In the current study, we present a series of numerical simulations describing a turbulent magnetohydrodynamic flow subjected to a transverse magnetic field in a square duct with arbitrary electrically conductive walls. The characteristic flow and electromagnetic non-dimensional parameters (Reynolds and Hartmann number, respectively) were fixed, while the wall conductivity ratio (Cd) was varied from the perfectly electrically insulated (Cd = 0) to perfectly electrically conducting (C d → ∞). We have assumed the one-way coupling between the flow of an electrically conducting fluid and the imposed magnetic field. The influence of the electrically conducting walls was imposed by simulating additional finite solid domains coupled with the channel interior. The turbulence was simulated by applying the large eddy simulation approach with the dynamic Smagorinsky sub-grid scale model. The obtained results confirmed a significant impact of the conductivity of the surrounding walls on the flow and turbulence reorganization. We have observed that the initially fully developed turbulence regime was gradually suppressed in the 0 ≤ C d < 0.15 range, while the fully laminarized state was obtained at C d = 0.15. We found that the process of turbulence suppression was accompanied by the appearance of the patterned turbulence phenomenon in the proximity of the walls parallel to the magnetic field direction. With a further increase in the wall conductivity parameter (0.15 < C d < ∞), we have observed a complete turbulence regeneration. We found that this turbulence regeneration was caused by the local reorganization of the total current density loops near the electrically conducting walls.

More than 96% of steel in the world is produced via the method of continuous casting. The flow condition in the mould, where the initial solidification occurs, has a significant impact on the quality of steel products. It is important to have timely, and perhaps automated, control of the flow during casting. This work presents a new concept of using contactless inductive flow tomography (CIFT) as a sensor for a novel controller, which alters the strength of an electromagnetic brake (EMBr) of ruler type based on the reconstructed flow structure in the mould. The method was developed for the small-scale Liquid Metal Model for Continuous Casting (mini-LIMMCAST) facility available at the Helmholtz-Zentrum Dresden-Rossendorf. As an example of an undesired flow condition, clogging of the submerged entry nozzle (SEN) was modelled by partly closing one of the side ports of the SEN; in combination with an active EMBr, the jet penetrates deeper into the mould than when the EMBr is switched off. Corresponding flow patterns are detected by extracting the impingement position of the jets at the narrow faces of the mould from the CIFT reconstruction. The controller is designed to detect to undesired flow condition and switch off the EMBr. The temporal resolution of CIFT is 0.5 s.

In the present study, we have performed a series of numerical simulations of the turbulent liquid metal flow in a laboratory-scale setup of the continuous casting. The liquid metal flow was subjected to an external non-uniform magnetic field reproducing a realistic electromagnetic brake (EMBr) effect. The focus of this research was on the effects of the finite electrical conductivity of Hartmann walls on the flow and turbulence in the mold. To be able to simulate distributions of the electric potential and current in both the fluid and solid wall domains, we applied our recently developed and validated in-house conjugate MHD solver based on the open-source code OpenFOAM. The dynamic Large Eddy Simulation (LES) method was used to simulate the turbulent flow. The results obtained for the neutral (non-MHD) and MHD cases over a range of the imposed EMBr strengths – all for the perfectly electrically insulated walls – were compared with the available Ultrasound Doppler Velocimetry (UDV) measurements. A good agreement between simulations and experiments was obtained for all simulated cases. Next, we completed a series of simulations including a wide range of the finite electric conductivities (ranging from a weakly to perfectly conducting wall conditions) of the Hartmann walls for a fixed value of the imposed EMBr. The obtained results demonstrated a significant influence of the electric wall conductivities on the flow and turbulence reorganization. It is expected that here provided insights can be applicable for the new generation of the laboratory- and real-scale continuous casting setups.

We present results of a series of numerical simulations of an initially fully developed turbulent flow of a liquid metal in a long duct under the influence of a constant uniform transverse magnetic field and various wall conductances (ranging from perfectly insulated to perfectly conducting walls). The changes in the wall conductance caused the appearance of novel flow regimes characterized by the coexistence of locally turbulent or laminar flow regions and a nonmonotonic behavior of the corresponding wall-friction coefficients. In contrast to the situation where an increase in the imposed magnetic field will lead to continuous suppression of turbulence and final complete relaminarization of the flow in a specific range of wall-conducting parameters, we also observe an apparent partial and complete turbulence regeneration from the magnetohydrodynamic-suppressed laminar state.

There is a continuous need for an updated series of numerical benchmarks dealing with various aspects of the magnetohydrodynamics (MHD) phenomena (i.e. interactions of the flow of an electrically conducting fluid and an externally imposed magnetic field). The focus of the present study is numerical magnetohydrodynamics (MHD) where we have performed an extensive series of simulations for generic configurations, including: (i) a laminar conjugate MHD flow in a duct with varied electrical conductivity of the walls, (ii) a back-step flow, (iii) a multiphase cavity flow, (iv) a rising bubble in liquid metal and (v) a turbulent conjugate MHD flow in a duct with varied electrical conductivity of surrounding walls. All considered benchmark situations are for the one-way coupled MHD approach, where the induced magnetic field is negligible. The governing equations describing the one-way coupled MHD phenomena are numerically implemented in the open-source code OpenFOAM. The novel elements of the numerical algorithm include fully-conservative forms of the discretized Lorentz force in the momentum equation and divergence-free current density, the conjugate MHD (coupling of the wall/fluid domains), the multi-phase MHD, and, finally, the MHD turbulence. The multi-phase phenomena are simulated with the Volume of Fluid (VOF) approach, whereas the MHD turbulence is simulated with the dynamic Large-Eddy Simulation (LES) method. For all considered benchmark cases, a very good agreement is obtained with available analytical solutions and other numerical results in the literature. The presented extensive numerical benchmarks are expected to be potentially useful for developers of the numerical codes used to simulate various types of the complex MHD phenomena.

The current study is focused on the magnetohydrodynamics and demonstrates how electrical conductivity of the wall can affect the turbulent flow in the square duct. Different variations of the boundary walls have been considered including arbitrary conductive walls. The Large Eddy Simulations method with the dynamic Smagorinsky sub-grid scale model have been used for the turbulent structures resolving. Results show the significant impact of the wall conductance parameters for both Hartmann and side walls.

In continuous casting, the flow structure of the liquid steel in the mould and the two-phase distribution in the submerged entry nozzle (SEN) are crucial for the quality of the produced steel. In order to effectively control the flow in the mould by electromagnetic brakes (EMBrs) and the injection of gas into the SEN, even a rough knowledge of the flow structure would be very helpful. In the framework of the TOMOCON project, the contactless inductive flow tomography (CIFT) and the mutual inductance tomography (MIT) will be integrated into a control loop for slab casters. This control loop will be developed and implemented at the Mini-LIMMCAST facility, which is available at the Helmholtz-Zentrum Dresden - Rossendorf. In this paper a short overview of this project will be given.