A 3-D numerical prediction of turbulent flow, heat transfer and solidification in a continuous slab caster for steel

This study describes the numerical modeling of three-dimensional coupled tu rbulent flow, heat transfer, and solidification in a continuous slab easter for stainless steel. The model uses generalized transport equations which are applicable to the liquid, mushy and solid regions within the easter. Th e turbulent characteristics in the melt pool and mushy region are accounted for using the low-Reynolds number k-epsilon turbulence model by Launder an d Sharma. This version of the low-Reynolds number turbulence model is found to be more easily adaptable to the coupled flow and mushy region solidific ation easter problem compared to the standard high-Reynolds number and othe r low-Reynolds number turbulence models. The macroscopic solidification pro cess itself is based on the enthalpy-porosity scheme. The governing transpo rt equations are solved employing the primitive variables and using the con trol volume based finite-difference scheme on a staggered grid. The process variables considered are the casting speed and the inlet superheat of the melt. The effects of these process variables on the velocity and temperatur e distributions and on the extent of the solidification and mushy regions a re reported and discussed. The numerical predictions of solidification prof ile are compared with the limited experimental data available in the litera ture, and very good agreement was found. (C) 1998 Canadian Institute of Min ing and Metallurgy. Published by Elsevier Science Ltd. All rights reserved.