Numerical Modeling of Transient Two-Phase Flow and the Coalescence and Breakup of Bubbles in a Continuous Casting Mold

The multiphase flow and spatial distribution of bubbles inside a continuous casting (CC) mold is a popular research issue due to its direct impact on the quality of the CC slab. The behavior of bubbles in the mold, and how they coalesce and break apart, have an important influence on the flow pattern and entrapment of bubbles. However, due to the limitations of experiments and measurement methods, it is impossible to directly observe the multiphase flow and bubble distribution during the CC process. Thus, a three-dimensional mathematical model which combined the large eddy simulation (LES) turbulent model, VOF multiphase model, and discrete phase model (DPM) was developed to study the transient two-phase flow and spatial distribution of bubbles in a continuous casting mold. The interaction between the liquid and bubbles and the coalescence, bounce, and breakup of bubbles were considered. The measured meniscus speed and bubble diameter were in good agreement with the measured results. The meniscus speed increased first and then decreased from the nozzle to the narrow face, with a maximum value of 0.07 m/s, and appeared at 1/4 the width of the mold. The current mathematical model successfully predicted the transient asymmetric two-phase flow and completely reproduced the coalescence, bounce, and breakup of bubbles in the mold. The breakup mainly occurred near the bottom of the submerged entry nozzle (SEN) due to the strong turbulent motion of the molten steel after hitting the bottom of the SEN. The average bubble diameter was about 0.6 mm near the nozzle and gradually decreased to 0.05 mm from the nozzle to the narrow face. The larger bubbles floated up near the SEN due to the effect of their greater buoyancy, while the small bubbles were distributed discretely in the entire mold with the action of the molten steel jet. Overall, the bubbles were distributed in a fan shape. The largest concentration of bubbles was in the lower part of the SEN and the upper edge of the SEN outlet.