ISIJ International, Vol. 55 (2015), No. 5, pp.

976983

Particle-based Numerical Analysis of Spray Water Flow in

Secondary Cooling of Continuous Casting Machines
Norimasa YAMASAKI,1)* Shozo SHIMA,1) Keiji TSUNENARI,2) Satoru HAYASHI3) and Masahiro DOKI4)
1) Plant Engineering and Facility Management Center, Nippon Steel & Sumitomo Metal Corporation, 20-1 Shintomi, Futtsu,
Chiba 293-8511 Japan.
2) Nippon Steel & Sumitomo Metal Corporation, 6-1, Marunouchi 2-chome, Chiyoda-ku, Tokyo 100-8071 Japan.
3) Process Research Laboratories, Nippon Steel & Sumitomo Metal Corporation, 20-1 Shintomi, Futtsu, Chiba 293-8511 Japan.
4) Kimitsu Works, Nippon Steel & Sumitomo Metal Corporation, 1 Kimitsu, Kimitsu, Chiba 299-1141 Japan.
(Received on August 19, 2014; accepted on February 4, 2015; originally published in Tetsu-to-Hagan,
Vol. 99, 2013, No. 10, pp. 593600)

In continuous casting process, solidification should evenly proceed to have as good steel quality as possible. Molten steel starts to solidify in a water-cooled mold to create solidified shell followed by shell
growth and termination in a secondary water cooling zone. Visualization of the flow pattern of spray water
greatly helps to analyze how to have even shell. Computational fluid dynamics is useful represented by
the grid based methods of FVM, FDM, and FEM. However, they are not appropriate for simulation of
spray water flow because of complex free surfaces. So, the particle based method of MPS has been
applied. A typical roll arrangement was modeled where spray water flow was particularly focused on. As
a result, standing water on rolls overflows according to the water flow rate of spray accounted for in this
study. Accuracy of the numerical model has been verified by water model experiments equipped by
acrylic plates, rolls and spray nozzles. The computational results with a practical condition agreed well
with the experimental results. Heat transfer coefficients between water and slab surface were estimated
by the calculated results to simulate how solidification proceeded in practice. It was found that uneven
water flow significantly affected unevenness in temperature distribution of a slab.
KEY WORDS: continuous casting; particle-based method; computational fluid dynamics; MPS; solidification; secondary cooling; spray water.

Therefore, rolls divided into plural pieces in width have

been recently used to have rolls less deflective. However, it
is necessary for a couple of roller bearings to be arranged
as a result of division. Because of these roller bearings,
spray water for slab cooling may unevenly flow downstream
through the space caused by roller bearings and a slab.
In order to analyze how this flow pattern affects uneven
solidification, it is important to visualize the flow pattern of
spray water quantitatively. Computational fluid analysis is
effective, however, since the conventional method of
employing grids (meshes) is judged to be inadequate for
treating complex free surfaces, a particle-based, meshless
method2) has been tried in this study.
In fact, this is the first trial to simulate the spray water
behavior in a secondary cooling zone in a continuous casting machine by means of the particle-based method. Therefore, the followings were unknown; how large the diameter
of particles should be, how to treat the contact angle of
water with the slab/rolls and how spray jet shapes influence
the fluid flow. That was why these factors were specifically
examined in the process of modeling.
Heat transfer coefficients between cooling water and a
slab under various conditions were measured using the flow
of the spray water obtained from the analyses. Solidification

1. Introduction
To ensure evenness of solidification in continuous casting
process is one of the important technologies for the production of high-quality slabs. In a secondary cooling zone, multiple sprays spaced in width between rolls cool down the
surfaces of slabs to solidify molten steels. However,
research of cooling by multiple spray units has never been
done so far. It is only by using simple spray units1) that have
been studied. Therefore, problems of unevenness as for
cooling in width by sprays are so difficult to be solved completely because no quantitative analyses have been conducted on the behavior of spray water. In particular, they include
dripping water passing through roller bearing portions of
split rolls with intricately arranged pattern, and standing
water on rolls. In order to support a slab with thinner shell
during casting at higher speeds, roll pitches have to be narrower because of weaker shell than at conventional speeds.
This may induce an issue to use rollers in smaller diameter
resulting in lower rigidity leading to larger deformation for
rolls.
* Corresponding author: E-mail: yamasaki.x3s.norimasa@jp.nssmc.com
DOI: http://dx.doi.org/10.2355/isijinternational.55.976

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progress of a slab was analyzed with the measured heat

transfer coefficients employed as the boundary conditions.
Solidification analyses3,4) have been carried out by one
dimensional calculation at the center of a slab and two
dimensional analysis by a cross section perpendicular to
casting direction. But, quantitative analyses were usually
considered to be difficult to clarify unevenness in slab
width.
Therefore, a model has been developed considering separate sprays and rolls, position of roller bearings and effect
of standing water and dripping water. Finally, the origin of
unevenness caused by cooling in slab width could be determined.

Accordingly, a study has been performed to understand

how uneven cooling takes place. Especially, we focused on
the influence of the arrangement of the split roller bearings
shown in Fig. 2 along with the behavior of spray water flowing in secondary cooling zones.
2.2. Modeling of Spray Water Flow
The particle-based method (Moving Particle Simulation;
MPS)6,7) was applied to calculate the spray water flow pattern.
Further, necessary functions were added to the commercial
computational fluid dynamics software of Particleworks.8)
The key point of the particle-based method is meshless
resulting in easily calculating free surfaces. The particlebased method can be classified into two types; one is DEM
method used to solve the target particles in analysis as particles, and the other is MPS method applied in this study,
that is good at solving a continuum as the calculation points
of particles as shown in Fig. 3.
As for the two formulas of continuation formula and
Navier-Stokes formula (Eq. (1)) which are also solved with
the finite volume method, the gradient term is discretized
using an inter-particle interaction model as shown in Fig. 3.

2. Modeling of Spray Water Behavior in Secondary

Cooling
2.1.

Actual Conditions of Uneven Temperature in a

Slab
Figure 1 shows the surface temperatures of a slab inside
the strand of a continuous casting machine of a common
vertical bending type.
This was measured by a radiation thermometer with scanning along the width direction, which was installed at 18 m
below the meniscus. The slab size was 300 mm 2 200 mm,
and the casting speed was 1.0 m/min. Secondary cooling
zones of a continuous casting machine typically consist of
plural segments with multiple rolls arranged. Thereby, surface of a slab cannot be generally observed except for the
spaces between the segments.
Measurement was conducted on the upstream side of an
unbent segment with a comparatively large gap due to the
extraction of a segment at the time of maintenance. A scanning radiation thermometer of mono-color (measurement
wave length: 1.0 m) was used to measure the surface temperatures. As realized in Fig. 1, the temperatures at the
width center of the slab are 100C lower than those at the
vicinity of both edges. Similar tendency can be also seen
under the different conditions of casting speeds, steel grade
and secondary cooling patterns.
The origins to bring uneven solidification has been so far
considered by effects of fluid flow of molten steel and
operations saving water at the edge portions to prevent
over-cooling in secondary cooling.5) However, the extreme
temperature drop in the width center as seen in Fig. 1 cant
be clarified by the conventional concept.

Fig. 1.

D
Du
1
= 0,
= p + v 2 + f .............. (1)
Dt
Dt

Where, u, p, , and f denote the flow velocity, the pressure, the density, the dynamic viscosity coefficient and the
external force (gravity), respectively. Figure 3 displays the
discretization of gradient vectors in the physical quantity
at the i-th position of particles. r, d, n0 and w denotes the
position of particles, the dimensional number of space, the
density of particles and the weight function defined for the
influences to be smaller with increasing the distances
between particles, respectively. <> denotes the symbol
expressing an inter-particle interactional model.
The following three matters were examined in detail
before modeling the spray water flow with the particlebased method.
(1) Study of effects of the particle diameter on the spray
water flow
Diameter of particles must be defined to calculate the fluid flow by the particle-based method. A smaller diameter of
particles induces an enormous number of particles and longer time is needed for calculation. A larger diameter of particles causes the problem that they can not flow into small
gaps.
Accordingly, the effects of the various diameters on the
flow pattern were analyzed using the model shown in Fig. 4.
The flow rate was measured at the positions indicated in
Fig. 4 with the respective diameters of particles; 2 mm, 3 mm
and 4 mm.

Fig. 2.

Measured surface temperature at 18 m below the meniscus.

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Schematic view of the flow pattern of spray water.

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ISIJ International, Vol. 55 (2015), No. 5

Fig. 3.

Fig. 4.

MPS Method and formulation of gradient .

Simulation model to set particle diameters (unit: mm).

The time average of flow rates (that for 3 seconds between

2 and 5 seconds) and the standard deviation of flow rates at
which the cooling water flows in Region A (the edges of the
slab) and Region B (the intermediate portion of the roller
bearings) are shown in Figs. 5(a) and 5(b), respectively.
The results in Region C presented the same behavior as
in Region A due to the symmetry of the model.
The minimum gap that allows water to flow is 10 mm
between the top plate on the roller bearings and the slab. The
average flow rate is not so greatly affected by the diameter
of particles, however, the larger the particles becomes, the
greater the variation of the flow rate does resulting in unstable flows into gaps. This is also attributed to higher standard
deviation of flow rates ranges. The number of particles and
calculation time employed for calculation are shown in Fig.
6. The particle diameter was determined as 3 mm after considering the practicability of the calculation time and stability to flow into the narrow gap. The gap of 10 mm between
the roller bearing and the slab can accommodate three particles with this condition.
(2) The effects of the contact angle between water and
the roll/slab on fluid flow
A study was made to see how the contact angle between
cooling water and the roll/slab affects fluid flow focusing on
whether the spray water through roller bearings portion flow
along the rolls or not.
Analysis was done on the water flow that freely falls
down in a space of 10 mm between the roller bearings and
the slab using the model shown in Fig. 7(a). There are no
remarkable differences between the contact angles of 30
and 60. (Figs. 7(b) and 7(c)) It is assumed that the flow is
dominated by inertia due to the higher flow speed of the
water with free fall. Therefore, 30 was applied for every
calculation.
(3) Shape expressions of spray jets
In a secondary cooling, it is preferable to minimize the
number of sprays in order to reduce maintenance costs.
Therefore, sprays should be only in sufficient number to
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Fig. 5.

Relationship between particle diameters and time-averaged

water flow rates or standard deviation of water flow rate at
(a) region A and (b) region B defined by Fig. 4.

Fig. 6.

Relationships between particle diameters and number of

particles or computational time.

achieve even cooling within the reachable positions.

For this reason, the nozzles are set to be the spray nozzles
expanded in width relative to the casting direction jetting
ovally with a large angle. The commercial software used in
this analysis did not assume oval jets but common circular
jets. Therefore, the program was properly modified to per978

ISIJ International, Vol. 55 (2015), No. 5

(a)

Fig. 7.

Fig. 8.

(b)

(c)

Effect of contact angles on water flow. (a) Simulation model. (b) Calculated flow pattern (Contact angle is
30 degree). (c) Calculated flow pattern (Contact angle is 60 degree).

Spray patterns. (a) Circle-shaped pattern. (b) Oval-shaped

pattern.

Table 1.

Fig. 9.

Simulation model for spray water flow between rolls (unit:

mm).

Calculation conditions of the spray water flow model.

Density (kg/m3)
Dynamic coefficient of viscosity (m2/s)
Coefficient of surface tension (N/m)
Boundary condition of wall
Turbulence model

1 000
1.0106
0.072
Non-slip
None
Fig. 10.

mit independent setting of different angular spreads in two

orthogonal directions.
Usually, the density of water droplets in a unit volume has
a distribution to some extent within the reachable positions
of an oval jet. It is therefore assumed that particles are
allowed to be jetted at random angles by providing angles
against the casting and width directions. The difference
between circular (Fig. 8(a)) and oval jets (Fig. 8(b)) is
shown in Fig. 8.
It should be noted that particles do not express actual
water droplets but calculation points. The purpose of the
present analysis is to simulate the macroscopic behavior of
fluid flow after the spray water has impinged with a slab.
Therefore the density distribution of water droplets in a unit
volume within an oval was not taken into consideration. The
above three considerations can suggest the conditions of a
particle diameter of 3 mm, a contact angle of 30 between
water and rolls/slab and oval spray jets. The properties of
water and the boundary conditions are shown in Table 1.
Analysis was performed through modeling with a characteristic pattern extracted from roller bearings arranged in the
strand; three steps of rolls and two steps of sprays as shown
in Fig. 9.
The sprays with upper steps of eight pieces and the lower
ones of seven pieces were reciprocally arranged along the

Calculated spray water flow (View from slab side).

casting direction. The rolls are divided into three pieces

while the intermediates roller bearings are provided in the
two places at the central part of the width. The distance
between the sprays and the slab, jetting angles of sprays
were set as 155 mm, 100 in width and 30 in the casting
direction, respectively.
3. Fluid Analysis of Spray Water by the Particle-based
Method and Verification Through Actual Measurement
An analysis result arranged as in Fig. 9 is shown in Fig.
10. This is the view from the side of the slab at 5 seconds
after the injection of the spray.
This output with the flow rate of 20 L/min a spray has
revealed that the cooling water jetted onto the slab unevenly
flows down as the dripping water. Obviously, it passes
through the roller bearings portions with a lot of water
standing still on the upper part of the rolls of the downstream side. In addition, some droplets spill over toward the
back side. Accuracy of the model was verified by using a
water model, in which water was jetted from the sprays
placed between acryl pipes attached to an acryl sheet that
simulates a slab. Figure 11 shows a typical example of the
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ISIJ International, Vol. 55 (2015), No. 5

Fig. 11.

Measured spray water flow from the water model (View

from slab side).

experimental result. The flow rate for each spray unit was
20 L/min the same as the calculation of Fig. 10. The behavior of the spray water was successfully simulated; water
flowed downward passing through the roller bearings along
with some water standing still on the rolls. For more quantitative evaluation, comparison was made on the flow rate
of water flowing out from the roller bearings portion and the
edges of the slab obtained by the calculation with the experiments as shown in Fig. 12.
At Regions 1-8 defined in Fig. 9, the flow rates obtained
by the calculation agreed well with the measurements. Three
figures of (a), (b) and (c) display the results with the flow
rates per spray piece of 5, 10 and 20 L/min, respectively.
The difference can be seen in the flow rates between the
actual measurements and the calculations at Regions 6 and
7 when the water flow rates are higher. This might be attributed to the variation of water amount that overflowed from
the system, since the amount of standing water on the rolls
varied owing to the slight difference in diameter of the acryl
pipes and the rolls of the calculation.
The subsequent analyses were performed only by calculation, because it was proved that fluid flow of spray water
could be more accurately analyzed by the particle-based
method.
Further analysis was carried out to see the effects of the
dripping water stood on the downstream side with increasing the step number of the rolls and spays. The behavior of
spray water was analyzed at a flow rate of 20 L/min per
spray piece in the model which consists of the five-step rolls
and the four-step sprays between the rolls. The results from
the slab and roll sides are shown in Figs. 13 and 14 at 5 seconds after the injection of the spray jets, respectively.
The standing water on the intermediate rolls overflows to
the rear side. The water amount becomes larger as it
approaches to the downstream side. On the other hand, the
outflow becomes larger at the edges of the slab with no significant effects on the flow rate at the roller bearing positions in the vicinity of the central part in width. This means
that modeling the characteristic sprays of around two-step
allows us to analyze the flow of spray water sufficiently.
This analysis allows us to understand the generation of a
large quantity of water kept standing on the intermediate
rolls of the split rolls that flows downward from the positions of the roller bearings. A question arises if this behavior
of the cooling water affects over-cooling in the vicinity of
the central part of slab width. Therefore, solidification analysis was performed taking the spray water flow into consideration.

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Fig. 12.

Comparison between the calculated and the measured water

flow rates. (a) Water flow rate of each nozzle is 5 L/min.
(b) Water flow rate of each nozzle is 10 L/min. (c) Water
flow rate of each nozzle is 20 L/min.

4. Estimation of Uneven Temperature in Width by

Means of Solidification Calculation in the Strand
Solidification calculation was made to understand the
solidification conditions of the strand considering abovementioned dripping water etc.
Before calculation, heat transfer coefficients were measured by the following method. Temperature variation of a
heated steel plate cooled by a spray was measured with mul980

ISIJ International, Vol. 55 (2015), No. 5

Fig. 13.

Fig. 14.

Fig. 15.

Calculated spray water flow (View from slab side).

Fig. 16.

Measured temperatures at the center and 210 mm from the

center of the steel plate.

Fig. 17.

Heat transfer coefficients (W/m2K) calculated from the

measured temperatures at the cooling test. (Online version
in color.)

Fig. 18.

Boundary conditions for the simulation model of solidification.

Calculated spray water flow (View from roll side).

Experimental image (Water is sprayed on the heated steel

plate). (Online version in color.)

tiple thermocouples simulating the dripping water and the

standing water.9) The procedure was that the plate was heated to 900C in a furnace under a controlled atmosphere followed by cooled with sprays immediately after being
extracted from the furnace. An image during the measurement with a single spray is shown in Fig. 15. Heat transfer
coefficients were determined by reverse analysis10) of the
measured temperatures of the steel plate. Figure 16 shows
the temperature variation of the steel plate as time at the
positions of the center and 210 mm away from the center.
Figure 17 shows the heat transfer coefficient distribution
with a water flow rate of 10.45 L/min when the surface temperature reached 800C. Reverse analysis of a result makes
it possible to calculate heat transfer coefficients as functions
of time implying that coefficients can be determined at various surface temperatures. However, at the lower temperatures, in general, obtained heat transfer coefficients are not
accurate enough due to the effect of the three-dimensional
heat conduction in the steel plate. Accordingly, heat transfer

coefficients were measured at a temperature 100C below

the initial temperature of the plate. For instance, when the
heat transfer coefficients at 700C are required, the plate
was initially heated to 800C.
Heat transfer coefficients were thus obtained as functions
of the density of sprayed water in a local unit volume, surface temperature of the steel plate and the impingement
pressure of the sprays by the experiments under various
water flow rates from the sprays in conjunction with various
temperatures of the steel plate.
The effect of the dripping water on heat transfer coefficients was determined by providing a water flow from
above the sprays simulating the dripping water on the roller
bearings.
The amount of dripping water was set referring to the
flow rates provided in Fig. 12. In consideration of the effect
of water standing on the rolls, cooling experiments were
performed with a steel sheet assembled with the steel plate
simulating an actual situation.
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Fig. 19.

Simulation model of solidification.

It was found that the water calmly standing on the rolls

did not show significant cooling effects. On the other hand,
an important finding was that cooling was facilitated when
the standing water was interfered with the spray water, that
leads to vigorous agitation. These experiments could
successfully determine the heat transfer coefficients in the
portions of sprays with and without interference of water
standing on the rolls, dripping water, and so forth. Therefore, these values were substituted as the boundary conditions of the solidification calculation in the strand.
The boundary conditions of heat transfer were given to
the four separated regions between the rolls. (Fig. 18) I, II,
III, and IV denote the roll cooling region, the air cooling
region or roller bearing dripping water region, the spray
cooling region, and the region of water standing on the rolls
or spray dripping water region, respectively. As for the variation of the heat transfer coefficient in width, in the portion
(II) of the dripping water interfered with the spray water,
heat transfer coefficient was given as 1.1 times higher than
that in the portion only with the dripping water. Similarly,
heat transfer coefficient in the portion (IV) of the standing
water interfered with the spray water was given as 1.5 times
higher than that in the portion only with the standing water.
These coefficients of 1.1 and 1.5 were determined by the
experiments described above. Various phenomena during
solidification were calculated by inputting the heat transfer
coefficients as the boundary conditions for every region
shown in Fig. 18. Here, the two-dimensional sections vertical to the casting direction were considered under a fixed
casting speed. The enthalpy method was used for the solidification calculation. Table 2 shows the values of material
properties and the boundary conditions. Calculation was
succeeded accounting for the effects of the split rolls, the
dripping water and standing water created due to the roller
bearings and the rolls. As explained above, these effects
were identified by the particle-based method providing heat
transfer coefficient distributions.
As a result, it was found that there was an over-cooled
part at the central portion in the width center of the slab. It
could clearly reveal the uneven solidification as shown in
Figs. 20(a), 20(b) and 20(c), indicating surface temperature,
heat transfer coefficient and solid fraction at the center of
the slab in thickness, respectively.
Heat transfer coefficients in Fig. 20(b) are larger in the
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Table 2.

Calculation conditions of the simulation model of solidification.

Density (kg/m3)

7 800

Reference specific thermal conductivity (W/mK)

59

Reference specific heat (kJ/kgK)

0.47

Latent heat (kJ/kg)

260

Reference temperature (C)

30
2

Heat transfer coefficient (W/m K)

Roll-Slab
Spray water-Slab

Fig. 20.

1 700
Measured data

Calculated results of solidification. (a) Surface temperatures. (b) Heat transfer coefficients. (c) Solid fraction at
the center of the slab in thickness.

central portion of the width in the vicinity of a point at 5 m

below the meniscus due to the previously mentioned interference between the standing water on the rolls and the
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Fig. 21.

because of good agreement with each other.

(3) The present model successfully simulated the
behaviors of dripping water flowing to the downstream side
in the roller bearing portion and water standing still on the
rolls.
(4) Determinations of heat transfer coefficients were
performed accounting for the interference of dripping water
with water standing on the rolls leading to vigorous agitation.
(5) Solidification calculation using the measured heat
transfer coefficients revealed that the dripping water
between the roller bearings and standing water on the rolls
contributed to the unevenness along the width direction.
(6) Temperature distribution along the width direction
obtained by the analyses well agreed with the measured values by a radiation thermometer.
(7) It was understood that interference of water standing
still on the intermediate roll portion among the split rolls
with the spray water caused temperature drop in the central
portion of the slab width.

Comparison between the measured and the calculated surface temperatures at 18 m below the meniscus.

spray water. Surface temperatures at 5 m below the meniscus are relatively lower due to this effect. Further, distribution of the center solid fractions in Fig. 20(c) shows that
solidification at the center portions complete prior to the
vicinity of the slab edges.
Figure 21 shows comparison of the surface temperature
between the measurement results obtained by the thermometer and the calculation results. This indicates that the temperatures of the central portions tend to be 100C lower or
less than those of the vicinity of the edge portions. The overcooled phenomena at the center are considered to be caused
by the higher heat transfer coefficients due to the vigorously
agitated water originated from the dripping water passing
through the roller bearings in the central portion of the split
rolls.

Acknowledgements
The present study was assisted by Professor Seiichi
Koshizuka, who majored in the Department of Systems
Innovation, Graduate School of Engineering, the University
of Tokyo and the staff of Prometech Software Company Ltd.
for the particle-based method analysis; Mr. Toshihiro
Kawano of Meitec Company Ltd. for construction/processing and visualization of the calculation models; and the staff
of Kyoritsu Gokin Company Ltd., for the measurement of
heat transfer coefficients. I am sincerely grateful for their
contributions.

5. Conclusions

REFERENCES

A study was undertaken to understand how uneven solidification phenomena occur along the width direction of a
slab during secondary cooling in continuous casting process.
Numerical analyses was performed by the particle-based
method to see the behavior of spray water inside the strand.
In addition, solidification analysis was conducted taking
heat transfer coefficients into consideration, which is affected by the fluid flow of spray water.
The following words conclude this study.
(1) The optimal diameter of particles used for calculation was found to be 3 mm. It was further found that the
effects of the contact angle between the water and the roll/
slab on the behavior of spray water were negligibly small.
(2) The present simulation by the particle-based method
was verified by the experiments using a water model

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