Analysis of a Full-Scale Bi–Sn Liquid Metal Model for the Continuous Casting of Steel

The complex multiphase flow behavior during the continuous casting of steel was investigated through a physically modeled full-scale liquid metal system. This system was operated using a stopper control system (2.5 ton Bi–Sn system). The obtained data, including nozzle pressures, were processed using a concise analytical model. Compared to water modeling, the use of a low-melting-point alloy (58% Bi and 42% Sn eutectic) allows for a full-scale system with material properties closer to those of steel (e.g., interfacial tension). An industrial-scale stainless-steel stopper and a submerged entry nozzle (SEN) were mounted on the system to prevent air permeation due to the negative pressure in the nozzle. Argon gas was injected into an industrial stopper–rod system through an argon line embedded in the stopper. The analytical model characterizes the pressure loss, flow separation, and cavitation of the stopper control system by considering the effects of argon in the nozzle. This study proposes the mapping of the pressure loss, throughput, flow separation, and cavitation based on the gas fraction and stopper position. Graphical Abstract