Fluid flow modeling of a curved continuous slab casting mold

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Flat product manufacturers are under constant pressure to increase productivity, and simultaneously maintain high quality of continuously cast steel slabs because of stringent quality demands imposed by their customers. However, increasing productivity has detrimental effects on slab quality, and defects and rejections have a major impact on the producers bottom-line. Controlling fluid flows in continuous casting tundishes, and moulds is one of the key parameters to ensure cleaner steel and reduce defects. Physical and mathematical modelling is an absolutely essential tool to understand and optimize fluid flows in continuous casting. This project will deal with fluid flow optimization in the moulds, and that is the motivation of STELCO to collaborate with the University of Toronto. U of T will build an innovative state of the art water model facility to understand multiphase flow in moulds. In order to make the water model realistic, a 1/2 scale water model curved mould will be built, and exact geometries of the stopper rod and SEN will be replicated. Innovative manufacturing techniques including 3D printing and CNC machining will be used to reconstruct complex nozzle designs. The goal is to increase caster productivity and improve product quality. The project will identify solution strategies related to the following aspects (a) Optimized argon injection in moulds (b) Minimizing Sliver defects (c) Minimizing inclusion entrapment in the solidified shell due to curved mould (d) SEN design for casting narrow, wide and ultra wide slabs (e) SEN design for low speed casting versus high speed casting (f) Meniscus fluctuations and mould powder entrapment (g) Quantification of mould flow index through F value optimization (h) Minimization of SEN clogging through effective SEN design. The cost savings arising from improving the continuous casting process and enhancing steel quality is expected to exceed $3 million/year which is aligned with STELCO'S strategic vision and business goals, and will create immediate benefits. There will be an economic impact which translates to $15 Million within five years after completion of this project and will significantly boost the manufacturing sector of Ontario.