Numerical Simulation, Physical Modeling and Plant Trial on the Slag Entrapment Behavior in a Four-Strand Tundish

Abstract

The continuous casting process yields more than 96% crude steel worldwide. Numerical simulation and physical modeling were employed to investigate the slag entrainment behavior during the final casting stage in a four-strand continuous casting tundish. It is demonstrated that the numerical and physical modelling results agree well. Vortex formation in the final casting stage can be divided into four distinct stages: surface rotation, vortex generation, vortex development, and vortex penetration, with significant variations in critical slag entrainment depths observed among different outlets. Increasing casting speed increases slag entrainment risks, while employing vortex inhibitors could reduce the critical slag entrainment height by up to 29%. Through optimized casting termination procedures in a plant trial, the tundish residual depth decreased from 400 to 200 mm; The tail-end billet cleanliness significantly improved to reach a normal billet quality level in the end billet range of 2–3 m. This study provides theoretical and technical support for reducing slag entrainment defects and improving steel cleanliness in continuous casting.OPEN ACCESS Received: 15/05/2025 Accepted: 10/07/2025 Published: 27/10/2025

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