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Modelling of Meniscus Behavior and Slag Consumption During Initial Casting Stage of Continuous Casting Process

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Abstract

The behavior of the meniscus region is crucial to the surface quality of continuous cast steel. A two-dimensional model was developed to study the evolution of the meniscus region during the initial casting stage of continuous casting process. The flow of multiphase fluids, transient heat transfer, melting and re-solidification of slag, and the solidification process of the steel shell were also considered in the model. The calculated results show a good agreement with experimental data of previous literature, which demonstrates the reliability of the model in predicting the behavior of the meniscus region. After the start of withdrawal, liquid slag infiltrates into the gaps, forming a slag layer structure composed of liquid slag films and solid slag films between the shell and the mold. As the distribution of each phase approaches stability, the initial shape of the meniscus was established. During the initial casting stage, as the casting speed increases, the curvature of the meniscus increases, accompanied by an elevated level of heat transfer within the meniscus region. Furthermore, from the perspective of the associated heat transfer and fluid flow variations during the increase in casting speed, the reasons for the decrease of the depth of the oscillation mark and the slag consumption are explained. This study provides new insights into the continuous and complex flow and heat transfer behavior within the meniscus region during the initial casting stage of continuous casting process.

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Abbreviations

\(\overline{v}\) :

Mean velocity vector (m s−1)

\(\overline{p}\) :

Mean pressure (Pa)

v T :

Turbulent Kinematic Viscosity (m2 s−1)

g :

Gravity vector (m s−2)

ρ :

Density of the mixtured (kg m−3)

F σ :

Surface tension (N m−1)

S mush :

Sink term (m s−3)

S k :

A user defined source term (kg m−1 s−3)

G k :

Generation of turbulent kinetic energy (kg m−1 s−3)

Y k :

Dissipation of turbulent kinetic energy (kg m−1 s−3)

Γ k :

Effective diffusivity of the turbulent kinetic energy (kg m−1 s−1)

Γ w :

Effective diffusivity of the specific dissipation (kg m−1 s−1)

T fsol :

Temperature chosen to fit the power law to experimental viscosity data (K)

Y w :

Dissipation of the specific dissipation (kg m−3 s−2)

S w :

A user defined source term (kg m−3 s−2)

ρ p :

Density of the steel phase (kg m−3)

ɑ q :

Volume fraction in the cell in the steel phase

ρ q :

Density of the slag phase (kg m−3)

ɑ p :

Volume fraction in the cell in the slag phase

S ɑ q :

A source term

T sol :

Solidus temperature (K)

T liq :

Liquidus temperature (K)

H :

Enthalpy in a given cell (J kg−1 K−1)

H :

Sensible enthalpy (J kg−1 K−1)

∆H :

Latent heat (J kg−1 K−1)

L :

Latent heat of the material (J kg−1 K−1)

A mush :

Mushy parameter

K :

Thermal Conductivity (W m−1 K−1)

\(\varphi\) :

Represents the turbulence parameter

v c :

Casting speed (m s−1)

ρ slag :

Density of the slag (kg m−3)

ρ steel :

Density of the steel (kg m−3)

Y :

Height of domain (mm)

Y Fe :

Steel surface level (mm)

S t :

Stroke (mm)

v m :

Velocity of mold (m s−1)

p m :

Position of mold (mm)

f :

Frequency (Hz)

k f :

Fluid thermal conductivity

k a :

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

T f :

The temperature of fluid (K)

T s :

The temperature of solid (K)

µ 0 :

Reference viscosity of slag at T0 (Pa s)

µ :

Dynamic viscosity (Pa s)

G w :

Generation of specific dissipation (kg m−3 s−2)

T 0 :

Reference Temperature

S :

Shell thickness (mm)

K :

Solidification factor (mm s−2)

P(x) :

Distribution of axial pressure (Pa)

T f,sol :

Solidus temperature of slag (K)

T m :

Temperature of mold hot face (K)

q f :

Heat flux (MW m−2)

A OM :

The area of oscillation mark (m2)

R f :

Thermal resistance (m2 K W−1)

q OM :

Oscillation mark consumption (kg m−2)

q lub :

Lubrication consumption (kg m−2)

q OM :

Oscillation mark consumption (kg m−2)

q tol :

Total consumption (kg m−2)

A OM :

The area of oscillation mark (m2)

k f :

Slag thermal conductivity (W m−1 K−1)

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Acknowledgements

The authors gratefully acknowledge the financial support of National Key Research and Development Plan (No. 2021YFB3702000) and National Natural Science of China (Nos. 52074076, 52174306 and U20A20272) and Fundamental Research Funds for the Central Universities (No. N2225023).

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Authors and Affiliations

  1. Key Laboratory for Ecological Metallurgy of Multimetallic Mineral (Ministry of Education), Northeastern University, Shenyang, 110819, Liaoning, China

    Wenjie Tong, Sen Luo, Weiling Wang & Miaoyong Zhu

  2. School of Metallurgy, Northeastern University, Shenyang, 110819, Liaoning, China

    Wenjie Tong, Sen Luo, Weiling Wang & Miaoyong Zhu

  3. Institute of Steel Sustainable Technology, Liaoning Academy of Materials, Shenyang, 110000, Liaoning, China

    Sen Luo, Weiling Wang & Miaoyong Zhu

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  1. Wenjie Tong
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Correspondence to Sen Luo or Miaoyong Zhu.

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Tong, W., Luo, S., Wang, W. et al. Modelling of Meniscus Behavior and Slag Consumption During Initial Casting Stage of Continuous Casting Process. Met. Mater. Int. (2024). https://doi.org/10.1007/s12540-024-01629-5

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