Experimental Validation and Numerical Analysis of the Swirling Flow in a Submerged Entry Nozzle and Mold by Using a Reverse TurboSwirl in a Billet Continuous Casting Process

As an alternative to some traditional methods to generate a swirling flow in the continuous casting process, the use of a new swirling flow generator, TurboSwirl, is studied. Specifically, a reversed TurboSwirl device is designed as part of a submerged entry nozzle (SEN) for a round billet continuous casting process. Mathematical modeling is used to investigate this new design and a water model experiment is carried out to validate the mathematical model. The predicted velocities by the turbulence models: realizable k-E model, Reynold stress model (RSM), and detached eddy simulation (DES) are compared to the measured results from an ultrasound velocity profile (UVP) method. The DES model can give the best prediction inside the SEN and has a deviation less than 3.1% compared to the measured results. Moreover, based on the validated mathematical model and the new design of the SEN, the effect of the swirling flow generated by the reverse TurboSwirl on the flow field of the SEN and mold is compared to the design of the electromagnetic swirl flow generator (EMSFG). A very strong swirling flow in the SEN and a stable flow pattern in the mold can be obtained by the reverse TurboSwirl compared to the EMSFG.