Experimental, statistical and numerical studies of the continuous casting process based on temperature profiles - part I

Statistical, experimental and numerical studies are carried out to investigate the frequencies of breakouts during solidification phenomenon in steel continuous casting process at Arcellor Mittal-Annaba plant (Algeria). These breakouts frequencies which have an impact on the management quality field in terms of the quality cost (CoQ) are statistically censused and experimentally investigated during the mould process. The molten steel fluctuation level is measured and the temperature is read during the solidification phenomenon using thermocouples at different locations in the mould connected to the data acquisition. The numerical model involves a generalized set of mass, momentum and heat equations that is valid for the solid, liquid and solidification interval in the mould. The melting and solidification model generated with the software package FLUENT is used to predict numerically the solidification behaviour during the mould process. The variation of the casting speed during the mould process, the molten steel level and the thermal behaviour denoted as temperature profiles are experimentally followed and compared with the statistical data. The effects of the components modifications of the mould, particularly the length, were investigated based on the predicted temperature profiles and field temperature distributions inside the mould.