Fluid flow modeling of a curved continuous slab casting mold

平板产品制造商面临着不断提高生产率的压力，同时由于客户对质量的严格要求，他们要保持连铸钢板的高质量。然而，提高生产率对板坯质量有不利影响，缺陷和次品对生产者的底线有重大影响。控制连铸中间包和结晶器内的流体流动是保证钢的清洁度和减少缺陷的关键参数之一。物理和数学建模是理解和优化连铸流体流动的绝对必要的工具。该项目将处理模具中的流体流动优化，这是STELCO与多伦多大学合作的动机。多伦多大学将建立一个创新的水模型设施，以了解模具中的多相流。为了使水模型逼真，将建立1/2比例的水模型弯曲模具，并复制塞杆和SEN的精确几何形状。包括3D打印和CNC加工在内的创新制造技术将用于重建复杂的喷嘴设计。其目标是提高铸型机的生产效率，提高产品质量。该项目将确定与以下方面相关的解决策略(a)优化模具中的氩气注入(b)最大限度地减少条子缺陷(c)最大限度地减少由于弯曲模具而导致的凝固壳中的夹杂物夹带(d)铸造窄的SEN设计，宽板坯和超宽板坯(e)低速铸造与高速铸造的SEN设计(f)半月板波动和结晶器粉末夹带(g)通过f值优化量化结晶器流动指数(h)通过有效的SEN设计将SEN堵塞最小化。通过改进连铸工艺和提高钢材质量，预计每年节省的成本将超过300万美元，这与STELCO的战略愿景和业务目标是一致的，并将立即产生效益。该项目完成后的五年内将产生1500万美元的经济影响，并将显著促进安大略省的制造业。

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.