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Modeling of Multiphase Flow, Superheat Dissipation, Particle Transport, and Capture in a Vertical and Bending Continuous Caster

A new model of particle entrapment during continuous casting of steel is presented, which includes the effects of multiphase flow from argon gas injection and thermal buoyancy from superheat in the strand. The model simulates three different capture mechanisms, including capture by solidified hooks at the meniscus, entrapment between dendrites, and engulfment by the surrounding of large particles. The fluid flow and bubble capture results are validated with plant measurements, including nail board dipping tests and ultrasonic tests, respectively, and good agreement is seen. Results suggest that the superheat has a negligible effect on the flow in the mold region. However, higher (30 K) superheat causes a more complex flow in the lower strand by creating multiple recirculation zones due to the thermal buoyancy effects. This causes less penetration deep into the strand, which leads to fewer and shallower particle captures. 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, which sometimes (0.003%) capture large (1 mm) bubbles. Capture bands occur near the transition line from vertical to curved, due to the downward fluid velocity balancing the particle terminal velocity, enabling capture in the relative stagnation region beneath the longitudinal recirculation zone. These findings agree with plant observations.