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Simulation of Argon Gas Flow Effects in a Continuous Slab Caster

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Abstract

Three-dimensional finite-volume-based numerical models of fluid, heat, and mass transport have been developed and applied to help explain the complex inter-related phenomena of multiphase fluid flow, superheat dissipation, and grade intermixing during the continuous casting of steel slabs. Gas bubbles are simulated using a continuum model, which calculates the volume fraction and velocities of the gas, and its effect on the liquid flow. Turbulence has been incorporated using the standardK-ε turbulence model. Reasonable agreement has been achieved between predicted velocities and corresponding measurements and observations in full-scale water models, both with and without gas injection. The effects of argon gas bubble injection on flow-related phenomena are investigated with simulations of a typical steel slab caster. Argon bubbles alter the flow pattern in the upper recirculation zone, shifting the impingement point and recirculation zones upward. The effect increases with increasing gas fraction and decreasing bubble size. Argon injection also causes superheat to be removed higher in the caster, moves the hot spot upward, lowers the peak heat flux, and increases heat extraction from the wide face and meniscus regions. During a steel grade transition, argon injection slightly affects slab surface composition but has no effect on intermixing in the slab interior.

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Abbreviations

C:

relative concentration in strand

C:

p specific heat (liquid steel) (J kg−1 K−1)

Deff :

effective diffusivity (liquid) (m2 s−1)

Do :

molecular diffusivity (liquid) (m2 s−1)

Dg :

apparent gas bubble diffusivity (m2 s−1)

dg :

diameter of gas bubbles entering mold (mm)

dgi :

diameter of gas bubbles at injection point in nozzle (mm)

E :

wall roughness constant (inK-ε wall laws)

F :

mass fraction of a given element

h :

heat transfer coefficient (top surface) (W m−2

K−1)K :

turbulent kinetic energy (m2 s2)

Ko :

turbulent kinetic energy (at inlet to mold) (m2 s−2)

ko :

laminar thermal conductivity (W m−1 K−1)

Kshell :

solidification constant (m s−0.5)

L o :

nominal nozzle submergence depth (from top surface to top of nozzle port) (m)

Lh :

inlet height (mm)

Lw :

inlet width (mm)

Ln :

jet submergence depth (from top surface to top of the jet) (m)

N :

strand thickness (across narrow face) (m)

n :

normal direction of boundaries

p :

static pressure (relative to outlet plane of domain) (N s−2)

Pr0 :

laminar Prandtl Number, (Cpμ0k -10 )

Prt :

turbulent Prandtl Number

Qg :

gas injection rate (entering nozzle gate) (m3 s−1)

Re:

Reynolds number (Vc√NWρμ -10 )

qsh :

superheat flux from liquid steel to solidifying shell (W m−2)

Sct :

turbulent Schmidt number(μ,ρ −1D -1g ) T temperature (°C)

To :

casting temperature (pour temperature) (at inlet to mold) (°C)

Tliq :

liquidus temperature (°C)

Tsol :

solidus temperature (°C)

T∞ :

ambient temperature (°C)

Vc :

casting speed (m s−1)

vgt :

gas bubble terminal velocity (m s−1)

vgx :

gas velocity component inx direction (m s−1)

vgy :

gas velocity component iny direction

(m s−1)vgz :

gas velocity component in z direction (m s−1)

vx :

liquid velocity component inx direction (m s−1)

Vx0 :

liquid normal velocity through inlet to mold (m s−1)

vy :

liquid velocity component in y direction (m s−1)

Vy0 :

liquid horizontal velocity through inlet to mold (m s−1)

vz :

liquid velocity component in z direction (m s−1)

vz0 :

liquid downward velocity through inlet to mold (m s−1)

W :

strand width (across wide face) (m)

Z:

strand length simulated (m)

z:

distance down strand or slab (m)

α :

jet angle at inlet (Figure 6) (°)

α0 :

nominal angle of nozzle port edges at inlet (Figure 6) (°)

ΔTS :

superheat temperatureT o - Tliq (°C)

ε:

dissipation rate (m2 s−3)

ε0 :

inlet dissipation rate (m2 s−3)

μeff :

liquid effective viscosity (kg m−1 s−1)

μo :

liquid laminar (molecular) viscosity

(kg m−1 :

s−1)

μi :

liquid turbulent viscosity (kg m−1 s−1)

ρ:

liquid density (kg m−3)

σg :

gas volume fraction (Pct)

σgo :

gas volume fraction (at inlet to mold) (Pct)

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, 61801, Urbana, IL

    B. G. Thomas (Associate Professor) & X. Huang (Postdoctoral Research Associate)

  2. Armco, Inc., 45043, Middletown, OH

    R. C. Sussman (General Manager of Process Research)

Authors
  1. B. G. Thomas
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  2. X. Huang
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  3. R. C. Sussman
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Thomas, B.G., Huang, X. & Sussman, R.C. Simulation of Argon Gas Flow Effects in a Continuous Slab Caster. Metall Mater Trans B 25, 527–547 (1994). https://doi.org/10.1007/BF02650074

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