Case Study: Tata Steel achieves reduced transition tonnage and improved casting quality with ANSYS Fluent

Prediction of Transition Tonnage During the Grade Change in a Continuous Casting Process

Tata Steel needed to predict and minimize the transition tonnage produced during grade changes in its continuous casting process, where intermixed billets must be downgraded or diverted. To tackle this, Tata Steel used ANSYS simulation software—specifically ANSYS® Fluent®—to model tundish flow and assess how varying casting speeds and strand availability affect transition zones.

ANSYS implemented a solution using ANSYS Fluent with the realizable k-ε turbulence model and an unsteady-state species transport model to generate residence time distributions and predict the start and end of transitions. The ANSYS-based model, validated against plant trials, helped Tata Steel optimize transition tonnage, reduce customer complaints, lower the cost of plant-scale experiments, and speed up analysis setup and post-processing.

Tata Steel

Mrityunjay Kumar Singh

Head-Process Modeling and Visualization