Design Optimization of Continuous Caster Refractory Components

The paper describes the design optimization of different refractory components used in the continuous casting process. In the first case, an impact pad of a continuous caster tundish is optimized for its turbulence suppression capability, while the inclusion particle trapping of the design is monitored. The impact pad is used in isolation as the only tundish furniture component. In the second case, the Submerged Entry Nozzle (SEN) of the continuous caster mold is optimized for minimum meniscus turbulent kinetic energy (i.e., stable meniscus). In both cases, the design variables are geometrical in nature. The steady-state flow and thermal patterns in the tundish and mold are obtained using the commercial CFD solver FLUENT. In order to perform optimization, the geometries are parameterized and incorporated into a mathematical optimization problem. FLUENT and its pre-processor GAMBIT are linked to a commercial design optimization tool, LS-OPT, to automatically improve the designs using metamodel approximations. The optimization results show a reduction of 12.5% in the turbulence on the slag layer of the tundish, while for the SEN, the results for one design iteration only are shown, due to the high cost of the function evaluations. The final paper will contain additional results. The SEN base and improved designs are validated using water modeling.