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Precise control of steel solidificationSolidification rate inside a continuous caster is crucial in ensuring excellent slab cast quality, especially with various steel grades produced. A caster operator must adjust casting conditions like steel superheat temperatureTemperature and spray coolingSpray cooling ratesCooling Rate to maintain consistency in the slab quality. Thus, a tool that accurately predicts the casting conditions and can provide necessary adjustments is valuable to the operator. A comprehensive computational fluid dynamics multiphase model of the continuous caster has been developed. The shell thickness in the caster mold predicted by the CFD model shows good agreement with the experimental results. However, the CFD model is not practical and user-friendly for plant operation use. To address this, an interactive software tool based on CFD simulationSimulation results has been developed. The interactive software predicts solidificationSolidification steel temperatureTemperature and solidificationSolidification in the caster, but it is currently limited to specific casting conditions and steel compositions.

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Development and Validation of Optimization Tool for Continuous Caster Operations Based on CFD Simulations

  • 会议论文

  • 发表日期：

    2025年

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  • Sai Bhuvanesh Nandipati,
  • Kyle Toth,
  • Armin K. Silaen,
  • Yufeng Wang,
  • Sunday Abraham,
  • Dallas Brown,
  • Chenn Q. Zhou

摘要

Precise control of steel solidificationSolidification rate inside a continuous caster is crucial in ensuring excellent slab cast quality, especially with various steel grades produced. A caster operator must adjust casting conditions like steel superheat temperatureTemperature and spray coolingSpray cooling ratesCooling Rate to maintain consistency in the slab quality. Thus, a tool that accurately predicts the casting conditions and can provide necessary adjustments is valuable to the operator. A comprehensive computational fluid dynamics multiphase model of the continuous caster has been developed. The shell thickness in the caster mold predicted by the CFD model shows good agreement with the experimental results. However, the CFD model is not practical and user-friendly for plant operation use. To address this, an interactive software tool based on CFD simulationSimulation results has been developed. The interactive software predicts solidificationSolidification steel temperatureTemperature and solidificationSolidification in the caster, but it is currently limited to specific casting conditions and steel compositions.