The application of the state-of-the-art turbulence models in the OpenFOAM CFD codes and the validation for different flow control cases in the continuous casting process

Computational fluid dynamics (CFD) is an established approach to study flow behaviour. Despite advances in mathematical numerical modelling in recent decades, accurately predicting the turbulent flow behaviour of steel using CFD remains a challenge. In the continuous casting process, two main flow control systems are employed to transfer liquid steel from the tundish to the mould, namely stopper control and slide gate control. In additional to these two main flow control systems, the casting nozzle geometries, casting rate, and casting mould dimensions vary considerably, and this complexity makes it difficult to precisely simulate turbulent flow in the casting channel. In this paper, examples are presented showing how different turbulence models influence the simulation results, using the latest version of the open source CFD simulation software OpenFOAM. Prior to the CFD modelling, RHI Magnesita's water modelling facilities in Leoben (Austria) were used to validate the state-of-the-art turbulence models selected for a particular casting nozzle geometry and flow control system.