A three-dimensional heat transfer model for continuous steel slab casting has been developed with realistic spray cooling patterns and a coupled microsegregation solidification model that calculates the solidification path for multicomponent steels. Temperature and composition dependent properties are implemented in a database for 15 chemical species. Considerable effort is made to accurately model the spray cooling heat transfer. Each spray nozzle position and distribution is considered, including variations of the spray patterns with flow rate, and spray overlap. Nozzle type, layout, nozzle-to-slab distance, and spray span and flux are variable. Natural convection, thermal radiation and contact cooling of individual rolls are computed. The present model provides more comprehensive information and realistic slab surface temperatures than results from a model using the "averaged" treatment of boundary conditions.Cooling operating conditions and parameters of individual spray nozzles can be analyzed to optimize nozzle spray distribution, improve product quality, and troubleshoot issues such as nozzle clogging that may arise during production.One spray cooling correlation is used for the entire machine, achieving as good or better agreement with surface temperature measurements than was found previously for the model using an "averaged" treatment of boundary conditions and using three machine-segment-dependent correlations.
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