Effect of Submerged Entry Nozzle Design on Fluid Flow Dynamics Inside the Thin Slab Caster Mold

In the present study, a design modification study for submerged entry nozzle (SEN) in funnel shape mold was conducted to enhance meniscus stability and fluid flow characteristics. State-of-the-art 1:1 scaled water model was used to study the effects of casting speed (3.5 to 6 m/min) and submergence depth (240–320 mm) on fluid flow behavior and slag entrainment for the two SEN designs. Extensive flow visualization experiments were performed using methylene blue dye. Meniscus velocity measurements using a vane anemometer sensor were performed. Plant trials in actual thin slab caster mold confirmed the laboratory findings. Increasing the casting speed from 3.5 to 6 m/min increased the maximum sub-meniscus velocity from 0.29 to 0.44 m/s. Dye injection confirmed that SEN 2 created the necessary double-roll fluid flow pattern with improved meniscus stability. Plate dipping tests at the plant also indicated that SEN 2 was a more suitable choice over SEN 1 in terms of meniscus turbulence.