The Influence of Process and Slag Parameters on the Liquid Slag Layer in Continuous Casting Mold for Large Billets

In the continuous casting of special steel blooms, low casting speeds result in slow renewal of the molten steel surface in the mold, adversely affecting mold flux melting and liquid slag layer supply, which may lead to surface cracks, slag entrapment, and breakout incidents. To optimize the flow and heat transfer behavior in the mold, a three-dimensional numerical model was developed based on the VOF multiphase flow model, k−ϵ RNG turbulence model, and DPM discrete phase model, employing the finite volume method with SIMPLEC algorithm for solution. The effects of casting speed, argon injection rate, and mold flux properties were systematically investigated. Simulation results demonstrate that when casting speed increases from 0.35 m·min−1 to 0.75 m·min−1, the jet penetration depth increases by 200 mm and meniscus velocity rises by 0.014 m·s−1. Increasing argon flow rate from 0.50 L·min−1 to 1.00 L·min−1 leads to 350 mm deeper bubble penetration, 10 mm reduction in jet penetration depth, 0.002 m·s−1 increase in meniscus velocity, and decreased meniscus temperature due to bubble cooling. When mold flux viscosity increases from 0.2 Pa·s to 0.6 Pa·s, the average liquid slag velocity decreases by 0.006 m·s−1 with a maximum temperature drop of 10 K. Increasing density from 2484 kg·m−3 to 2884 kg·m−3 results in 0.005 m·s−1 higher slag velocity and average 8 K temperature reduction. Comprehensive analysis indicates that optimal operational parameters are casting speed 0.35–0.45 m·min−1, argon flow ≤ 0.50 L·min−1, mold flux viscosity 0.2–0.4 Pa·s, and density 2484–2684 kg·m−3. These conditions ensure more stable flow and heat transfer characteristics, effectively reducing slab defects and improving casting process stability.