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<p>To tackle the challenges of liquid steel reoxidation and mixing control during grade changes, a three-dimensional mathematical model incorporating turbulence, multiphase flow, and mass transfer is developed for a single-strand tundish–mold system. The model is validated through water modeling experiments and systematically examines the effects of tundish emptying time and refilling strategies on the behavior of the steel–slag–air multiphase system and the mixing of steel grades. The results demonstrate that a liquid-level drop of 371.5 mm during the 5-minute tundish emptying process prior to introducing the new grade is optimal. Under this condition, a 90 pct concentration of the new grade is achieved at the mold outlet in approximately 2400 seconds, without prolonged steel exposure caused by an excessively low liquid level. Furthermore, with this emptying strategy, maintaining a low casting level of 620 mm without a tundish refilling operation further shortens the mixing time to 1948 seconds, with a transition slab length of 35.7 m, while effectively controlling surface fluctuations and steel exposure, and completely eliminating secondary exposure. This study offers valuable insights for the integrated control of the tundish–mold system during transient casting operations.</p>

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Analysis of Multiphase Flow and Steel Mixing in a Single-Strand Tundish–Mold System During Grade Change

  • 期刊论文

  • 发表日期：

    2026年2月23日

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  • Pengsheng Lu,
  • Kejie Huang,
  • Qing Fang,
  • Jianhao Wang,
  • Yuxiang Li,
  • Hua Zhang,
  • Hongwei Ni

摘要

To tackle the challenges of liquid steel reoxidation and mixing control during grade changes, a three-dimensional mathematical model incorporating turbulence, multiphase flow, and mass transfer is developed for a single-strand tundish–mold system. The model is validated through water modeling experiments and systematically examines the effects of tundish emptying time and refilling strategies on the behavior of the steel–slag–air multiphase system and the mixing of steel grades. The results demonstrate that a liquid-level drop of 371.5 mm during the 5-minute tundish emptying process prior to introducing the new grade is optimal. Under this condition, a 90 pct concentration of the new grade is achieved at the mold outlet in approximately 2400 seconds, without prolonged steel exposure caused by an excessively low liquid level. Furthermore, with this emptying strategy, maintaining a low casting level of 620 mm without a tundish refilling operation further shortens the mixing time to 1948 seconds, with a transition slab length of 35.7 m, while effectively controlling surface fluctuations and steel exposure, and completely eliminating secondary exposure. This study offers valuable insights for the integrated control of the tundish–mold system during transient casting operations.