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JOURNAL OF IRON AND STEEL RESEARCH, INTERNATIONAL. 2012, 20(1) : 34-39, 46

Large Eddy Simulation of Turbulent Fluid Flow in

Liquid Metal of Continuous Casting
JIChuan-bo, LI Jing-she, YANG Shu-feng, SUN Li-yuan
(School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China)

Abstract; T h e transient turbulent flow in continuous casting steel plays a key role in minimizing defects. Compared
with the k-ε model, the large eddy simulation ( L E S ) of turbulence provides much more accurate representation of
turbulent flow by resolving large-scale dynamics. The turbulent flow in a liquid metal model of continuous casting
has been simulated by L E S and measured using ultrasonic Doppier velocimetry ( U D V ) . The result of measurement
and LES has been compared to validate the LES model and furthermore enhance the understanding of the transient
turbulent feature in the flow field. The results show that the jet exiting from the nozzle port swings, which is not
steady, and turbulent velocity variation frequencies decreased with distance from the nozzle port region and also the
LES mode can capture the high frequency fluctuation, which the measurement cannot detect.
Key words: L E S ; turbulent flow; nozzle; mold; continuous casting

Turbulent flow in submerged entrance nozzle
and mold of continuous casting is associated with
costly failure such as the entrainment of slag inclu­
sions and the formation of surface defects. A num­
ber of previously studies have analyzed the flow using
Reynolds-Averaged Navier-Stokes models (RANS), in
which the k-ε model is the most typical one cl ~ 6] .
However RANS models are usually aimed to obtain
a time-averaged velocity flow field and the velocity
fluctuations with time are damped because of the
strong eddy viscosity provided by RANS. Relatively
less studies exists on fine-grid transient large eddy
simulation (LES) calculations in the nozzle and mold
of continuous casting process [7_13] . S Sivaramakrish-
nan et al[12] combined LES and particle image veloci­
metry (PIV) measurements in a scaled water model.
Many transient phenomenons have been observed using
LES and PIV measurement which RANS model can­
not simulate. There are considerable, persistent,
asymmetric flow existing between the two rolls in
the lower mold region, which is important for the
inclusion motion and bubble entrapment. Q Yuan et
a l M studied LES and inclusion transport in a full
scale water model, and the LES predictions matched
well with the measurement. The asymmetry flow
patterns in the mold appear most of the time and the
flow switched between the double roll. R Liu et
al[14] performed LES on transient flow pattern in a
continuous casting mold and found that the flow in
upper roll may break into series of small scale vorti­
ces which are chaotically distributed.
LES has been applied in previous model to pre­
dict many turbulent flows in continuous casting
mold; however few assessments have been under­
taken to investigate the accuracy of turbulent flow
simulation with measurement. LES of the flow in a
liquid metal model have been conducted to under­
stand the instantaneous flow structures by compa­
ring prediction results and ultrasonic Doppler veloci­
metry (UDV) measurement in a liquid metal model.
The time history of velocity magnitude predicted by
LES was also processed to identify the significant
modes in the turbulent fluctuation.
1 Computational Model
In the context of LES only large scale struc­
tures are resolved. The dissipative effect of eddies
smaller than the filter size is represented by a sub-
grid scale (SGS) model. Based upon the filtering
procedure, the filtered N-S equations can be written

Foundation Item:Item Sponsored by National Natural Science Foundation of China (51074021)

Biography:J1 Chuan-bo(1985—), Male, Doctor; E-mail: chuanboji@gmail.com; Received Date: September 18, 20-11
Issue 1 Large Eddy Simulation of Turbulent Fluid Flow in Liquid Metal of Continuous Casting · 35 ·

as follows; mesh of the domain including 1. 3 million meshes

and fine grid spacing ( a b o u t 0. 2 m m ) was set at the
0 (1)
dx: nozzle outlet port and near the narrow face walls.
dUi .dUiUj 1 dp
-i>effV2Wi (2)
dt dXj D 3Xi 0.3 "(a) '(b)
J
veii = uo ru, (3)
w h e r e , p is density; t is t i m e ; p and M, represent the 0.2 (c)
pressure and filtered velocities respectively; υ0 is 0.03
molecule viscosity; and the subscripts i and j repre­ 0.1 s~\
sent the t h r e e Cartesian directions. T h e residual 0.02
s t r e s s e s , which arise from the unresolved small ed­ ' 0
dies, are modeled by a t u r b u l e n t eddy-viscosity ( u t ) .
T h e SGS-k model employed in this w o r k requires
0.01 . \J
-0.1
solving the following t r a n s p o r t equation, which in­
cludes advection, p r o d u c t i o n , dissipation and vis­ 1 1 1 -0.005 0 0.005
cous diffusion c l 5 ~ 1 6 ] . -0.10-0.05 0 0.05 -0.05 0 0.05
x/m y/m
dks, dks ■c. *-s _i_
+ U
1T ' ϊχ~Γυ< Fig. 1 Sketch of model in front view (a) , side view
3 3k,i (b) and zoom in (c) at port region
(uo+C^K^A) (4)
dXi dXi
1/3 .
Table 1 Process parameters
A=(AxAyAz) \S\ — \f2SijSij ;
Liquid metal
1 dUi No. Property
model
and Su =
dXj dXi
Average nozzle inlet velocity/(m ■ 1.4
w h e r e , ks is t u r b u l e n t kinetic e n e r g y ; S is the rate- Mold w i d t h / m 0.14
of-strain t e n s o r ; K G is the subgrid-scale kinetic en­ Mold thickness/m 0.035
e r g y ; Δ is mesh l e n g t h ; and the p a r a m e t e r s Ct, C kk Mold length/m 0.33
and C„ are empirical n u m b e r , which were adopted as. Nozzle diameter/m 0.01

constant n u m b e r 1, 0. 1, and 0. 05 in this work. Nozzle length/m 0. 3

SEN depth (from meniscus to
T h e governing equations are discretized using 0.072
top nozzle p o r t ) / m
Finite Volume Method ( F V M ) in fluent with 2 nd -order
Density/(kg · m~3) 6360
central differencing scheme for convection terms. T h e
9 Viscosity/(kg ■ m _ 1 · s _ 1 ) 0.00216
time integration is achieved using 2 n d -order implicit Shell No
10
scheme. T h e velocity-pressure coupling is obtained 11 Gas flow rate 0
using implicit fractional step m e t h o d ( I - F S M ) . T h e
time dependent L E S calculations were started w i t h
zero velocity fields in the whole domain and flow
was allowed to develop for 26 s before starting col­
lecting time statistics. T i m e statistics were collected
for 24 s with a time step Δί = 0. 000 2 s.

2 Domains and Boundary Conditions

2.1 Domains
T h e liquid model system has a 300 m m long
nozzle with a constant inner bore of 10 m m with zero
degree bifurcated ports feeding liquid metal into the
mold cavity. Fig. 1 gives the sketch of the liquid metal
model. More details on various d i m e n s i o n s , process
parameters (casting s p e e d , flow r a t e , etc) are p r e s ­ 0 0.1 -i^
ented in T a b l e 1. Fig. 2 ( a ) s h o w s the computational y/m

domain including the s u b m e r g e d entry nozzle ( S E N ) Fig. 2 Model geometry and mesh computational
and the entire mold region. Fig. 2 ( b ) shows the domain (a) , nozzle and mold mesh (b)
 • 36 · Journal of Iron and Steel Research, International Vol. 20

2. 2 Boundary conditions Fig. 3 ( a ) compares the average horizontal ve­

1) Inlet
C o n s t a n t velocity profile was applied at the noz­
zle inlet which is 1. 4 m / s . T o reduce computational
c o s t , the nozzle and mold were simulated separately.
T h e transient flow p a r a m e t e r s (velocity, kinetic en­
e r g y , dissipation r a t e ) at the nozzle p o r t s were col­
lected from the nozzle simulation results as the mold
inlet boundary condition.
2) Outlet
A condition with constant pressure and zero normal
gradients for the other variables was employed at the
nozzle outlet p o r t s and exit plane.
3) Mold top surface and wall
Free-slip boundaries with zero normal velocity
were employed at the top free surface. All walls of
the domain were considered no-slip, and the wall
boundary was handled using Werner-Wengle formu­
lation.
3 Model Validations
T h e application of L E S to flows with complex
configurations in this system has not yet been quan­
tified. T h e r e f o r e , it is necessary to validate t h e L E S
model by comparing results with accurate m e a s u r e ­
m e n t s such as P I V and U D V . In this w o r k , t u r b u ­
lent flow in a liquid eutectic alloy has been simulated
using L E S and t h e velocity was measured by U D V in
the mold.
locity between L E S and m e a s u r e m e n t s . T h e velocity
m e a s u r e m e n t s are collected by 0. 2 s interval and av­
eraged over 25 s total time performed using U D V
method along the horizontal lines ( 1 1 0 m m from
mold t o p ) at the mid-plane between wide faces.
Qualitatively the L E S matched the m e a s u r e m e n t
perfectly. Fig. 3 ( b ) s h o w s the side to side compari­
son of horizontal velocity contour between L E S and
m e a s u r e m e n t in the mold center plane. Compared
with the m e a s u r e m e n t s the L E S can capture the cor­
rect spread of the jet in the whole mold domain with
the exception close at the S E N because of the inaccu­
racy of the m e a s u r e m e n t in this position. T h e r e are
t w o reasons to illustrate the inaccuracy of the velocity
close to the port of the nozzle:
1) T h e ultrasonic beam might be disturbed by
the nozzle.
2) T h e measuring grid is rather coarse. Indeed,
the measuring volume can be considered as a series
of consecutive discs with the diameter lined up con­
centrically along the ultrasonic beam. Because of the
divergence of the ultrasonic beam the lateral size of
the measuring volume increases with the distance
from the transducer. In this measurement, the 4 MHz
transducers have a divergence angle of about 2. 3°.
T h e measured values represent an average for t h a t
measuring volume. T h a t issue has to be taken into
account for a comparison b e t w e e n numerical calcul-

500 (a) ^Measurement LES

400
J> #χ
Γ300
$
to \
4-200
Ό
% 100
p&zsa^ • Measurement h
0 OLES <
10 30 50 70 -0.06 -0.02 0 0.02 0.06
Distance from center of mold/mm x/m

Fig. 3 Comparison of LES predicted and measured average horizontal velocity along line 110 mm below top of
mold (a) , average horizontal velocity contour at mold mid plane (b)

ations and experiment. p o r t s region. T h e L E S suggests slightly s h o r t e r r e ­

4 Computational Results and Discussion
4.1 Nozzle flows
Fig. 4 ( a ) s h o w s the velocity magnitude contour
at the lower nozzle region mid-plane, and indicates
that the most of fluid exits the p o r t s from the lower
gion of plug flow from the nozzle bore with a steeper
jet angle which is about 38°. T h e port velocity m a g ­
nitude contours and vectors are presented in Fig. 4
( b ) . T h e reverse flow can be observed in the upper
region of t h e p o r t s w h e r e the back flow zone rate is
25. 3 % calculated using weighted averages based on the
Issue 1 L a r g e E d d y S i m u l a t i o n of T u r b u l e n t F l u i d F l o w in L i q u i d M e t a l of C o n t i n u o u s C a s t i n g · 37 ·

local outward flow rate. The details of the jet char­

1.0 m/s acteristics is given in Table 2. The time-averaged
0.025 - flow speed (ν2χ + νΙ)ιη and turbulent energy along
the nozzle port vertical centerline is shown in Fig. 5.
The turbulent kinetic energy can be quantified by
0.020 -
means of the turbulence normal stresses which de­
scribes as below:
o» 0.015 -
1
(5)
, -L ,—7 7— i —7 7—_i_—7 7— Λ

k ~-(V XV X-\~V yV y-TV ZV z)

0.010
As expected, the turbulent kinetic energy is
-0.005 0 0.005 much higher in the higher velocity forward flow re­
ylm
gion along the line. The peak velocity speed and tur­
Fig. 4 Comparison of average velocity magnitude in bulent energy occurs at 3. 7 and 7. 3 mm separately
lower nozzle region (a) and nozzle port (b) from the bottom edge of the nozzle port.

Table 2 Jet characteristic in half nozzle port

Properties LES (right port)

Weighted average nozzle port velocity in x-direction ( o u t w a r d ) / ( m · s - 1 ) 0.7

Weighted average nozzle port velocity in ^-direction ( h o r i z o n t a l ) / ( m · s " 1 ) 0.11
Weighted average nozzle port velocity in z-direction ( h o r i z o n t a l ) / ( m · s - 1 ) 0.57
Weighted average nozzle port turbulent kinetic e n e r g y / ( m 2 · s~ z ) 0. 13
Vertical jet angle/(°) 38
Average jet speed/Cm · s - 1 ) 0.9
Back-flow zone/J'o 25.3

0.16 (c) and (d) shows the mean velocity streamlines with
different time average (12 and 30 s) at the mold mid-
plane. The flow at upper mold region is quite sym­
metric after about 12 s averaged, however not in the
lower region of the mold until with more time avera­
ging about 30 s which suggests the importance of
large scale flow structures in the lower mold region.

4. 3 Transient flows in nozzle and mold

0 0.002 0.006 0.010
Distance from bottom of porfm
Fig. 5 Comparison of mean velocity magnitude and
turbulent kinetic energy in nozzle port center line
4. 2 Mold flows
The mold is fed through the flow exiting from
two bifurcate nozzle ports which controls the flow
pattern and corresponding phenomenon such as mold
surface fluctuation and inclusion entrapment. Fig. 6
(a) and ( b ) shows the instantaneous flow field at
49. 86 s and time-averaged (about 22. 60 s) flow field
near nozzle port region at the mold mid-plane. Com­
pared between the two flow fields, the instantaneous
flow patterns are consistent with the time-averaged
flow, and the maximum instantaneous velocity at
49. 86 s is 1. 59 m / s which is about 11. 97% higher
than the maximum mean velocity ( 1 . 42 m / s ) . Fig. 6
0.014 0.018 Fig. 7 compares the time history of horizontal
velocity between the measurement and LES at the
location point 5 ( — 41 mm, 0, 0) in the mold. The
measurement was extracted using an UDV profiler
with ultrasonic beam pulses sent from the narrow
face wall into the liquid along the transducer axis.
Because of divergence of the beam, the measurement
represents an average over a cylindrical volume,
with about 0. 7 mm in thickness in the beam direc­
tion, and a diameter that increases with distance
from the narrow face which is shown in Fig. 8. The
axial resolution Ax is 0. 7 mm and the lateral resolu­
tion is ΔΓ.
_ ί 4 mm (x<C50 mm
1 :rtan2a ( Λ ; ^ 5 0 mm) '
a = 2 . 32° (half angle of beam divergence)
(6)
 • 38 · Journal of Iron and Steel Research, International Vol. 20

(b)
0.10 0.10 0.10 -
Velocity/

1.2 0

-0.10 0 -0.10 ■ -0.10

-0.20 0.20 0.20

-0.05 0.05 -0.05 0.05
x/m

(a) Instantaneous velocity at 49. 86 s; (b) Mean velocity (about 22. 60 s time averaged);
(c) Mean velocity of 12 s time average) (d) Mean velocity of 30 s time average.
Fig. 6 Velocity magnitude contour and streamlines at mold mid-plane

shows the locations of various points w h e r e velocity

0
-0.2
3 i -0.4
-0.6
SB £ -0.8 — Simulated real signal
— 0.2 s time and spatial average Z^fo m
-1.0
• Measurement
Time/s
Fig. 7 Instantaneous horizontal velocity histories comparing
LES and measurement at point 5 in nozzle and mold mid-plane
4 mm
Transducer xtan2or i?60mm
Δχ=0.7 mm
Fig. 8 Schematic lateral resolutions for UDV measurement
where, x represents the position in the mould (χ=χ—
άτν); and aw is thickness of the wall ( a b o u t 8 m m )
w h e r e the sensor has been attached. T h e overall
temporal resolution was about 0. 2 s for the data col­
lected rate used to obtain the data presented here.
T o compare the L E S prediction with m e a s u r e m e n t
realistically, the spatial averaging over the same vol­
umes and moving time averaging of 0. 2 s was per­
formed in Fig. 7. Overall, the L E S result agrees
well with the m e a s u r e m e n t as proper time averaging
is applied. T h e higher resolution of t h e L E S model
can capture the real high-frequency fluctuations of
the t u r b u l e n t flow better t h a n the measurement.
T h e time histories of the velocity magnitude
collected at other various points at the nozzle and
mold mid-plane are presented in Fig. 9. Fig. 9 ( a )
magnitude as a function of time is presented in Fig. 9
( b ) to ( f ) . A s expected, since point 1 and 2 falls in
the way of s t r o n g bore and jet flow therefore point 1
has the m a x i m u m time average velocity followed by
point 2. O t h e r points are off from the strong m o ­
m e n t u m in the nozzle and mold domain and therefore
■"TIC
have much lower velocity than point 1 and 2. T h e
velocity fluctuations ( a t points 1, 2 , 3 ) close to
S E N suggest higher frequency fluctuations compared
to points ( a t points 4 and 6) away from the SEN.
T h i s behavior is based on the Reynolds n u m b e r in
different p a r t s of the region. T h e high Reynolds
A<50mm
number (J?e=47 000 in nozzles bore) , inside and around
nozzle, gives higher frequency fluctuations sugges­
ting dominance of small scales. T h e Reynolds n u m ­
ber in the mold is around 1/10 of t h a t in the nozzle
bore ( a b o u t 4 0 0 0 , based upon hydraulic diameter of
the mold cross-section and bulk velocity) and t h e r e ­
fore suggests low frequencies.
5 Conclusions
L E S t u r b u l e n t model is used with U D V meas­
u r e m e n t in a liquid metal model of continuous cast­
ing process to u n d e r s t a n d its performance in predic­
ting the t u r b u l e n t flow in nozzle and mold. W h e n
compared with the m e a s u r e m e n t the L E S model can
match the U D V experiment perfectly except the r e ­
gion close to the S E N ports because of the inaccura­
cy of the m e a s u r e m e n t . T h e L E S can capture the
high frequency fluctuation, which the m e a s u r e m e n t
cannot detect.
After 12 s time a v e r a g e , L E S is found to be giv­
ing slightly asymmetric flow p a t t e r n s in the lower re-
Issue 1 L a r g e E d d y S i m u l a t i o n of T u r b u l e n t F l u i d F l o w in L i q u i d M e t a l of C o n t i n u o u s C a s t i n g · 39 ·

0.10 2.5
(a) 1(0,0,19) (b) · Point 1
2(-7.5,0,12) — Average velocity at point 1=1.381 m/s
3(-17.5,0,10) 2.0
0.05 4(-35,0,0)
6(-52.5,0,0) „ „

D D I—I
6 4

-0.05

-0.05 0 0.05 0 24 25 27 29 31 33 35
x/m Time/s
2.5 2.5
(c) · Point 2 (Φ • Point 3
2.0 h — Average velocity at point 2=1.354 m/s 2.0 — Average velocity at point 3=0.577 m/s

1.5

1.0

0.5

0 24 25 27 29 31 33 35 0 24 25 27 29 31 33 35
1.5 -(e) • Point 4 1.5 "(f)
• Point 6
— Average velocity at point 4=0.484 m/s — Average velocity at point 6=0.269 m/s
1.0 1.0
& fl« lf*Jt fhtJTitlftl f^Il·* kit (bit &A 1
0.5 0.5

1 1 1 1 1 1

0 24 25 27 29 31 33 35 0 24 25 27 29 31 33 35
Time/s

(a) Various points; ( b ) Point 1; (c) Point 2; (d) Point 3) (e) Point 4» (f) Point 6.
Fig. 9 Velocity magnitude as a function of time at various points with point coordinates in nozzle and mold mid-plane

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