Abstract
A transient numerical model was proposed and validated by the current authors for nozzle clogging (Barati et al. in Powder Technol 329:181-98, 2018). The model can reproduce the experiment in pilot scale satisfactorily. In the present article, the main objective is to validate the model for application in industry process continuous casting of steel, referring to the model accuracy and calculation efficiency. The results have shown that for the complex geometry of submerged entry nozzle (SEN), where it is difficult to create hexahedron mesh in the entire domain, a mixed mesh type is recommended, i.e., the wedge mesh for regions adjacent to SEN walls and the tetrahedron mesh for inner regions. Another challenge to the calculation of real SEN clogging is the huge number of particles involved in the industry process. An artificial factor, the N-factor, has to be introduced to reduce the calculation cost. A dimensionless number (α) is defined to limit the N-factor and ensure the modeling accuracy. Simulation of a test case has indicated that by an appropriate N-factor (1000, corresponding to α = 6 × 10−5), the calculation time would be reduced significantly to a reasonable time.
Highlights
NOZZLE clogging describes a phenomenon of the blockage of the flow passage, which is due to a gradual buildup of solid materials on the nozzle wall
The wall roughness height enhanced by particle deposition at the initial stage is shown by contours on the wall
Before 20 seconds, almost no difference can be seen for all four cases; a horizontal clogging band is seen on the top edge of the clogging area and several spots are shown near the symmetry planes, corresponding to the result of Figure 4
Summary
NOZZLE clogging describes a phenomenon of the blockage of the flow passage, which is due to a gradual buildup of solid materials on the nozzle wall. This buildup of solid materials would disturb the fluid flow in the passage before the blockage. During the continuous casting of steel, clogging of the submerged entry nozzle (SEN) is a long-term problem leading to undesired issues or even process disruptions.
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