The quality of steel produced by continuous casting depends mainly on the characteristics of the liquid steel flow pattern within the mold. This pattern depends on the flow dynamics of the nozzle that is immersed in liquid steel. This work characterizes the fluid dynamics within two separate submerged entry nozzle models with a square cross section bore. The Froude similarity criterion and water as working fluid have been used. The models consist of a square-shaped tube with one inlet and two lateral squared exits at the bottom. To enhance the flow visualization, the models do not have exit ports. Moreover, one of the models has a “pool,” a volume at the bottom, and the other prescinds of it. The geometrical parameters and operational conditions of physical experiments were reproduced in the numerical simulations. The turbulence model used in this work is large eddy simulation (LES) with dynamic k-equation filtering. It was found that transient numerical simulations reproduce the dynamic nature of the internal flow pattern seen in physical experiments. The results show that the flow pattern within the pool nozzle is defined by only one large vortex; on the other hand, in the nozzle, without the pool, the flow pattern achieves a complex behavior characterized by two small vortexes. This study will allow to build nozzles that produce a symmetric, regular fluid flow pattern inside the mold, which leads to improvements on the process such as low energy consumption and finally in cost reductions.

Electrochemical cells with a rotating disc electrode are the preferred devices to characterize electrochemical reactions because simple analytical expressions can be used to interpret the information obtained from physical experiments. These equations assume that the velocity field in the vicinity of the electrode active face is in accordance with the ideal behavior described by von Kármán. Experimental liquid velocity measurements inside the cell reported in recent works suggest that the actual liquid flow pattern is not fully in accordance with the assumed ideal behavior. In this work, the Computational Fluid Dynamics technique was employed to characterize numerically the flow pattern inside the electrochemical cell. By using a three-dimensional model, symmetric conditions were not imposed. A biphasic system was employed to evaluate the influence of liquid free surface over the flow pattern. Unsteady state numerical simulations were performed using the commercial software Fluent. Multiple electrode rotation speeds and several cell sizes were employed. Contrary to the assumed behavior, it was obtained that the flow pattern inside the electrochemical cell is not symmetric due to the synergetic effect of the cell walls, the submerged electrode side wall and the liquid free surface. This work states that the differences between actual and the ideal flow patterns can be minimized with plain electrode and cell geometrical modifications.

To minimize the product imperfections due to slag entrapment and surface defects, the fluid flow pattern inside the mold must be symmetric, commonly named double-roll flow. Thus, the liquid steel must enter into the mold evenly distributed. The submerged entry nozzle (SEN) is crucial in product quality in vertical steel slab continuous casting machines because it distributes the molten steel from the tundish into the mold. This work evaluates the performance of a novel bifurcated nozzle design named “SEN with flow divider”. The symmetry at the outlet ports is obtained by imposing symmetry inside the SEN. The flow divider is a solid barrier attached at the SEN bottom inner wall, the height of which slightly surpasses the upper edges of the outlet ports. The performance analysis is done first using numerical simulations, where the Computational Fluid Dynamics (CFD) technique and the Smoothed Particle Hydrodynamics (SPH) approach are used. Then, experimental tests on a scaled model are also used to evaluate the SEN performance. Numerical and physical simulations showed that the flow divider considerably reduces the SEN outlet jets’ broadness and misalignment, producing compact, aligned, and symmetric jets. Therefore, the SEN design analyzed in this work is a promising alternative to improve process profitability.

This work evaluates the performance of a novel design for a bifurcated submerged entry nozzle (SEN) used for the continuous casting of steel slabs. The proposed design incorporates fluid flow conditioners attached on SEN external wall. The fluid flow conditioners impose a pseudosymmetric pattern in the upper zone of the mold by inhibiting the fluid exchange between the zones created by conditioners. The performance of the SEN with fluid flow conditioners is analyzed through numerical simulations using the CFD technique. Numerical results were validated by means of physical simulations conducted on a scaled cold water model. Numerical and physical simulations confirmed that the performance of the proposed SEN is superior to a traditional one. Fluid flow conditioners reduce the liquid free surface fluctuations and minimize the occurrence of vortexes at the free surface.

Some 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.