Design and optimization of stirrers are complex activities for two main reasons: there is no standard in steelmaking plants, meaning that a personalized design is typically required, and it is not possible to accurately predict the flow induced to liquid steel in the mould. To overcome these complexities two ways can be followed: experimental analysis on scale models and computer-aided numerical simulation. On these basis Ergolines Lab has developed a new design and simulation software tool which is capable to provide engineering solutions and process optimization in times compatible with design requirements, and that can lead to better metallurgical results and lower energy consumption. This paper describes an example of analysis made on a billet caster production facility. In particular, the following has been evaluated: influence of electric operating parameters (current and frequency), influence of process parameters (casting speed and type of entry nozzle adopted).
