scholarly journals Effect of SEN immersion depth on mold flow profile and slag entrapment during continuous casting of steel

10.30544/653 ◽  
2021 ◽  
Author(s):  
Mallikarjuna Rao P ◽  
Vaibhav Vasantrao Chougale ◽  
Satish Kumar D ◽  
Rajendra T ◽  
Balachandran G
Keyword(s):  
Continuous Casting ◽  
Casting Speed ◽  
Immersion Depth ◽  
Water Model ◽  
Flow Profile ◽  
Continuous Casting Of Steel ◽  
Water Modeling ◽  
Wide Range ◽  
Mold Flow ◽  
Slag Entrapment

Mold flux entrapment during continuous casting of steel contributes to both surface and sub-surface defects in the final product. Continuous casting operating parameters such as casting speed, SEN immersion depth, SEN port geometry, argon flow, and mold EMS significantly affect the mold flow conditions and flow profile. During continuous casting operation, SEN immersion depth is continuously varied to avoid localized erosion of SEN, and it impacts the flow dynamics in the mold. In the present work, water modeling studies were carried out for a wide range of mold widths (1200-1800 mm) and casting speeds (0.8-1.4 m/min) on a 0.5 scaled down water model to optimize casting speed for different combinations of SEN immersion depth and mold width. Results from water modeling were further validated using nail board studies in the actual plant. A safe operating matrix was identified from these experiments to avoid mold slag entrapment during continuous casting.

Study of Mold Fluid Flow on a New Type Nozzle Bottom in Continuous Casting of Steel

2011 ◽  
Vol 284-286 ◽  
pp. 1205-1208 ◽  
Author(s):  
Chuan Bo Ji ◽  
Jing She Li ◽  
Xiao Chuan Lin
Keyword(s):  
Continuous Casting ◽  
Flow Pattern ◽  
Water Model ◽  
Velocity Variation ◽  
Mold Surface ◽  
Continuous Casting Of Steel ◽  
Slab Casting ◽  
New Type ◽  
Mold Flow ◽  
The Impact

There are many serious problems are directly associated with the flow pattern in the mold in the continuous casting of steel process. The nozzle flow plays an important role in determining the mold flow pattern and to minimize casting defects. In this work a new type nozzle designed for a slab casting mold is developed. The 3-D steady k-ε finite-volume model has been applied to study the turbulent flow in nozzle and mold, which predict velocities agree with the impeller measurements in the water model well. The results show that nozzles with a mountain bottom are more impressionable to problems from asymmetric flow and large fluctuation on the mold surface. The impact of liquid at wave bottom nozzle can suppress the jet flow effectively and reduce the velocity variation.

scholarly journals Optimization on Reducing Slag Entrapment in 150 × 1270 mm Slab Continuous Casting Mold

Materials ◽  
2019 ◽  
Vol 12 (11) ◽  
pp. 1774 ◽  
Author(s):  
Yang Wang ◽  
Shufeng Yang ◽  
Feng Wang ◽  
Jingshe Li
Keyword(s):  
Numerical Simulation ◽  
Continuous Casting ◽  
Casting Speed ◽  
Surface Velocity ◽  
Continuous Casting Mold ◽  
Slab Continuous Casting ◽  
Eddy Simulation ◽  
Submerged Entrance Nozzle ◽  
Dynamics Simulations ◽  
Slag Entrapment

To reduce slag entrapment in 150 × 1270 mm slab continuous casting molds at the Tang Steel Company, the effect of submerged entrance nozzle (SEN) depth and casting speed on the phenomenon was studied by computational fluid dynamics simulations. Then, the slag entrapment behavior in continuous casting molds, utilizing Large Eddy Simulation (LES) by coupling the volume of fluid (VOF) method, was also used. Finally, the effect of several common oils usually used to simulate slag in water modelling on slag entrapment was discussed and the water modelling results were used to validate the numerical simulation findings. The results showed that the optimum scheme is a submerged depth of SEN 90 mm and a casting speed of 1.6 m/min. Under optimal conditions, the maximum surface velocity is smallest (0.335 m/s) and the maximum slag entrapment ratio (0.44%) appears in the position of 0.1 m below the meniscus after 15 s. The water modelling results were in good agreement with the numerical simulation results.

Study on Fluid Flow in a Large Round Bloom Continuous Casting Mold

2011 ◽  
Vol 402 ◽  
pp. 196-201 ◽  
Author(s):  
Liang Cai Zhong ◽  
Mao Qiang Zhang ◽  
Xi Hai Liu
Keyword(s):  
Fluid Flow ◽  
Mold Wall ◽  
Vertical Section ◽  
Immersion Depth ◽  
Water Model ◽  
Continuous Casting Mold ◽  
Recirculating Flow ◽  
Large Round ◽  
Mold Flow ◽  
Good Agreement

The fluid flow in an 800 mm diameter bloom mold from two kinds of submerged entry nozzles (SEN) was investigated numerically with a mathematical model and experimentally in a water model. It was shown from the research results that the impacting depths measured in the water modeling experiments are in good agreement with the ones from the numerical calculation. The impacting depths obtained from the 4-port down 5° SEN are 140~220 mm at immersion depths from 100 to 180 mm, while those from 5-port up 5° SEN are 60~120 mm at immersion depths from 100 to 140 mm. There are an upper and a lower recirculating zone for these two SENs at the vertical section through a port center. Dimension of these two recirculating flow zones varies with the immersion depth of the SENs. At 100 mm immersion depth of the tow SENs the eye of the upper recirculating flow is not evident. The eyes of the upper recirculating flows for 5-port up 5° SEN are close to the SEN, while the ones for 4-port down 5° SEN are close to the mold wall. On the liquid surface in the mold, flow produced with the 4-port SEN creates 8 recirculating flow zones close to the SEN, while 10 recirculating flow zones close to the mold wall are formed with the 5-port SEN.

scholarly journals Bubbly Mold Flow in Continuous Casting: Comparison of Numerical Flow Simulations with Water Model Measurements

2020 ◽  
Vol 91 (12) ◽  
pp. 2000415
Author(s):  
Mirko Javurek ◽  
Raimund Wincor
Keyword(s):  
Continuous Casting ◽  
Water Model ◽  
Flow Simulations ◽  
Mold Flow

scholarly journals RANS versus Scale Resolved Approach for Modeling Turbulent Flow in Continuous Casting of Steel

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1140
Author(s):  
Jurij Gregorc ◽  
Ajda Kunavar ◽  
Božidar Šarler
Keyword(s):  
Continuous Casting ◽  
Flow Behavior ◽  
Turbulence Models ◽  
Experimental Results ◽  
Water Model ◽  
Particle Image Velocimetry System ◽  
Continuous Casting Of Steel ◽  
Continuous Casting Mold ◽  
Vertical Orientation ◽  
Numerical Predictions

Numerical modeling is the approach used most often for studying and optimizing the molten steel flow in a continuous casting mold. The selection of the physical model might very much influence such studies. Hence, it is paramount to choose a proper model. In this work, the numerical results of four turbulence models are compared to the experimental results of the water model of continuous casting of steel billets using a single SEN port in a downward vertical orientation. Experimental results were obtained with a 2D PIV (Particle Image Velocimetry) system with measurements taken at various cut planes. Only hydrodynamic effects without solidification are considered. The turbulence is modeled using the RANS (Realizable k-ε, SST k-ω), hybrid RANS/Scale Resolved (SAS), and Scale Resolved approach (LES). The models are numerically solved by the finite volume method, with volume of fluid treatment at the free interface. The geometry, boundary conditions, and material properties were entirely consistent with those of the water model experimental study. Thus, the study allowed a detailed comparison and validation of the turbulence models used. The numerical predictions are compared to experimental data using contours of velocity and velocity plots. The agreement is assessed by comparing the lateral dispersion of the liquid jet in a streamwise direction for the core flow and the secondary flow behavior where recirculation zones form. The comparison of the simulations shows that while all four models capture general flow features (e.g., mean velocities in the temporal and spatial domain), only the LES model predicts finer turbulent structures and captures temporal flow fluctuations to the extent observed in the experiment, while SAS bridges the gap between RANS and LES.

Water Model Experiments on Surface Flow Velocity of Molten Steel in Slab Caster Mold

2011 ◽  
Vol 287-290 ◽  
pp. 2735-2738 ◽  
Author(s):  
Xiao Hui Mao ◽  
Jing She Li ◽  
Xiao Chuan Lin
Keyword(s):  
Flow Velocity ◽  
Molten Steel ◽  
Casting Speed ◽  
Liquid Steel ◽  
Surface Flow ◽  
Immersion Depth ◽  
Water Model ◽  
Slab Caster ◽  
Model Experiments ◽  
Port Angle

Based on the slab caster mold of ChengGang Company as prototype, the water model with 1:1 scale was used to study the effects of casting speed、nozzle port angle、immersion depth、bottom structure、mold width and other parameters on the surface flow velocity of liquid steel in slab caster mold. The results show that the effect of casting speed is biggest and with increase in the casting speed, the surface flow velocity of liquid steel is prominently increased, when the mold width at 1650mm, the surface flow velocity from 0.04m/s to 0.1m/s with the casting speed from 0.7m/min increased to 1.4m/min

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.

scholarly journals Isothermal and Non-isothermal Crystallization Kinetics of Mold Fluxes used in Continuous Casting of Steel: A Review

2021 ◽  
Author(s):  
Rahul Sarkar ◽  
Zushu Li
Keyword(s):  
Continuous Casting ◽  
Crystallization Kinetics ◽  
Isothermal Crystallization ◽  
Steel Shell ◽  
Continuous Casting Of Steel ◽  
Copper Mold ◽  
Isothermal Crystallization Kinetics ◽  
Wide Range ◽  
Mold Fluxes ◽  
Kinetics Of

AbstractCasting powders or mold fluxes, as they are more commonly known, are used in the continuous casting of steel to prevent the steel shell from sticking to the copper mold. The powders first melt and create a pool of liquid flux above the liquid steel in the mold, and then the liquid mold fluxes penetrate into the gap between water-cooled copper mold and steel shell, where crystallization of solid phases takes place as the temperatures gradually drop. It is important to understand the crystallization behavior of these mold fluxes used in the continuous casting of steel because the crystalline phase fraction in the slag films plays a crucial role in determining the horizontal heat flux during the casting process. In this work, the existing literature on the crystallization kinetics of conventional and fluoride-free mold fluxes used in the continuous casting of steel has been reviewed. The review has been divided into two main sections viz. the isothermal crystallization kinetics and non-isothermal crystallization kinetics. Under each of these sections, three of the most widely used techniques for studying the crystallization kinetics have been included viz. thermoanalytical techniques such as differential scanning calorimetry/differential thermal analysis (DSC/DTA), the single and double hot thermocouple technique (SHTT and DHTT), and the confocal scanning laser microscopy (CSLM). For each of these techniques, the available literature related to the crystallization kinetics of mold fluxes has been summarized thereby encompassing a wide range of investigations comprising of both conventional and fluoride-free fluxes. Summaries have been included after each section with critical comments and insights by the authors. Finally, the relative merits and demerits of these methods vis-à-vis their application in studying the crystallization kinetics of mold fluxes have been discussed.

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