
Herein, three‐phase numerical and experimental studies were performed to investigate the effect of various ladle shroud designs on the hydrodynamic performance of steelmaking tundish and size of the tundish open eye (TOE) formed. It is known that gas shrouding is necessary to prevent air ingression; however, it leads to the formation of TOE, which seriously impairs the steel cleanliness. This article considers a 0.35 reduced scale model of single‐strand slab casting tundish fabricated using PERSPEX sheets, fitted with four different shrouds, namely, conventional ladle shroud (CLS), bell‐shaped ladle shroud (BLS), reverse‐tapered ladle shroud (RTLS), and direct‐tapered ladle shroud. The experimental and numerical investigations have been performed for gas‐to‐liquid loading ratios of 10%, 20%, and 30%. The numerical modeling has been done using volume of fluid method in ANSYS Fluent 2021R1 and is validated against the experimental results. With the use of BLS and RTLS, significant improvement in tundish hydrodynamics can be observed when compared to CLS, as increase in plug flow varies from 10% to 25%, and decrease in dead region ranges from 15% to 35% at various gas‐to‐liquid loading ratios. Further, size of TOE decreases by ≈25% with the implementation of BLS and RTLS at higher gas‐to‐liquid loading ratio.
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