Flow Dynamics studies for Flexible Operation of Continuous Casters

Important results from the project

The project focus is to perform flow dynamics studies of the CC process based on advanced numerical/physical models and plant trials in order to assess the performance/optimize 2 types of SEN named as Cup and Mountain. In summary the project aims: 1)To study the flow pattern to determine what´s the optimal flow in the mould for a variety of slab sizes. 2)To produce an optimized nozzle design that achieves such optimal flow and improves process stability. 3)To build and test the optimized nozzles in an Experimental Casting Simulator and industrial casters to determine their efficiency.

Expected long term effects

A series of objectives have been fulfilled to achieve the project aims: 1)Developing advanced numerical models. 2)Evaluating and optimizing process parameters and nozzles design in a modified experimental Continuous Casting Simulator. 3)Testing new nozzles designs in industrial casters to evaluate their efficiency and performance. This takes the steelmakers one step closer to choose nozzles through CFD and/or casting simulator tests rather than expensive “trial-error” experiments in the plant.

Approach and implementation

An advanced CFD capable of predicting transient meniscus behavior and SEN performance was developed. Furthermore, a modified CC Simulator has been used to assess the CC process. Then, CFD simulations were successfully validated with the simulator results. Finally, these tools combined with plant trials used to design and test different SEN types in order to optimize their flow pattern and performance.