Numerical Simulation of a Continuous Caster

Heat transfer and solidification models were developed for use in a numerical model of a continuous caster to provide a means of predicting how the developing shell would react under variable operating conditions. Measurement data of the operating conditions leading up to a breakout occurrence were provided by an industrial collaborator and were used to define the model boundary conditions. Steady-state and transient simulations were conducted, using boundary conditions defined from time-averaged measurement data. The predicted shell profiles demonstrated good agreement with thickness measurements of a breakout shell segment – recovered from the quarter-width location. Further examination of the results with measurement data suggests pseudo-steady assumption may be inadequate for modeling shell and flow field transition period following sudden changes in casting speed. An adaptive mesh refinement procedure was established to increase refinement in areas of predicted shell growth and to remove excess refinement from regions containing only liquid. A control algorithm was developed and employed to automate the refinement procedure in a proof-of-concept simulation. The use of adaptive mesh refinement was found to decrease the total simulation time by approximately 11% from the control simulation – using a static mesh.