Physical and Numerical Modeling of Exposed Slag Eye in Continuous Casting Mold using Euler–Euler Approach

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Gas injection through the submerged entry nozzle (SEN) into the continuous casting mold can be an effective approach for preventing SEN clogging and promoting the floatation of the non‐metallic inclusions. However, sometimes the exposed slag eyes due to gas injection appear on the top surface of the liquid slag layer, resulting in heat losses, re‐oxidation, and nitrogen pickup in the molten steel. An Eulerian multiphase‐flow model is developed to predict the argon‐steel‐slag three‐phase flow in a slab continuous casting mold. All the phases are treated based on Eulerian approach. The mathematical model is compared with the industrial observations and the water model experiments. Both of physical and numerical results reproduce the phenomenon of the high gas concentration at the SEN exit port. Most of the argon bubbles stay below the slag layer for quite long time because the slag blocks their floatation. Furthermore, the argon bubbles would gradually gather in a dense plume while escaping through the slag layer. Scattered argon exit spots are found at the top surface of slag layer. Two main locations of the exposed slag eye are found: 1) adjacent to the SEN; 2) at the mold's mid‐section at the position where a concentrated argon plume breaches through the slag layer. The near‐SEN exposed eye occurs under any of considered conditions. The one at the mid‐section is formed when the meniscus convex reaches a critical level, been dependent on the casting conditions.