Internal SEN Design and Its Influence on Fluid Dynamics in Slab Molds: A Combined Numerical and Experimental Analysis

The optimization of submerged entry nozzle (SEN) designs plays a pivotal role in achieving stable flow conditions and high-quality steel production during continuous casting. This study presents a comparative analysis of two SEN geometries under identical operational parameters using a combined approach of numerical simulation and physical modeling. A full-scale water model and a validated CFD framework based on the realizable k-ε and VOF models were employed to evaluate velocity distribution, turbulence intensity, free surface behavior, and flow symmetry. Results reveal that the SEN-2 design enhances flow stability near the meniscus region, promotes a consistent double-roll flow pattern (DRF), and reduces surface oscillations and sub-meniscus velocities, thereby minimizing the risk of mold flux entrapment. The proposed dimensionless KE number effectively quantifies the energy dissipation behavior of both designs, highlighting SEN-2’s superior hydraulic performance. This integrated methodology offers a robust evaluation framework for future nozzle development aimed at improving product quality without compromising productivity.