Model of multiphase flow, superheat transport, and particle capture in a steel continuous caster

Abstract

A model of turbulent multiphase flow, heat transfer, and particle entrapment during continuous casting of steel is presented. The model includes the top 7m of the vertical and curved strand, and considers the effects of argon gas injection and thermal buoyancy. RANS model flow results are compared with LES. Lagrangian particle transport through the Eulerian-Eulerian multiphase flow field from the k-ɛ RANS model is based on random walk and features advanced particle capture criteria, improved from previous work by including anisotropic turbulent velocity fluctuations near the walls. Particle capture via 3 mechanisms is included: capture by solidified hooks at the meniscus, entrapment between dendrites, and engulfment by surrounding large particles. The fluid flow and bubble/inclusion capture results are validated with plant measurements, including nail board dipping tests and ultrasonic tests of particle locations, and good agreement is seen. The superheat has negligible effect on flow in the mold region but causes complex flow in the lower strand by creating multiple recirculation zones due to the thermal buoyancy. With high (30 K) superheat, this leads to less penetration, and slightly fewer and shallower capture of particles. Lower (10 K) superheat may enable significant top surface freezing, leading to very large internal defect clusters. Lower superheat also leads to deeper meniscus hooks, and more surface capture. Capture bands occur near the transition from vertical to curved, where downward liquid flow velocity balances the particle terminal velocity.