Effect of Submerged Entry Nozzle Design on Fluid Flow Dynamics Inside the Thin Slab Caster Mold

In the present study, a design modification study for submerged entry nozzle (SEN) in funnel shape mold was conducted to enhance meniscus stability and fluid flow characteristics. State-of-the-art 1:1 scaled water model was used to study the effects of casting speed (3.5 to 6 m/min) and submergence depth (240-320 mm) on fluid flow behavior and slag entrainment for the two SEN designs. Extensive flow visualization experiments were performed using methylene blue dye. Meniscus velocity measurements using a vane anemometer sensor were performed. Plant trials in actual thin slab caster mold confirmed the laboratory findings. Increasing the casting speed from 3.5 to 6 m/min increased the maximum sub-meniscus velocity from 0.29 to 0.44 m/s. Dye injection confirmed that SEN 2 created the necessary double-roll fluid flow pattern with improved meniscus stability. Plate dipping tests at the plant also indicated that SEN 2 was a more suitable choice over SEN 1 in terms of meniscus turbulence.