In the world of steel production, precision and efficiency are paramount, and a recent study published in the journal *Teshugang* (translated as “Iron and Steel”) is shedding new light on optimizing the continuous casting process. The research, led by Zhao Zhigang, delves into the fluid flow dynamics within the mold of a vertical slab caster, offering insights that could significantly impact the energy sector’s steel production lines.
Continuous casting is a critical process in steel manufacturing, where molten steel is solidified into a semi-finished billet, bloom, or slab for subsequent rolling. The quality of the final product heavily depends on the flow dynamics within the mold. Zhao Zhigang’s study focuses on a 200 mm x 1,300 mm vertical slab caster, exploring how different nozzle structures affect the flow field and level fluctuations in the mold.
Using a combination of physical simulations with a 1:1 water mold and advanced computational fluid dynamics (CFD) software, Fluent, the research team conducted a three-dimensional numerical simulation of the flow field. “The numerical simulation results coincide remarkably well with the physical simulation results,” Zhao Zhigang noted, highlighting the accuracy of their computational model.
The study varied the side hole size and angle of the submerged entry nozzle, ranging from 40 mm x 40 mm to 40 mm x 80 mm and angles from +15° to -15°. The findings revealed that the nozzle structure parameters significantly influence the turbulent kinetic energy at the liquid level. Among the nozzles tested, No2 (40 mm x 40 mm, +15°, downward, bottom with an inverted Y shape) demonstrated the best performance.
One of the key insights from the research is the relationship between the strand impact depth and the free surface turbulent kinetic energy. “The shallower the strand impact depth, the larger the free surface turbulent kinetic energy,” Zhao Zhigang explained. This understanding could lead to more precise control over the casting process, reducing defects and improving product quality.
The implications for the energy sector are substantial. Steel is a fundamental material in energy infrastructure, from power plants to renewable energy installations. Enhancing the continuous casting process can lead to higher-quality steel products, reducing waste and energy consumption. “Optimizing the nozzle structure can potentially lower operational costs and increase production efficiency,” Zhao Zhigang added, underscoring the commercial benefits of the research.
As the steel industry continues to evolve, research like Zhao Zhigang’s plays a crucial role in driving innovation. The findings published in *Teshugang* not only advance our understanding of fluid dynamics in continuous casting but also pave the way for more efficient and sustainable steel production. In an era where precision and efficiency are key, this study offers valuable insights that could shape the future of the energy sector’s steel supply chain.