Академический Документы
Профессиональный Документы
Культура Документы
791798
A three-dimensional full-coupled mathematical model is established to study the fluid flow, heat transfer
and solidification in a 450 mm 350 mm 90 mm beam-blank mold with two different types of submerged
entry nozzle (SEN), namely single-port straight SEN and three-port radial flow SEN. Water modeling experiments, industrial trials and public results available in literature are performed to validate the numerical
results. The results show that, with the straight SEN which has been widely applied in beam-blank continuous casting, there is a very inactive top free surface in the mold which level fluctuation magnitude is less
than 1 mm and velocity magnitude is far from a reasonable interval, and the shell thickness distribution at
the mold exit is very uneven, thick at the web but thin at the fillet. Moreover, there exists a wavy contour at the flange due to the washing effect of the off-center molten steel jet. While with the new
designed radial flow SEN, a suitable meniscus status and a more uniform shell thickness at the mold exit
can be obtained, which is helpful to avoid the breakouts caused by the rupture of thin fillet and the flange
depression. The self-braking effect caused by two radial flow SENs provides good flow stability at the
web center.
KEY WORDS: beam-blank; continuous casting; submerged entry nozzle; transport phenomena; numerical
simulation.
1. Introduction
Recently, as a near-net-shape continuous casting technique, the need of beam-blank steel has been experiencing
a dramatic rapid increase and more than ten beam-blank
continuous casting machines have been put into production
in China due to its special usage, economic advantages and
outstanding mechanical properties. However, there is a common problem that the producers have to face, that is the
quality of continuously cast beam-blank, especially the
crack of the strand. As it is known, most of defects affecting
steel quality in the continuous casting process are associated
with fluid flow in the mold which is largely determined by
the SEN structure.1) SEN structure can strongly affect the
transport phenomena in mold, including meniscus status,
superheat dissipation, solidified shell growth and inclusion
removal. However, the complicated mold geometry shape
creates great difficulties for the design of a suitable SEN.
Although the beam-blank caster was installed at Maanshan
Steel in China in 1998, the simple straight SEN is still widely used. With this nozzle, molten steel is directly open
poured into two ceramic funnels, which are located in the
central flange regions, as shown in Fig. 1. Such pouring
method can give rise to serious problems on the quality of
final products, especially in the production of some new
steel grade, so new types of SEN are necessary to be pro-
Fig. 1.
* Corresponding author: E-mail: myzhu@mail.neu.edu.cn
DOI: http://dx.doi.org/10.2355/isijinternational.55.791
791
Molten steel open poured into ceramic funnels: (a) industrial trial, two nozzles per mold are used for uniform steel
feeding; (b) schematic of upper nozzle and SEN.
2015 ISIJ
2.2.
2. Mathematical Models
2.1. Mathematical Formulations
The general assumptions applied in the present solidification of beam-blank continuous casting can be found
elsewhere.11) There are seven partial equations in the threedimensional mathematical model which are solved by the
algorithm of SIMPLE, including one mass equation, three
momentum equations, two standard k- turbulence
equations12) and one energy equation.13) When the residual
for energy is smaller than 106 and others are smaller than
104, the converged solution is obtained. The general form
of all the partial equations can be written as the form of Eq.
(1).
( ui ) = + S ................. (1)
xi
xi
xi
where is the steel density, ui is the speed in i direction,
is the variables including velocities at three directions, temperature, enthalpy, turbulence energy and its dissipation
rate, xi is the direction, is the coefficient of diffusion and
S is the source term.
To accountant for the macro-solidification process, additional source terms SDarcy10) are added to momentum equations and turbulence equations, as shown in Eqs. (2) and (3),
respectively.
SDarcy_mom = A
fs2
(1 fs )
SDarcy_tur = A
+ 0.001
( ui us,i )
fs2
(1 fs )
+ 0.001
........ (2)
z =
p pmean
( flux ) g
.......................... (4)
Fig. 2.
792
....... (6)
where q is the heat flux, W is the water flow rate, Tslab is the
temperature of the slab surface, Tspray is the temperature of
the spray cooling water, and is a machine-dependent
calibration factor.
3. Results and Discussion
Fig. 3.
Values
Geometry
Mold Length, m
0.8
0.7
Casting parameter
Casting speed, m/min
0.6, 1.0
Superheat, K
20
60100
115
1 791
Solidus temperature, K
1 753
700
272 000
32
7 020
3 000
0.0062
793
2015 ISIJ
Fig. 4.
Top free surface characteristics: (a) level fluctuation, calculate by using Eq. (4); (b) velocity magnitude, which is
defined as ux2 + uy2 , where ux and uy are the velocities in x direction and in y direction, respectively; (c) temperature distribution.
Fig. 4(a) which generates the thinnest liquid flux layer may
prevent the mold powder from penetrating into the gap
between the mold and the solidifying shell, which is not
favorable for the mold lubrication, and the maximum temperature of the top free surface appears at the web center as
shown in Fig. 4(c), and the mold flux at high temperature
locations may be burned, thus, more reoxidation will occur
due to the reaction with air, and therefore reduce the steel
cleanliness. For a suitable meniscus status, the radial flow
SEN with a positive angle should use a submergence depth
deeper than 115 mm and the radial flow SEN with a negative angle could be used at a faster casting speed.
Fig. 5.
Fig. 6.
Flow patterns obtained with different nozzles in the mold at casting speed 1.0 m/min: (a) straight SEN: (b) radial
flow SEN, port angle 15 degree; (c) radial flow SEN, port angle 0 degree; (d) radial flow SEN, port angle +15
degree.
Fig. 7.
Flow pattern in the beam-blank mold: (a) characteristics of straight SEN, locating in an off-center position; (b)
flow field obtained with straight SEN, wide face center-plane, the velocity higher than 0.2 m/s is blanked for a
more clearly visual effect; (c) flow field obtained with straight SEN, three-dimensional arrangement; (d) flow field
obtained with radial flow SEN with port angle 15 degree at casting speed 1.0 m/min.
Fig. 8.
2015 ISIJ
Fig. 9.
Fig. 10.
Temperature distribution along the strand surface in the beam-blank mold and the legend could be found in Fig.
10: (a) flange tip center; (b) web center.
Shell thickness distribution along Z direction, the liquid fraction was set to be 0.2, which stands for a full solidified shell: (a) flange tip center; (b) web center.
Fig. 11.
thinner at the fillet but thicker at the web. The thin solidified
shell thickness of the fillet could be validated by Fig. 15.
According to the experience in a few steelworks, the break-
Fig. 12.
Fig. 13.
Fig. 14.
Comparison of solidified shell thickness at the mold exit: (a) single-port straight SEN with submergence depth 80
mm at casting speed 1.0 m/min; (b) radial flow SEN with port angle 15 degree.
Fig. 15.
Photographs of solidified shell: (a) obtained by adding radioactive tracer to the liquid pool;27) (b) obtained by a
breakout.2)
Fig. 16.
Solidified shell profile: (a) flange depression, from some steelworks in China; (b) calculated shell profile, an
average value of solid fraction 0.5 is chosen in order to have a better view; (c) calculated shell thickness distribution of the flange at the mold exit at casting speed 1.0 m/min.
797
2015 ISIJ
the fillet. With the radial flow SEN, the shell thickness is
thinner at the web center, as shown in Fig. 14(b), and it
should be mentioned that the molten steel jet angle largely
determined by the port angle could influence the heat flux
at the interface of mold cooper and solidified shell,26) so the
shell thickness at the web center as Fig. 14(b) shows should
be treated critically.
Using the single-port straight SEN, the depression sometimes occurs at the flange, as shown in Fig. 16(a). This
defect should be caused by the structure of straight SEN.
The characteristics of this nozzle locating in an off-center
position have been introduced in Fig. 7(a), and the washing
effect results in shell erosion in local thin spots and cause a
wavy contour as shown in Figs. 14(a) and 15(b). The
flange depression indicates that the wavy contour shell
could be unable to withstand the stress of solidified shell
shrinkage process and could be pushed back by the mold
inner surface or the retaining rolls in the secondary cooling
zone.
The simulated shell profile in the beam-blank mold is
shown in Fig. 16(b), and how the impinging molten steel jet
pouring from the straight SEN affects the shell distribution
of the flange can be found. Fig. 16(c) clearly shows that the
shell thickness of the flange at the mold exit is very nonuniform. Using the radial flow SEN, the shell thickness at
the flange is more uniform and thicker, and may avoid the
flange depression. In addition, shell thickness is the minimum in the position which is about 0.03 m away from the
flange center in Fig. 16(c), this may be induced by the
reverse flow from the web region, as shown in Figs. 7(b)
and 12, because the reverse flow can push the molten steel
jet and change its shape slightly.
of the single-port straight SEN in a beam-blank mold locating in an off-center position are illustrated and the flange
depression is possibly caused by the off-center molten steel
jet washing effect.
(2) The new designed three-port radial flow SEN has
the advantage to obtain an active meniscus status and a uniform shell thickness distribution except the web center. This
type nozzle could decrease the risk of breakouts caused by
the rupture of skin at the fillet and reduce the probability of
flange depression, center looseness and the crack of strand.
(3) The self-braking effect caused by two radial flow
SENs provides a good stability of flow at the meniscus, but
this braking effect could confine a large amount of superheat
to a small region and a further improvement is necessary in
future.
Acknowledgements
The authors would like to thank the financial support
from the Fundamental Research Funds for the Central
Universities No. N130602005.
REFERENCES
1) B. G. Thomas and L. F. Zhang: ISIJ Int., 41 (2001), 1181.
2) L. C. Hibbeler, S. Koric, K. Xu, B. G. Thomas and C. Spangler: Iron
Steel Tech., 6 (2009), 60.
3) W. Chen, Y. Z. Zhang, C. J. Zhang, L. G. Zhu, B. X. Wang, W. G.
Lu and J. H. Ma: Acta Metall. Sin., 20 (2007), 241.
4) J.-E. Lee, T.-J. Yeo, K. H. Oh, J.-K. Yoon and U.-S. Yoon: Metall.
Mater. Trans. A, 31A (2000), 225.
5) H. L. Xu, G. H. Wen, W. Sun, K. Z. Wang, B. Yan and W. Luo: Ironmaking Steelmaking, 37 (2010), 380.
6) W. Luo, B. Yan, X. Lu and G. H. Wen: Ironmaking Steelmaking, 40
(2013), 582.
7) W. Luo, B. Yan, Y. X. Xiong, G. H. Wen and H. L. Xu: Ironmaking
Steelmaking, 39 (2012), 125.
8) Y. Zhao, D. F. Chen, M. J. Long, J. L. Shen and R. S. Qin: Ironmaking Steelmaking, 41 (2014), 377.
9) J.-E. Lee, J.-K. Yoon and H. N. Han: ISIJ Int., 38 (1998), 132.
10) D. R. Poirier: Metall. Trans. B, 18B (1987), 245.
11) H. L. Yang, L. G. Zhao, X. Z. Zhang, K. W. Deng, W. C. Li and Y.
Gan: Metall. Mater. Trans. B, 29B (1998), 1345.
12) D. E. Hershey, B. G. Thomas and F. M. Najjar: Int. J. Numer. Meth.
Fluids, 17 (1993), 23.
13) V. R. Voller and C. Prakash: Int. J. Heat Mass Transfer, 30 (1989),
1709.
14) H. P. Liu, M. G. Xu, S. T. Qiu and H. Zhang: Metall. Mater. Trans.
B, 43B (2012), 1657.
15) F. M. Najiar, B. G. Thomas and D. E. Hershey: Metall. Mater. Trans.
B, 26B (1995), 749.
16) M. Kamal and Y. Sahai: Steel Res. Int., 76 (2005), 44.
17) H. Nam, H.-S. Park and J. K. Yoon: ISIJ Int., 40 (2000), 886.
18) B. G. Thomas, L. J. Mika and F. M. Najiar: Metall. Trans. B, 21B
(1990), 387.
19) J. Savage and W. H. Pritchard: J. Iron Steel Inst., 178 (1954), 268.
20) T. Nozaki, J. L. Matsuno, K. Murata, H. Ooi and M. Kodama: Trans.
Iron Steel Inst. Jpn., 18 (1978), 330.
21) E. Torres-Alonso, R. D. Morales, S. Hernandez-Garcia and J.
Palafox-Ramos: Metall. Mater. Trans. B, 39B (2008), 840.
22) Y. J. Jeon, H. J. Sung and S. Lee: Metall. Mater. Trans. B, 41B
(2010), 121.
23) Y. F. Chen, L. F. Zhang, S. F. Yang and J. S. Li: JOM, 64 (2012),
1080.
24) B. G. Thomas: Fluid Flow in the Mold, Vol. 5, ed. by A. Cramb,
AISE Steel Foundation, Pittsburgh, PA, (2003), 9.
25) L. C. Hibbeler and B. G. Thomas: AIST 2010 Steelmaking Conf.
Proc., AIST, Warrendale, PA, (2010).
26) X. Huang, B. G. Thomas and F. M. Najjar: Metall. Mater. Trans. B,
23B (1992), 339.
27) J.-E. Lait, J. K. Brimacombe, F. Weinberg and F. C. Muttitt: Open
Hearth Conf. Proc., Vol. 56, ISS, Warrendale, PA, (1973), 259.
4. Conclusions
Since there are a number of quality problems in beamblank casting using the straight SEN, such as the weak and
calm meniscus status, non-uniform shell thickness distribution at the mold exit, flange depression and breakouts
induced by the rupture of the fillet, mathematical modeling
has been used to investigate the suitable structure of SEN by
the analysis of the transport phenomena in the mold. In
order to facilitate the comparison and analysis, in all the
simulations, the same thermal boundary is assumed. Though
the Savage and Prichards relation could provide a reasonable tendency to describe the heat flux profile along the
height of the mold, there are unavoidable partial difference
in solidification, especially when the radial flow SEN is
used and the results of solidification should be treated critically.
(1) Using the single-port straight SEN, the major shortcomings are inactive top free surface and non-uniform shell
thickness distribution at the mold exit. Its hard to obtain a
suitable meniscus status by simply changing the SEN submergence depth. Center looseness of a transverse section of
the beam-blank is related with large temperature gradient
caused by molten steel jet from this nozzle. Characteristics
2015 ISIJ
798