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/m and the instantaneous peaks exceed 1500 kW/m. 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/m. Employing a static-k subgrid-scale (SGS) model into the three-dimensional (3-D) finite-volume code had little effect on the solution.