Modeling Flow Turbulence in a Continuous Casting Slab Mold Comparing the use of Two Bifurcated Nozzles with Square and Circular Ports

Flow patterns of liquid steel in a thick slab mold, fed by bifurcated nozzles, are modeled through water modeling using characterization techniques such as particle image velocimetry (PIV), ultrasound velocimetry probe (UPV), and mathematical simulations using the large eddy simulation (LES) model. Geometries of nozzle ports include circular and square shapes with similar cross‐section area. Square ports deliver wandering jets that occupy about 66% of the port area, and are raveled during their pass through the mold impacting the narrow face. Circular ports deliver compact jets mainly through the lower edge occupying only about 45% of the port area. The analysis of the flow structures indicates that the circular ports form more turbulent jets than square ones for the same flow rate of liquid. Mathematical simulations, using the LES model, predict acceptably well measured velocity fields. Slag entrainment through mechanisms of shear‐drag forces at the metal–slag interface is estimated through a critical capillary number which involves slag viscosity, interfacial tension, and fluid velocity. At deep nozzle immersions, this capillary model predicts more slag entrainment using the bifurcated nozzle with circular ports. Turbulence of liquid steel flows in a slab caster mold are studied through physical modeling and mathematical simulations. Velocity spikes at the meniscus are identified by PIV measurements. Flux entrainment is determined by capillary number that includes the velocity spikes. LES simulations and physical modeling measurements observe very good agreement.