform distortional rate and casting velocity were established for a computer model of the continuous casting process. The range of waveform distortional rate was ascertained. The choosing method of amplitude and oscillation frequency was given. These offered a theory basis to the application of the advanced technique. Industrial scale experiments showed the new type waveform is effective on improving the quality of continuous casting slab and reducing breakout.

scholarly journals Numerical and Physical Parametric Analysis of a SEN with Flow Conditioners in Slab Continuous Casting Mold

2017 ◽  
Vol 62 (2) ◽  
pp. 927-946 ◽  
Author(s):  
J. Gonzalez-Trejo ◽  
C.A. Real-Ramirez ◽  
R. Miranda-Tello ◽  
F. Rivera-Perez ◽  
F. Cervantes-de-la-Torre
Keyword(s):  
Fluid Flow ◽  
Continuous Casting ◽  
Submerged Entry Nozzle ◽  
Casting Process ◽  
Continuous Casting Mold ◽  
Fluid Exchange ◽  
Standard Equipment ◽  
Symmetric Pattern ◽  
Physical Simulations ◽  
Flow Symmetry

AbstractSome of the most recent technologies that improves the performance in continuous casting process has installed infrastructure outside the mold to modify the natural fluid flow pattern to obtain a quasi-steady condition and promote a uniform solidified shell of steel. The submerged entry nozzle distributes the liquid steel in the mold and can be used to obtain the flow symmetry condition with external geometry improvements. The fluid flow conditioners were located near the outlet ports of the nozzle. The aim of the modifiers is to impose a pseudo symmetric pattern in the upper zone of the mold by inhibiting the fluid exchange between the zones created by conditioners. This work evaluates the effect of the thickness and length of the fluid-flow modifiers on the overall performance of the submerged nozzle. These properties of the fluid-flow modifiers were normalized based on two of the geometric dimensions of the standard equipment. Numerical and physical simulations suggest that the flow modifier should be as thin as possible.

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