Validation of Fluid Flow and Solidification Simulation of a Continuous Thin-Slab Caster
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1 Validation of Fluid Flow and Solidification Simulation of a Continuous Thin-Slab Caster Brian G. Thomas 1, Ron O'Malley 2, Tiebiao Shi 1, Ya Meng 1, David Creech 1, and David Stone 1 1 University of Illinois at Urbana-Champaign, Department of Mechanical and Industrial Engineering, 1206 West Green Street, Urbana, IL USA, AK Steel Research 703 Curtis Street Middletown, Ohio 45043
2 Acknowledgements Continuous Casting Consortium AK Steel, Columbus Steel, LTV Steel, National Science Foundation (Grant DMI ) NCSA (computing time and use of CFX) AK Steel (water model and plant measurements) M. Langeneckert and G. Webster (finite element analysis of the mold) Allegheny Ludlum Corp., Ispat-Inland Steel, Stollberg Inc.
3 Objective Validate fluid flow and solidification models with extensive measurements: velocities within the liquid pool (from water models) temperatures measured in the molten steel pool (plant trial) temperatures measured in the copper mold walls (mold thermocouples) heat flow rate (heat balance on the mold cooling water) thickness of the solidified steel shell (from breakout shell measurements)
4 The Continuous Casting Process B.G. Thomas
5 Thin Slab Casting Mold
6 Fluid Flow Model 3D Domain and Mesh of ¼ of Liquid Pool: Includes 3-port nozzle Standard high-re K-ε turbulence model and wall laws Solidification front (boundary): liquidus temperature Predicts velocities and superheat distribution
7 3-D K-e Simulation Water Model
8 Water Model Flow Velocity (m/s) Calculated Speed (Jet Centerline) Calculated Speed (Average) Measured Speed Velocity Along Flowing Jet (Calculated and Water Model Measurements) Horizontal Distance from Mold Center (mm)
9 Pour Molten Steel Temperature (Model Validation) Superheat (C) Probe (insertion) Probe (withdrawal) Model SEN Profile Location Middle Point Measurement Position NF Distance below the Meniscus (mm) Liquidus 56 C superheat 1505
10 Superheat Flux Profiles (Calculated Around the Exterior of the Strand Surface) 0 Distance below Meniscus (m) Corner Wideface centerline Narrow face centerline SuperHeat Flux from liquid to shell (KW/m 2 )
11 Temperature Contours in 3-D Portion of Mold Wall Wide Face
12 Instrumented Mold (106 Thermocouples) Dist (mm)
13 Heat Flux and Cooling Water Heat Balance Heat Flux (MWm -2 ) Wide Face Narrow Face Unit : o C Wide Face Narrow Face Distance below Meniscus (mm) measurements Steady state Breakout shell CON1D predicted
14 Temperatures Down Mold Walls (Calculated and Measured at Thermocouple Locations) Temperature (C) Wide Face IR WF 325 mm East of of CL IR WF 75 mm East of of CL IR WF 75 mm west of of CL IR WF 325 mm west of of CL OR WF 325 mm East of of CL OR WF 75 mm East of of CL OR WF 75 mm west of of CL OR WF 325 mm west of of CL CON1D predicted WF Distance from Top of Mold (mm) Temperature (C) Narrow Face East NF center West NF center CON1D predicted NF Distance from Top of Mold (mm) CON1D calculation offset: 4.5mm 10.3mm
15 Solidification and Heat Transfer Model: CON1D 4 Heat flux 3 Peak near meniscus Copper Mold and Gap 2 (MW/m 2 ) Heat flux Distance below meniscus (mm) Heat Removed from shell surface to gap (q ) int Water Spray Zone z top of mold x 1500 ÞC 1400 ÞC 1300 ÞC 1200 ÞC 1100 ÞC Solidifying Steel Shell 23 mm 1.0 Meniscus (MW/m 2 ) Wide face (Very little superheat ) Narrow face (Peak near mold exit) Heat Input to shell inside from liquid (q ) sh Liquid Steel Mold Exit 1-D transient finite-difference model of solidifying steel shell 2-D steady-state heat conduction within the mold wall detailed treatment of interfacial gap including mass and momentum balances on slag layers uses superheat flux from flow model predicts: -shell thickness down the mold -temperature in the mold and shell -slag layer thicknesses (solid & liquid) -heat flux down the mold -mold water temperature rise -ideal taper of mold walls
16 Solid Fraction Effect on Steady-state Shell Thickness 20 Shell Thickness (mm) fs=0 fs=0.1 fs=0.3 fs=0.7 fs= Distance below meniscus (mm)
17 Section through slab showing longitudinal crack that started breakout Narrow Face Centerline
18 Casting Conditions & Simulation parameters Casting Speed: 1.524m/min Pour Temperature: 1563 o C (61 o C superheat) Slab Size: 984mm*132mm Mold Length: 1200mm Nozzle Submerge depth: 127mm Mold Powder Consumption Rate: 0.48kg/m 2 Mold Thickness: wide face 35mm; narrow face 25mm Steel Grade: 434 Stainless Steel Inlet Cooling Water Temperature: 25 o C Fraction Solid for Shell Thickness Location: 0.1
19 Events during breakout Distance below steady-state meniscus (mm) Estimated liquid level Bottom of breakout hole mold exit t 0-57 t t t 0-30 t t Top of breakout shell Measured liquid level Time (s) t 0
20 Shell Thickness Along Wide Face (WF) (Calculated Compared with Breakout Shell Measurements) Shell Thickness (mm) Solidifcation Time (s) IR WF 86mm East of CL IR WF 86mm West of CL OR WF 86mm East of CL OR WF 86mm West of CL CON1D Transient CON1D Steady-State Distance below Meniscus (mm)
21 Shell Thickness Along Wide Face (WF) (Calculated Compared with Breakout Shell Measurements) Shell Thickness (mm) Solidifcation Time (s) IR WF 86mm East of CL IR WF 86mm West of CL OR WF 86mm East of CL OR WF 86mm West of CL IR WF 238mm East ofcl IR WF 238mm West of CL OR WF 238mm East of CL OR WF 238mm West of CL CON1D Transient CON1D Steady-State Distance below Meniscus (mm)
22 Shell Thickness Along Narrow Face (NF) (Calculated Compared with Breakout Shell Measurements) 30 Solidifcation Time (s) Shell Thickness (mm) East NF Center West NF Center CON1D Transient CON1D Steady-State Distance below Meniscus (mm)
23 Model Applications These validated modeling tools can now be applied to study related phenomena of practical significance in a quantitative manner, which include: ideal taper of the mold walls to match the shell shrinkage, critical shell thickness to avoid breakouts, behavior of flux layers in the interfacial gap, crack formation, relationships between mold wall temperatures and events in solidifying shell to enable online quality prediction.
24 Conclusion An efficient model of 3-D turbulent flow, heat transfer and solidification in a thin slab caster has been developed, featuring one-way coupling between K-ε flow model (CFX) and 1-D transient model of heat transfer in the mold, interface, and solidifying steel shell (CON1D). The accuracy of this modeling approach has been demonstrated by comparison with experimental measurements of fluid flow in the liquid pool, temperature in the molten steel, temperature in the copper mold walls, temperature increase of the cooling water, and breakout shell thickness.
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