Analysis of flux flow and the formation of oscillation marks in the continuous caster

In the industrial process of continuous steel casting, flux added at the top of the casting mould melts and forms a lubricating layer in the gap between the steel and the oscillating mould walls. The flow of flux in the gap plays an essential role in smoothing the casting operation. The aim of the present work is to better understand the mechanics of flux flow, with an emphasis on such problems as how the flux actually moves down the mould, the physical parameters governing the consumption rate of the flux and the geometry of the lubricating layer. The problem considered is a coupled problem of liquid flow and multi-phase heat transfer. In the first part of the paper, the formation of the lubricating layer is analysed and a set of equations to describe the flux flow is derived. Then, based on an analysis of the heat transfer from the molten steel through the lubricating layer to the mould wall, a system of equations correlating the temperature field in the steel and flux with the geometry of the lubricating layer is derived. Subsequently, the equations for the flux flow are coupled with those arising from heat-transfer analysis and then a numerical scheme for the calculation of the consumption rate of flux, the geometry of the lubricating layer and the solidification surface of the steel is presented.