Flow and thermal behavior of the top sur

Steady-state finite-element models have been formulated to investigate the coupled fluid flow and thermal behavior of the top-surface flux layers in continuous casting of steel slabs. The 3-D FIDAP™ model incorporates shear stresses imposed on the flux/steel interface by calculated flow velocities in the molten steel pool, as well as temperature-dependent properties for solidification and melting of the flux. The results show good agreement between the modeled outcomes and experimental measurements, indicating the accuracy of the model. It was found that the shear forces from the steel surface motion towards the submerged entry nozzle create a significant recirculation zone in the liquid flux pool, with its depth varying based on casting speed and flux properties. The study quantified that under typical conditions, this zone holds approximately 4 kg of flux with an average residence time of about 2 minutes. Furthermore, the research revealed that flow separation occurs 200 mm from the narrowface wall, contributing to potential deficiencies in mold feeding and creating a cold spot at the wideface mold wall. This non-uniformity in temperature distribution potentially leads to non-uniform heat removal and initial shell growth, linking flow dynamics in the liquid flux pool to steel quality issues.