Enhanced design and optimization of distribution system for twin-roll strip casting

In the twin-roll strip casting process, the stability of the molten pool is a critical determinant of strip quality, with the distributor’s structural design playing a pivotal role. This study focuses on the optimization of a V-shaped distributor, systematically analyzing the effects of the arrangement, number, and height of side outlets, as well as the inclination angle of end outlets, on flow and thermal characteristics. A three-dimensional numerical model was established, and simulations were performed using Fluent software to evaluate the flow and temperature fields within the high-temperature molten pool. Key performance indicators, including turbulent kinetic energy distribution at the molten pool surface and temperature uniformity at the strip outlet along the casting roll width, were thoroughly investigated. By using surface uniformity and stability as evaluation criteria, the distributor's structural parameters were optimized to provide practical guidance for industrial applications. The findings reveal that sinusoidal arrangements of side outlets offer limited improvements in liquid surface stability, while horizontally aligned outlets effectively reduce temperature fluctuations at the strip outlet. Increasing the number of side outlets proportionally reduces the peak turbulent kinetic energy on the molten pool surface. A distributor design featuring seven outlets was identified as the most effective, achieving superior uniformity in turbulent kinetic energy. Additionally, a dimensionless analysis of side nozzle height demonstrated that at a parameter value of 0.10, the molten pool surface stability, uniformity, and strip outlet temperature distribution were optimized. These insights provide valuable design strategies for improving the performance of V-shaped distributors, contributing to enhanced strip quality and process efficiency in twin-roll strip casting. After continuous optimization, the control ideas of the above flow distributor structure have been successfully applied to industrial test sites. The fluctuation of the liquid level in the high-temperature melt pool was captured by a high-temperature camera. The results indicate that there are significant liquid level fluctuations in the molten pool when the distributor structure is not optimized. However, after optimizing the design of the distributor mechanism, only slight fluctuations in the liquid level in the molten pool were generated.