Numerical & physical modelling of fluid flow in a continuous casting mould : Flow dynamics studies for flexible operation of continuous casters

Sammanfattning: The current demands on Swedish steel industry to produce low quantity batches of specialized products requires research on steel casting processes. There are several physical processes that need be taken into account for this problem to be viewed in full light such as thermal-processes, solidification and fluid dynamics. This work focuses on the fluid-dynamics part; more specifically, the dependence of flow quality within the caster on nozzle and mould geometry. The simulations are carried out using a scale-resolving method, in specific LES (Large Eddy Simulation) which is coupled with a DPM (Discrete Phase Model) to model Argon behaviour. The results of these simulations are presented and validated against physical experiment and data from industrial trials. Conclusions are drawn regarding optimal nozzle types in respect to different mould geometries. The mould eigenfrequencies are shown to exhibit a connection with the casting velocity. This results in so called sweet spots in casting velocity where flow irregularities due to sloshing is minimal. It is shown that the mountain type nozzle is preferable for smaller geometries whilst comparatively larger geometries benefit from a cup type.