Computational Fluid Dynamic (CFD) Simulation for Continuous Casting Process of Steels

Abstract

A comprehensive numerical simulation of flow behavior of molten steel as well as slag inside tannish and mold of continuous casting machine has been performed using Computational Fluid Dynamics (CFD). Modeling of continuous casting process of steels is very important as fluid flow behavior inside tannish, sub-entry nozzle (SEN) and mold directly influence the quality of steel product. Investigations on inclusion entrapment and the chances of SEN clogging study during continuous casting process for steel are objectives of this thesis work. The outcrop of the developed mathematical model is beneficial to study effect of flow controller (e.g. dam and weir) putting inside tundish on the fluid flow behavior throughout tannish, sub-entry nozzle (SEN) and mold of continuous casting machine. In addition to that, a massless particle is injected from the inlet and the trajectories of the particle inside tundish have been investigated using Discrete Phase Model (DPM) along with k-e turbulence models. All the numerical simulation of fluid flow has been performed using ANSYS 15.0 software. This CFD simulation work demonstrates the correlation of flow controller’s shape, size and position with inclusion flotation possibility and path in tundish. This work also elaborates and shows the significance of flow controller position inside tundish on fluid flow behavior in tundish, sub-entry nozzle (SEN) and mold and quality of steel. The extract and underlying theory for this developed CFD model can be extended to different kinds of CCM process for various metal or metallic alloys to reveal the interrelation between inclusion removal kinetics and fluid flow behavior of molten steel and slag