Submerged Entry Nozzle Flow Control via Tapered Distribution Zone
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Solution Overview
Problem
Existing submerged entry nozzles in continuous steel casting face challenges in achieving a well-controlled symmetric flow, minimizing recirculation zones, maximizing flow filling, and maintaining a balanced flow ratio between discharge openings, while also being easy to manufacture and avoiding flow disturbances.
Innovation Solution
A submerged entry nozzle design featuring a conduit with an inlet and discharge openings, a distribution zone with a main divider and secondary dividers, and tapered sections that guide the flow through secondary channels, ensuring stable and controlled fluid flow by using a combination of tapering and widening geometries to maintain flow control and prevent recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a nozzle with four discharge openings is used to increase heat transfer to the meniscus, then more heat is brought to the meniscus and mould powder melts more completely, but four recirculation zones interact and cause instabilities in the fluid steel in the mould
Solution Approach 1:
The nozzle is divided into multiple discharge openings (two or four) that are spatially separated and oriented at different angles. This segmentation allows each opening to create its own recirculation zone that does not interact negatively with others, while collectively providing sufficient heat transfer to the meniscus without causing flow instabilities.
Solution Approach 2:
Each discharge opening is given specific local characteristics including different orientations (e.g., one opening at 0° and another at 90°), different discharge areas, and different positions relative to the meniscus. This local differentiation allows optimization of heat transfer in specific areas while controlling recirculation patterns to maintain overall flow stability.
2Quantity of substance
If the distribution zone is designed to maximize flow filling of channels, then complete filling is achieved, but flow disturbances may occur without proper geometric control
Solution Approach 1:
The distribution zone incorporates specific geometric parameters including a length-to-diameter ratio (L/D) between 0.5 and 2.0, taper angles between 5° and 15°, and channel dimensions that are precisely controlled. These parameter optimizations ensure complete channel filling while maintaining flow uniformity and preventing disturbances through mathematically optimized geometry.
3Manufacturing precision
If the nozzle geometry is optimized for precise flow control, then symmetric and stable flow is achieved, but manufacturing complexity increases
Solution Approach 1:
The distribution zone is designed as a universal component that performs multiple functions: it divides the incoming flow, fills multiple channels completely, controls flow symmetry, and maintains stability. This multi-functionality is achieved through a standardized geometric design that can be manufactured using conventional techniques while delivering precise flow control performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The nozzle design achieves a stable and well-defined flow of molten steel into the mould, reducing recirculation zones and ensuring complete filling of channels, resulting in improved control over fluid flow and heat transfer, leading to enhanced quality of the cast product.
Implementation Method 1
The distribution zone has a taper seen in downstream direction and perpendicular to an axial plane defined by the longitudinal axis of the secondary channels
Data Source
Figure 1~2
AI summary
The invention relates to a submerged entry nozzle for use in continuous casting provided with a conduit, distribution zone, two lower and two upper channels and corresponding discharge openings, wherein the geometry of these parts is adapted to maintain the nozzle at all times completely filled with fluid steel resulting in a good control of the jets of fluid steel leaving the nozzle.