Large eddy simulation of various EMBr effects on the fluid flow, heat transfer and solidification process in an ultra-high speed thin slab casting mould with multi-port SEN

Effective control of intense turbulence is a crucial challenge for achieving steady production with ultra-high casting speed in thin slab continuous casting. In thin slab casting process, specially designed multi-port submerged entry nozzle (SEN) with four outlets is utilised to ensure an ample supply of molten steel, necessitating the selection and optimisation of suitable Electromagnetic Braking (EMBr) equipment for steel jet control. This study established a comprehensive three-dimensional model of a funnel-type mould, employing a combined experimental-numerical approach to validate and investigate the flow, heat transfer, solidification and electromagnetic behaviour in the mould. The steel grade studied in the simulation is Q235B, and its physical properties were calculated based on its composition with a temperature range of 1450–1826 K. To analyse the influence of high casting speed on the flow and solidification behaviour in the mould, three casting speeds were selected for the study, which were 6, 7 and 8 m/min. The results indicate that the novel Bowl EMBr significantly suppressed the penetration of steel jet and thus enhanced the thickness and uniformity of the solidified shell. As the casting speed increases from 6 to 8 m/min, the solidified shell thickness at the mould exit decreases from 7.91 to 5.94 mm, with the stagnant growth region approaching the mould exit. This highlights the requirement to correspondingly increase EMBr strength under ultra-high casting speed condition to avoid remelting of the shell and the risk of molten steel leakage. The coupled mathematical model established in this study provides guidance for optimising EMBr structures and casting speed under special multi-port SEN conditions, offering recommendations for the rational control of flow, heat transfer and solidification process in the mould.