Effects of a Magnetic Field on Turbulent Flow in the Mold Region of a Steel Caster

Electromagnetic braking (EMBr) greatly influences turbulent flow in the continuous casting mold and its transient stability, which affects level fluctuations and inclusion entrainment. Large eddy simulations are performed to investigate these transient flow phenomena using an accurate numerical scheme implemented on a graphics processing unit. The important effect of the current flow through the conducting solid steel shell on stabilizing the fluid flow pattern is investigated. The computational model is first validated with measurements made in a scaled physical model with a low melting point liquid metal and is then applied to a full-scale industrial caster. The overall flow field in the scale model was matched in the real caster by keeping only the Stuart number constant. The free surface-level behaviors can be matched by scaling the results using a similarity criterion based on the ratio of the Froude numbers. The transient behavior of the mold flow reveals the effects of EMBr on stability of the jet, top surface velocities, surface-level profiles, and surface-level fluctuations.     

Effect of Electromagnetic Ruler Braking (EMBr) on Transient Turbulent Flow in Continuous Slab Casting using Large Eddy Simulations

Static electromagnetic braking (EMBr) fields affect greatly the turbulent flow pattern in steel continuous casting, which leads to potential benefits such as decreasing flow instability, surface defects, and inclusion entrapment if applied correctly. To gain a fundamental understanding of how EMBr affects transient turbulent flow, the current work applies large eddy simulations (LES) to investigate the effect of three EMBr ruler brake configurations on transient turbulent flow through the bifurcated nozzle and mold of a liquid-metal GaInSn model of a typical steel slab-casting process, but with deep nozzle submergence and insulated walls with no solidifying shell. The LES calculations are performed using an in-house graphic-processing-unit-based computational-fluid-dynamics code (LES-CU-FLOW) on a mesh of ~7?million brick cells. The LES model is validated first via ultrasonic velocimetry measurements in this system. It is then applied to quantify the mean and instantaneous flow structures, Reynolds stresses, turbulent kinetic energy and its budgets, and proper orthogonal modes of four cases. Positioning the strongest part of the ruler magnetic field over the nozzle bottom suppresses turbulence in this region, thus reducing nozzle well swirl and its alternation. This process leads to strong and focused jets entering the mold cavity making large-scale and low-frequency (<0.02?Hz) flow variations in the mold with detrimental surface velocity variations. Lowering the ruler below nozzle deflects the jets upward, leading to faster surface velocities than the other cases. The double-ruler and no-EMBr cases have the most stable flow. The magnetic field generates large-scale vortical structures tending toward two-dimensional (2-D) turbulence. To avoid detrimental large-scale, low-frequency flow variations, it is recommended to avoid strong magnetic fields across the nozzle well and port regions.     

Transient fluid flow and superheat transport in continuous casting of steel slabs

The turbulent flow of molten steel and the superheat transport in the mold region of a continuous caster of thin steel slabs are investigated with transient large-eddy simulations and plant experiments. The predicted fluid velocities matched measurements taken from dye-injection experiments on full-scale water models of the process. The corresponding predicted temperatures matched measurements by thermocouples lowered into the molten steel during continuous casting. The classic double-roll flow pattern is confirmed for this 132×984 mm slab caster at a 1.52 m/min casting speed, with about 85 pct of the single-phase flow leaving the two side ports of the three-port nozzle. The temperature in the top portion of the molten pool dropped to about 30 pct of the superheat-temperature difference entering the mold of 58 °C. About 12 pct of the superheat is extracted at the narrow face, where the peak heat flux averages almost 750 kW/m² and the instantaneous peaks exceed 1500 kW/m². Two-thirds of the superheat is removed in the mold. The jets exiting the nozzle ports exhibit chaotic variations, producing temperature fluctuations in the upper liquid pool of ±4 °C and peak heat-flux variations of±350 kW/m². Employing a static-k subgrid-scale (SGS) model into the three-dimensional (3-D) finite-volume code had little effect on the solution.     

Investigation on Water Model for Fluid Flow in Slab Continuous Casting Mold With Consideration of Solidified Process

This study aims to propose suitable simulation methods, which enable to reduce the major differences between water model and real caster, such as the gradually decreased flow space, flow mass in the casting direction, and the momentum decay in the mushy zone. With consideration of solidified process, the method is concerned with the change of flow space and flow mass at the casting direction in water model. The level fluctuations, stimulus–response curves, velocities of liquid surface, and distributions of liquid slag have been changed in the water model to study the differences of flow character and the variation of fluid flow in molds. The mold with a solidified shell leads to significant differences in flow behaviors, such as higher level fluctuations, higher surface velocities, and worse liquid slag distributions. Neglecting the solidified shell causes unrealistic lower surface velocities and level fluctuations in water model. The mold with consideration of flow mass balance has higher level fluctuations and surface velocities than the mold without shell, and has lower level fluctuations and surface velocities than that of mold with a shell. The results indicate that it is necessary for water model to take the solidified process into account to acquire more accurate and reliable experiment results, especially for thinner slab.     

Numerical Analysis of the Influences of Operational Parameters on the Braking Effect of EMBr in a CSP Funnel-Type Mold

A three-dimensional mathematical model of the magnetic field, flow field, and temperature field in a 1500 mm × 90 mm CSP funnel-type mold is used to numerically study the effect of an electromagnetic brake (EMBr) on flow and heat transfer behavior of molten steel. A number of effects of EMBr on the flow pattern and temperature distribution of molten steel are simulated. The jet flow discharge from the submerged entry nozzle (SEN) is significantly suppressed. In addition, heat transfer in the upper part of the mold increases under the influence of EMBr, which can improve the mobility of liquid steel at the meniscus and achieve low superheat casting. The relations between casting speed and magnetic flux density, and between SEN submergence depth and the installation position of the EMBr device, are taken into account to study the effects of braking on molten steel. The results show that the braking effect is weakened with an increase in either the casting speed or the SEN submergence depth. In order to insure the efficient and stable operation of a continuous casting production, the magnetic flux density should be increased by approximately 0.1 T when the casting speed increases by 1 m/min. In addition, an optimal braking effect for molten steel can be obtained when the distance between the bottom of the nozzle and the upper surface of the EMBr device is 100 mm.     

电磁制动下结晶器内流体流动行为的数值研究

 数值模拟了在电磁制动作用下结晶器内金属液的流动行为,并研究了诸如磁感应强度,水口出口角度和磁场位置等各种操作条件对电磁制动效果的影响。数值模拟结果表明：应用电磁制动使结晶器内的流场有很大的改变。施加0.5 T的磁场使结晶器内金属液的表面流速最小,这一计算结果与实验结果十分吻合。为此,应用磁场对结晶器内的流场进行控制,有必要在一定的浇注条件下优化磁感应强度的大小。当磁感应强度、拉坯速度和水口出口角度一定时,磁场位置与水口浸入深度之比有一最佳值,可达到理想的电磁制动效果。     

Study of transient flow and particle transport in continuous steel caster molds: Part I. Fluid flow

Unsteady three-dimensional flow in the mold region of the liquid pool during continuous casting of steel slabs has been computed using realistic geometries starting from the submerged inlet nozzle. Three large-eddy simulations (LES) have been validated with measurements and used to compare results between full-pool and symmetric half-pool domains and between a full-scale water model and actual behavior in a thin-slab steel caster. First, time-dependent turbulent flow in the submerged nozzle is computed. The time-dependent velocities exiting the nozzle ports are then used as inlet conditions for the flow in the liquid pool. Complex time-varying flow structures are observed in the simulation results, in spite of the nominally steady casting conditions. Flow in the mold region is seen to switch between a “double-roll” recirculation zone and a complex flow pattern with multiple vortices. The computed time-averaged flow pattern agrees well with measurements obtained by hot-wire anemometry and dye injection in full-scale water models. Full-pool simulations show asymmetries between the left and right sides of the flow, especially in the lower recirculation zone. These asymmetries, caused by interactions between two halves of the liquid pool, are not present in the half-pool simulation. This work also quantifies differences between flow in the water model and the corresponding steel caster. The top-surface liquid profile and fluctuations are predicted in both systems and agree favorably with measurements. The flow field in the water model is predicted to differ from that in the steel caster in having higher upward velocities in the lower-mold region and a more uniform top-surface liquid profile. A spectral analysis of the computed velocities shows characteristics similar to previous measurements. The flow results presented here are later used (in Part II of this article) to investigate the transport of inclusion particles.     

拉速对小方坯结晶器液面波动影响的数值模拟

利用流体力学软件Fluent建立180 mm×180 mm铸坯结晶器内"钢-渣"两相流模型,对结晶器液面波动行为进行数值模拟,研究浸入式水口自结晶器中心位置偏离量(0~30 mm)和拉速(2.0~3.0 m/min)对结晶器液面波动行为的影响。发现在相同浸入式水口偏离量下增加拉速,钢液面波动的整体趋势增加,且偏移量与拉速越大,液面波动增幅越大;低拉速时,波谷出现在水口边缘,水口周围剧烈波动;高拉速时,波谷出现在结晶器右壁面,使得钢液液面波动加剧,容易产生卷渣。     

Effect of Stopper-Rod Misalignment on Fluid Flow in Continuous Casting of Steel

Misalignment of metal-delivery systems can cause asymmetric fluid flow in the mold region of continuous casters, leading to abnormal surface turbulence, insufficient superheat transport to the meniscus, slag entrainment, inclusion entrapment, and other quality problems. This work investigates the effect of stopper-rod misalignment on nozzle and mold flow velocities in a conventional continuous casting process using both a water model and a computational model. Three stopper-rod configurations are studied (aligned, front misaligned by 2 mm, and left misaligned by 2 mm). The 3-D steady k–ε finite-volume model matched well with impeller probe measurements of both velocity and its fluctuations. Negligible asymmetry was found near the narrow faces. Asymmetry close to submerged entry nozzle is the main cause of vortex formation observed in all cases. The left-misaligned stopper-rod produces a shallower jet with a higher flow rate from the right port, leading to higher surface velocities on the right surface. This produced substantially more large vortices on the left side. The asymmetry produced by the nozzle length bore diameter ratio of ~21 in this work is consistent with the theoretical critical entrance length of ~24 for turbulent pipe flow.     

Improvement of Castability and Surface Quality of Continuously Cast TWIP Slabs by Molten Mold Flux Feeding Technology

An innovative continuous casting process named POCAST (POSCO’s advanced CASting Technology) was developed based on molten mold flux feeding technology to improve both the productivity and the surface quality of cast slabs. In this process, molten mold flux is fed into the casting mold to enhance the thermal insulation of the meniscus and, hence, the lubrication between the solidifying steel shell and the copper mold. Enhancement of both the castability and the surface quality of high-aluminum advanced high-strength steel (AHSS) slabs is one of the most important advantages when the new process has been applied into the commercial continuous casting process. A trial cast of TWIP steel has been carried out using a 10-ton scale pilot caster and 100-ton scale and 250-ton scale commercial casters. The amount of mold flux consumption was more than 0.2 kg/m² in the new process, which is much larger than that in the conventional powder casting. Trial TWIP castings at both the pilot and the plant caster showed stable mold performances such as mold heat transfer. Also, cast slabs showed periodic/sound oscillation marks and little defects. The successful casting of TWIP steel has been attributed to the following characteristics of POCAST: dilution of the reactant by increasing the slag pool depth, enlargement of channel for slag film infiltration at meniscus by elimination of the slag bear, and decrease of apparent viscosity of the mold slag at meniscus by increasing the slag temperature.     

280 mm×380 mm方坯连铸结晶器钢水流场的数值模拟

借助商业软件CFX4.4,对拉速0.8 m/min、两孔浸人式水口结构内腔中的钢水流动和(mm)280×380 ×800结晶器内70L(0.70%C)钢水流场进行了数值模拟。结果表明,侧孔倾角度10°、20°时,结晶器液面附近有二次漩涡出现,易造成卷渣;倾角30°时,液面相对平静;水口插入深度175~225 mm时,水口射流对结晶器钢水液面没有明显的冲击。     

160 mm×160 mm小方坯连铸结晶器内流场数值模拟

采用Fluent软件对断面为160 mm×160 mm小方坯结晶器建立了三维稳态数学模型,以结晶器表面流速以及结晶器内钢液的流场状态为主要参考目标,模拟研究了160 mm×160 mm小方坯结晶器在不同拉速条件下相适应的水口浸入深度,并对数值模拟结果相应地进行了水模拟验证。结果表明,当小方坯结晶器的拉速为1.7 ～1.9 m/min、浸入深度为80～100 mm时,结晶器内流场较为适宜,不会因液面波动剧烈而造成卷渣等问题。研究结果为小方坯连铸结晶器制定合理的浇注工艺提供了理论指导。     

Computational Modeling of Temperature, Flow, and Crystallization of Mold Slag During Double Hot Thermocouple Technique Experiments

A three-dimensional finite-difference model has been developed to study heat transfer, fluid flow, and isothermal crystallization of mold slag during double hot thermocouple technique (DHTT) experiments. During the preheating stage, temperature in the middle of the mold slag sample was found to be significantly [~350 K (~77 °C)] lower than near the two thermocouples. During the quenching stage, the mold slag temperature decreases with the cooled thermocouple. The temperature across the mold slag achieves a steady, nonlinear temperature profile during the holding stage; the insulating effect of the crystallizing layer in the middle of the slag sample causes the high temperature region to become hotter, while the lower temperature mold slag becomes cooler. Fluid flow is driven by Marangoni forces along the mold slag surface from the hotter region to the cooler region, and then recirculates back through the interior. Slag velocities reach 7 mm/s. Crystallization is predicted to start in the middle of the slag sample first and then grows toward both thermocouples, which matches well with observations of the DHTT experiment.     

板坯连铸结晶器内钢液表面流速的水模型研究

以承德钢铁厂板坯连铸结晶器为原型,采用1∶1的水模型进行试验,研究了拉速、浸入式水口出口角度、水口浸入深度、水口底面结构及结晶器断面宽度等工艺参数对板坯结晶器内表面流速的影响。结果表明:拉速对表面流速的影响最大,随着拉速的提高,结晶器内钢液表面流速明显增大,当断面宽度为1 650 mm,拉速由0.7 m/min提高到1.4 m/min,表面流速由0.04 m/s提高到0.1 m/s;波浪面结构的浸入式水口表面流速效果最优。     

立式板坯连铸机结晶器内流场的数值物理模拟

采用1:1的水模型研究了200 mm×1:300 mm立式板坯连铸结晶器内流场和在水口浸入深度115mm、拉坯速度0.55 m/min时水口结构参数(侧孔尺寸40 mm×40 mm～40 mm×80 mm,侧孔角度+15。～一15。)对液面波动的影响,基于流体力学计算,利用Fluent软件和采用κ-ε双方程高雷诺数湍流模型对板坯结晶器内的流场进行了三维数值模拟。结果表明,数值模拟结果与物理模拟结果较吻合;水口结构参数对液面湍动能的影响较明显;在1~#～4~#水口中,2~#水口(40 mm×40 mm,+15°,向下,倒Y形底部)的使用性能相对较好;流股的冲击速度越浅,自由液面湍动能越大。     

板坯结晶器内流场作用下钢液传热凝固的数值模拟

以钢厂230 mm×2 150 mm板坯连铸机为研究对象,通过三维数值模拟分析了拉坯速度(0.8～2.3m/min)、水口浸入深度(100～200 mm)、铸坯宽度(1 100～2 150 mm)对结晶器内流场作用下的钢液传热、凝固特征的影响。结果表明,拉坯速度等参数变化不会改变结晶器内钢液流动的基本特征,但会显著影响到结晶器内窄边坯壳的发育状况。水口浸深、铸坯宽度和拉坯速度的变化对于结晶器熔池液面钢水过热度也有不同程度影响:小断面,大拉速和水口浸入深度较小时熔池液面过热度较大,最大达6.2 K。     

Effect of EMBr on Flow in Slab Continuous Casting Mold and Evaluation Using Nail Dipping Measurement

The nail dipping method was developed to investigate the effect of electromagnetic brake on the mold top surface flow in a certain slab caster with different casting speed and submerged entry nozzle (SEN) depth. The shape of the meniscus profile and direction of flow were quantified by analyzing the angular profile of the lump for each solidified nail, and the error evaluation for the nail dipping measurement was also determined. The results show that the meniscus level fluctuates with time variation; the electromagnetic force suppresses the high‐speed flow and decreases the meniscus flow velocity, which makes the meniscus level flatter and slower. A stronger meniscus velocity and fluctuation were created by increasing casting speed and decreasing the SEN depth. Furthermore, the effect of magnetic field on the fluid flow in the mold has been investigated.     

圆坯钢电磁软接触连铸的实验研究

为确定工业实验基本参数,对电磁软接触连铸结晶器进行了优化设计计算,设计制作了φ100 mm圆坯电磁软接触连铸结晶器,利用Sn-Pb-Bi合金实验研究了结晶器内的弯月面行为,并进行了w(C)为0.22%钢坯的电磁软接触连铸实验。结果表明,电磁软接触连铸结晶器内磁场和弯月面变形具有不均匀性,切缝数为12时,磁场周向分布和弯月面变形较均匀。输入功率增加,弯月面高度增高,液面波动加剧。对于100 mm圆坯电磁软接触连铸系统,功率可控制在50~60 kW左右。实际应用中,浇注液面应控制在线圈中心偏上位置。较低的电源频率可获得较高的弯月面,频率应控制在20 kHz左右,可获得较高的周向均匀的磁场。获得了表面质量改善的电磁软接触连铸钢坯。随功率增加,铸坯表面依次会出现环状振痕、无振痕和波纹状振痕等3种振痕形态。     

Online Measurement for Transient Mold Friction Based on the Hydraulic Oscillators of Continuous-Casting Mold

The interaction of the strand shell surface and mold copper plates has significant effects on the slab surface quality and casting productivity. This article focuses on developing a reliable approach to measure the transient friction force between the slab and the mold for the purpose of the investigation of lubrication and friction behavior inside a mold. This method is presented to monitor transient mold frictions for the slab continuous caster equipped with hydraulic oscillators. A mathematical model is also developed to calculate the empty working force of the no casting state, and a new algorithm, based on the particle swarm optimization, is proposed to predict the dynamic characteristic parameters of mold oscillation. The results have shown that the method has a sufficient sensitivity to variation, especially to the periodical variation of the mold friction, and it has been identified that the transient mold friction can be used as an effective index with regard to detecting mold oscillation and optimizing the casting parameters for process control. It may lay the practical foundation for the online detection of powder lubrication and the visualization of the continuous-casting mold process.