Numerical Simulation of the Effects of Horizontal and Vertical EMBr on Jet Flow and Mold Level Fluctuation in Continuous Casting

In this article, a new type of electromagnetic braking (EMBr), named vertical EMBr (V-EMBr) was introduced in the continuous casting process. In order to investigate its capability and applicability, the impacts of horizontal and vertical EMBrs on the flow pattern in a continuous casting mold were simulated by means of an implemented Reynolds-averaged Navier–Stokes (RANS) SST k–ω turbulence model. The characteristics of electromagnetic field and flow field inside a 1450 mm × 230 mm mold with Ruler-EMBr and V-EMBr have been compared. The numerical simulation results indicate that the static magnetic field generated by Ruler-EMBr can cover the main part of the discharging jet flow, which has a better control of the flow pattern in lower part of the mold. The static magnetic field generated by V-EMBr can cover both the vicinity of the mold narrow faces and the impingement region of the jet flow, which can effectively control the liquid steel flow in the upper recirculation zone. The parametric study also shows that the large vortices beneath the jet flow can be almost completely eliminated at an optimized magnetic flux density with Ruler-EMBr. In addition, the surface velocity and steel/slag interface fluctuation can be suppressed with the application of V-EMBr to acceptable values even with a wide variation of SEN port angles. It is estimated that to reach the same level of braking effect on the upper recirculation flow, a magnetic flux density of 0.1 T is sufficient for V-EMBr, while 0.2 T is needed for Ruler-EMBr. Based on the results, a second-generation V-EMBr has been developed, which combines both of the merits of Ruler-EMBr and V-EMBr.