The process of continuous casting of steel is a complex technological task, including issues related to heat transfer, the steel solidification process, liquid metal flow and phase transitions in the solid state. This involves considerable difficulty in creating the optimal process control system, which would include the influence of all the physico-chemical phenomena which may occur. In parallel, there is an intensive development of new mathematical models and an increase in computer performance, therefore complex numerical simulations requiring substantial computing time can be conducted. This paper presents a review of currently applied numerical methods allowing the phenomena accompanying the process of continuous casting of steel to be accurately represented. Special attention was paid to the selection of appropriate methods to solve the technological problem selected. The possibilities of applying selected numerical models were analysed in order to modify and improve the existing process or to design a new one linked to the implementation of new steel grades in the current production. The description of the method of defining the boundary conditions, initial conditions and material parameters as vital components ensuring that numerical calculations based upon them in the finite element method, which is that most frequently applied, are correct is an important element of the paper. The possibility of reliably defining the values of boundary parameters on the basis of information on the intensity of cooling in individual zones of the continuous casting machine was analysed.

This paper presents a strategy of the cooling parameters selection in the process of continuous steel casting. Industrial tests were performed at a slab casting machine at the Arcelor Mittal Poland Unit in Krakow. The tests covered 55 heats for 7 various steel grades. Based on the existing casting technology a numerical model of the continuous steel casting process was formulated. The numerical calculations were performed for three casting speeds - 0.6, 0.8 and 1 m min^-1. An algorithm was presented that allows us to compute the values of the heat transfer coefficients for the secondary cooling zone. The correctness of the cooling parameter strategy was evaluated by inspecting the shell thickness, the length of the liquid core and the strand surface temperature. The ProCAST software package was used to construct the numerical model of continuous casting of steel.

The problem of macrosegregation of alloying elements occurring during cast strand solidification in the continuous casting process is still valid; it is the subject of numerous experiments and theoretical considerations. A large percentage of this research is dedicated to carbon segregation, which, for understandable reasons, is vital for the production of high-carbon steels. The background knowledge on the mechanism of segregation occurrence indicates that it is a very complex effect, and a broad range of factors influencing the continuous casting process need to be considered. Therefore, it is difficult to translate information (provided by complex models of metal flow through a diphase area at the solidification interface of a cast strand) into practical engineering recommendations to reduce the macrosegregation effect. The presented study shows the latest research related to the carbon macrosegregation effect for selected high-carbon steel grades cast with a continuous caster. Problems related to the recording of the effect concerned have been pointed out. The second part of the paper presents the influence of selected casting parameters on carbon macrosegregation intensity when casting 160 × 160 billets with a six-strand caster. In this case, the main subject of the research was the influence of the casting speed on macrosegregation intensity. In the following step, an attempt was made to find the relationship between the cast strand structure and the distribution of carbon content on its cross-section. The ultimate objective of the presented study was to find an answer to the question on the technological capabilities of restricting the segregation effect.