Modeling study of EMBr effects on molten steel flow, heat transfer and solidification in a continuous casting mold

During continuous casting process, the internal molten steel flow pattern of the mold is one of the important factors affecting the quality of slab products. The application of electromagnetic braking (EMBr) technology in the slab caster provides an effective solution to improve the molten steel flow pattern in the mold. In the current research, one of the commonly used EMBr technology is studied, namely the Ruler-EMBr technology. In detail, the effect of magnetic flux density on the behavior of the molten steel jet flow, heat transfer, and solidification in a 1450 mm x 230 mm slab mold is numerically simulated through a Reynolds-averaged Navier-Stokes (RANS) turbulence model together with an enthalpy-porosity approach. The simulation results indicate that the electromagnetic force generated by the Ruler-EMBr can significantly suppress the diffusion of the impinging jet to the narrow face of the mold with the increase of magnetic flux density. By that, the impact of the upward backflow on the meniscus region in the mold is suppressed. Correspondingly, the uniformity of the temperature distribution in the mold is effectively improved. The parametric studies suggest that the optimized magnetic flux density is 0.3 T to ensure the improvement of steel quality with a casting speed of 1.6 m/min. By applying the magnetic flux density of 0.3 T, the Ruler-EMBr has a better capability to reduce the maximum amplitude of the surface velocity by 24.5% and increase the average surface temperature of the molten steel by 0.25% when compared to the case of No-EMBr. With this electromagnetic parameter, the Ruler-EMBr technology can well prevent the mold flux entrapment and promote solidified shell uniform growth along the casting direction.