Simulation of fluid flow inside a continuous slab-casting machine

Thomas, Brian G.; Mika, Łukasz; Najjar, Fady

doi:10.1007/bf02664206

Cited by 137 publications

(92 citation statements)

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“…Further discussion of how this fluid flow model works and comparisons of the model results with water model observations and measurements are given elsewhere. [12,13] The Reynolds number in the caster, based on the hydraulic diameter, (Table I) always exceeds 10,000 even far below the mold. This indicates that the flow is highly turbulent everywhere.…”

Section: -D Mass Transfer Model Of Upper Strandmentioning

confidence: 97%

“…[12,13] Therefore, fluid flow can be assumed to be steady, incompressible, turbulent, single-phase Newtonian flow when no change in casting speed occurs. Further discussion of how this fluid flow model works and comparisons of the model results with water model observations and measurements are given elsewhere.…”

Section: -D Mass Transfer Model Of Upper Strandmentioning

confidence: 99%

“…Equations [8] through [12] were solved with the same time integration and spatial difference schemes used for the 3-D model. It took only about 120 s CPU time on the SGI, with an 800 node mesh of a 14 m long domain.…”

Section: -D Mass Transfer Model Of Lower Strandmentioning

confidence: 99%

“…Standard conditions, which assume a jet angle of about 25˚ down, correspond to the flow exiting a typical bifurcated nozzle with oversized ports angled about 15˚ downward. [12] The extreme case of increasing the nozzle port angle to more than 30˚ up to produce a 5˚ downward jet [12] is compared in Figure 17 with the standard case. The results indicate that changing nozzle design affects intermixing only at the slab surface, with almost no change in the slab interior.…”

Section: E Nozzle Designmentioning

confidence: 99%

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Modeling of steel grade transition in continuous slab casting processes

Huang

Thomas

1993

Metall Trans B

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Mathematical models have been developed and applied to investigate the composition distributions that arise during steel grade changes in the continuous slab casting processes. Three-dimensional turbulent flow and transient mixing phenomena in the mold and the strand were calculated under conditions corresponding to a sudden change in grade. The composition distribution in the final slab was then predicted. Reasonable agreement was obtained between predicted and experimental concentration profiles in the slab centerlines. Intermixing in the center extends many meters below the transition point while intermixing at the surface extends above. Higher casting speed increases the extent of intermixing. Mold width, ramping of casting speed, and nozzle design have only small effects. Slab thickness, however, significantly influences the intermixing length of the slab.The axial transport of solute due to turbulent eddy motion was found to be many orders of magnitude greater than molecular diffusion and thus dominates the resulting composition distribution. Different elements, therefore, exhibited the same mixing behavior under the same casting conditions, despite having different molecular properties. Numerical diffusion caused by the finite difference schemes was investigated and confirmed to be much less important than turbulent diffusion. In the lower portion of the strand (lower than 3 meters below the meniscus), the convection and diffusion can be reasonably approximated as one dimensional axial flow.2

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Section: -D Mass Transfer Model Of Upper Strandmentioning

confidence: 97%

Section: -D Mass Transfer Model Of Upper Strandmentioning

confidence: 99%

Section: -D Mass Transfer Model Of Lower Strandmentioning

confidence: 99%

Section: E Nozzle Designmentioning

confidence: 99%

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Modeling of steel grade transition in continuous slab casting processes

Huang

Thomas

1993

Metall Trans B

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“…Por estas razones los métodos numéricos se utilizan ampliamente. Entre estos los más comunes están: diferencias finitas (Choudhary et al, 1993;Shi y Guo, 2004), elementos finitos (Thomas et al, 1990;Janik et al, 2004), volúmenes finitos (Huespe et al, 2000) y elementos de contorno (Fic, 2000). Estos métodos son capaces de formular y resolver las ecuaciones de transmisión de calor.…”

Section: Introduciónunclassified

Modelado del Proceso Convencional de Colada Continua de Aceros Libres de Interticios

et al. 2010

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El objetivo del trabajo fue desarrollar un modelo matemático capaz de simular el proceso convencional de colada continua de aceros IF (Interstitial Free), y determinar las condiciones operacionales óptimas. La formulación del modelo incluye las ecuaciones de momento lineal de materiales líquidos y solidificados junto con la evolución térmica de la plancha. Las ecuaciones diferenciales y las condiciones de contorno son resueltas numéricamente mediante volúmenes finitos. Ciertas condiciones de contorno como el flujo de calor para el enfriamiento en cada región, además de la resistencia al flujo de la capa de fundente y las oscilaciones en la región del molde, son especificadas. Las predicciones del modelo fueron comparadas con datos industriales para las condiciones de las coladas continuas convencionales y extendidas a aceros IF. Palabras clave: colada continua, acero IF, modelado matemático, simulación computacional, volúmenes finitos. Modeling of the conventional process of continuous Interstitial Free casting AbstractThe purpose of this work was to develop a mathematical model able to simulate the continuous casting process of IF steel (Interstitial Free).and to determine the optimum operating conditions. The model formulation involves the momentum equations of liquid and solidified materials coupled with the temperature evolution of the slab. The differential equations and boundary conditions are numerically solved using the finite volume technique with appropriated boundary conditions for each region of the casting machine. The model predictions were compared with industrial data for conventional continuous casting conditions and extended to IF steel.

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Magnetic Field, Flow Field and Inclusion Collision Growth in a Continuous Caster with EMBR

Lei

2007

Chem Eng & Technol

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A three-dimension mathematical model has been developed to describe the magnetic field, fluid flow and inclusion transport in a continuous caster with electromagnetic brake (EMBR). According to the model, all the governing equations can be expressed as a general differential equation, so a general numerical method was developed to solve these equations. The numerical results agree well with the experimental result. In the continuous caster, the inclusion distributions have 'M' shape under the nozzle and 'W' shape at the exit, which come from the centrifugal effect and the collision and aggregation among inclusions. The three-dimensional static magnetic field can effectively damp local flows and affect the inclusion transport in a continuous caster. If EMBR is installed under the nozzle, it can promote the inclusion removal and the inclusion 'M' distribution disappears. IntroductionThe flow pattern of molten steel in the continuous casting mold is of great interest because of its influence on many important phenomena related to product quality, such as entrapment of inclusions and bubbles on the solidified shell, and entrainment of mold slag at the slag-metal interface. These foreign phases will cause various defects in the slabs. The problems were addressed by the ABB and Kawasaki Steel corporations in the early 1980s. The first generation EMBR [1][2][3][4][5] consists of two braking areas, each covering the steel flowing out of one nozzle port. It was developed to act directly on the molten steel discharged from the immersion nozzle and to reduce its flow velocity. Afterwards, the second-generation EMBR [6][7][8][9][10][11], known as EMBR Ruler, was developed. Its innovative feature is that the two magnetic poles at the same side of the mold in the first generation EMBR were combined into one larger pole that substantially covers the entire width of the slab. Later, the third generation EMBR [7,[11][12][13], called the FC Mold, was made up of two sets of the second generation EMBR Ruler. The FC Mold creates two equally strong static magnetic fields, one field at the meniscus level to control the surface stream, and another field at the lower part of the mold to control the stream directed downwards. In all, three generations of EMBR are the division or combination of the second generation EMBR.The transport of inclusions depends obviously on the fluid flow. Therefore, great modeling efforts were made to study the fluid flow in the mold. And recently, some metallurgists also investigated the influence of fluid flow on inclusion transport. For the numerical simulation of EMBR, the researchers always assumed that the magnetic field caused by EMBR could be simplified as a uniform distribution [4] Chem. Eng. Technol. 2007, 30, No. 12, 1650-1658 [5] or a one-dimensional distribution [6,7,12,13], and solved a Poisson equation for the electric potential to get the distribution of the electric potential in the mold. For the numerical simulation of the inclusion behavior, most of these publications investigate the incl...

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Simulation of fluid flow inside a continuous slab-casting machine

Cited by 137 publications

References 3 publications

Modeling of steel grade transition in continuous slab casting processes

Modeling of steel grade transition in continuous slab casting processes

Modelado del Proceso Convencional de Colada Continua de Aceros Libres de Interticios

Magnetic Field, Flow Field and Inclusion Collision Growth in a Continuous Caster with EMBR

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