CFD modeling of Indiana Harbor 2 Steel Producing 2 and 3 Slab Casters

Three-dimensional single phase (liquid steel) and multi-phase (liquid steel and argon gas) k-ε turbulence models were developed to characterize the mold flow structures and to evaluate the performances of different SEN designs on different continuous casting problems at ArcelorMittal Indiana Harbor Number 2 Steel Producing Nos. 2 and 3 Slab Casters. Despite the number of assumptions introduced in CFD modeling, very good correlations between plant experiences and modeling can be achieved. In the present study, it is shown that CFD modeling can be used as a powerful tool in order to understand the experiences in plants, to explain the fundamentals of problems and solutions, to propose certain modifications that can lead to significant improvements in real caster operations, and to complement plant trials. For the Number 3 Slab Caster, the CFD modeling was performed to determine which SEN would provide higher meniscus activity to obtain better mold powder melting characteristics. For the Number 2 Slab Caster, the modeling was performed to determine which SEN would provide less defect penetration deep into the strand with more dispersed distribution. These efforts along with plant trials and water model tests, helped reduce the customer rejection rate at the Number 2 Slab Caster and improve the castability at the Number 3 Slab Caste