A 3D mathematical model was proposed to investigate the molten steel–slag–air multiphase flow in a two-strand slab continuous casting(CC)tundish during ladle change.The study focused on the exposure of the molten st...A 3D mathematical model was proposed to investigate the molten steel–slag–air multiphase flow in a two-strand slab continuous casting(CC)tundish during ladle change.The study focused on the exposure of the molten steel and the subsequent reoxidation occurrence.The exposure of the molten steel was calculated using the coupled realizable k–εmodel and volume of fluid(VOF)model.The diffusion of dissolved oxygen was determined by solving the user-defined scalar(UDS)equation.Moreover,the user-defined function(UDF)was used to describe the source term in the UDS equation and determine the oxidation rate and oxidation position.The effect of the refilling speed on the molten steel exposure and dissolved oxygen content was also discussed.Increasing the refilling speed during ladle change reduced the refilling time and the exposure duration of the molten steel.However,the elevated refilling speed enlarged the slag eyes and increased the average dissolved oxygen content within the tundish,thereby exacerbating the reoxidation phenomenon.In addition,the time required for the molten steel with a high dissolved oxygen content to exit the tundish varied with the refilling speed.When the inlet speed was 3.0 m·s^(-1)during ladle change,the molten steel with a high dissolved oxygen content exited the outlet in a short period,reaching a maximum dissolved oxygen content of 0.000525wt%.Conversely,when the inlet speed was 1.8 m·s^(-1),the maximum dissolved oxygen content was 0.000382wt%.The refilling speed during the ladle change process must be appropriately decreased to minimize reoxidation effects and enhance the steel product quality.展开更多
A rotating stopper-rod technique was proposed to suppress the formation of free-surface vortex in the tundish.The large eddy simulation model coupled with volume of fluid model was developed to study the steel–slag–...A rotating stopper-rod technique was proposed to suppress the formation of free-surface vortex in the tundish.The large eddy simulation model coupled with volume of fluid model was developed to study the steel–slag–gas three-phase flow behavior.The critical slag entrapment height of the free-surface vortex and mass of residual steel were predicted at different rotating speeds(30,60,90 and 120 r/min)of the rotating stopper-rod.The numerical model was verified by water model experiment.The results showed that by rotating the stopper-rod in the opposite direction of the vortex above the submerged entry nozzle,the formation of vortex can be effectively disturbed and the critical height of the free-surface vortex can be reduced.Particularly for the 2nd strand,when the rotating speeds are 30,60,90 and 120 r/min,the critical height of the free-surface vortex above the 2nd strand is 7.3,4.7,6.3 and 7.4 cm,respectively.A reasonable rotating speed should be 60 r/min,which can reduce about 2 tons of residual steel.Other rotating speeds just can reduce about 1.6 tons of residual steel.展开更多
The external residence time distribution(RTD)curve is extensively used to characterise fluid flow within the single-strand continuous casting tundish.Dead volume fraction determination typically relies on the external...The external residence time distribution(RTD)curve is extensively used to characterise fluid flow within the single-strand continuous casting tundish.Dead volume fraction determination typically relies on the external RTD curve to reveal macroscopic fluid flow behaviour.Based on the external RTD to effectively assess dead volume fractions and other fluid characteristics under conditions of internal non-uniform flow,an internal RTD was introduced.In a smooth pipe under laminar flow conditions,the dead region occupies 25%of the total volume,which is defined as the space between the pipe wall and a radius of 0.866 R0(where R0 is the radius of pipe).Under turbulent flow conditions,the dead region only occupies 0.38%of the reactor’s internal volume,spanning from the pipe wall to a radius of 0.00189 R0.The results obtained using the external RTD method are consistent with the theoretical analysis.Experimental trials involving water were conducted to examine the flow of molten steel within a five-strand tundish.Subsequently,an analysis approach employing internal RTD was employed to evaluate fluid mixing within a multi-flow continuous casting tundish.Using the internal RTD method,the analysis revealed that the whole dead zone volume fraction of the intermediate package decreased from 26.9%to 18.9%after the addition of the flow control device.The dead volume fraction can be accurately depicted by utilising the internal mean RTD function.The association between the internal RTD function and the external average RTD can be effectively employed to scrutinise the response curve of the tracer within a system exhibiting uneven flow distribution.展开更多
A three-dimensional mathematical model has been established for a novel metallurgy process coupling an annular gas curtain with swirling flow at tundish upper nozzle. The discrete phase model and volume of fluid model...A three-dimensional mathematical model has been established for a novel metallurgy process coupling an annular gas curtain with swirling flow at tundish upper nozzle. The discrete phase model and volume of fluid model were applied to simulate the gas–liquid multiphase flow behavior in tundish and nozzle. The effect of argon flow rate on the migration behavior of bubbles and interface behavior between steel and slag was also investigated. The presented results indicate that the novel coupling process can significantly change the flow pattern in the stream zone of a tundish, prolong the average residence time of liquid steel, and reduce the dead fraction. A complete annular gas curtain is formed around the stopper rod of tundish. Under the action of drag force of liquid steel, a part of small bubbles enter the nozzle through the swirling grooves and gather toward the center of the nozzle by centripetal force. As the argon flow rate increases, the volume fraction of argon gas entering the nozzle increases, which enhances the swirl intensity and increases the concentration of bubbles in the nozzle. To avoid the formation of slag open eye in tundish, the argon flow rate should not exceed 8 L min−1.展开更多
The research on tundish metallurgy has focused mainly on taking countermeasures to avoid and remove inclusions and the recent developments on tundish metallurgy were surveyed.The authers'advices for future develop...The research on tundish metallurgy has focused mainly on taking countermeasures to avoid and remove inclusions and the recent developments on tundish metallurgy were surveyed.The authers'advices for future development of tundish metallurgy were given in summary section.展开更多
A detailed mathematical procedure of the optimization of the fluid flow in a tundish water model with and without flow control devices （weir and dam） was carried out using the commercial CFD eode FLUENT 6.0. The （...A detailed mathematical procedure of the optimization of the fluid flow in a tundish water model with and without flow control devices （weir and dam） was carried out using the commercial CFD eode FLUENT 6.0. The （k- ε） two-equation model was used to model turbulence. The residence time distribution （RTD） curves were used to analyze the behavior of the flow in tundish. The location of flow control devices in the tundish was studied. The results show that the flow modifiers play an important role in promoting the floatation of nonmetallic inclusions in steel. Comparing the three geometric configurations that are considered （bare tundish, weir, weir＋dam）, the tundish equipped with the arrangement （weir＋dam） is a best and optimal geometric configuration of tundish.展开更多
The optimization of flow control devices in a single-slab continuous casting tundish was carried out by physical modeling, and the optimized scheme was presented. With the optimal tundish configuration, the minimum re...The optimization of flow control devices in a single-slab continuous casting tundish was carried out by physical modeling, and the optimized scheme was presented. With the optimal tundish configuration, the minimum residence time of liquid steel was increased by 1.4 times, the peak concentration time was increased by 97%, and the dead volume fraction was decreased by 72%. A mathematical model for molten steel in the tundish was established by using the fluid dynamics package Fluent. The velocity field, concentration field, and the resi-dence time distribution （RTD） curves of molten steel flow before and after optimization were obtained. Experimental results showed that the reasonable configuration with flow control devices can improve the fluid flow characteristics in the tundish. The results of industrial applica-tion show that the nonmetallic inclusion area ratio in casting slabs is decreased by 32% with the optimal tundish configuration.展开更多
A 1∶2.5 scale tundish model was set up in laboratory for a six-strand billet continuous casting tundish with different configurations to investigate fluid flow characteristics under different operational conditions b...A 1∶2.5 scale tundish model was set up in laboratory for a six-strand billet continuous casting tundish with different configurations to investigate fluid flow characteristics under different operational conditions by measuring residence time distribution curves.It was found that minimum residence time,maximum concentration time and average residence time of the three strands on the same side of the tundish with the former configuration under normal operation,that is,six strands were open,were small and non-uniform and the tundish had large dead volume fraction.Vortexes easily formed on the liquid surface in the pouring zone of the tundish.The fluid flow characteristics in the tundish with the optimal turbulence inhibitor and baffles were improved and became less non-uniform among the strands.Vortexes were not found on the pouring zone surface in the optimal tundish.For non-normal operation,that is,one strand was close,it was important to choose which strand to be closed for maintaining flow characteristics of the rest two strands.It was found from this investigation that fluid flow characteristics in the optimal configuration tundish with closing strand 2 were better than those with closing strand 3 on the same side.展开更多
In the water modeling experiments, three cases were considered, i. e, , a bare tundish, a tundish equipped with a turbulence inhibitor, and a rectangular tundish equipped with weirs （dams） and a turbulence inhibitor...In the water modeling experiments, three cases were considered, i. e, , a bare tundish, a tundish equipped with a turbulence inhibitor, and a rectangular tundish equipped with weirs （dams） and a turbulence inhibitor. Comparing the RTD curves, inclusion separation, and the result of the streamline experiment, it can be found that the tundish equipped with weirs （dams） and a turbulence inhibitor has a great effect on the flow field and the inclusion separation when compared with the sole use or no use of the turbulent inhibitor or weirs （dams）. In addition, the enlargement of the distance between the weir and dam will result in a better effect when the tundish equipped with weirs （dam） and a turbulence inhibitor was used.展开更多
A conventional turbulence inhibitor is compared with a swirling chamber from the points of view of fluid flow and removal rate of inclusion in the tundish. Comparing the RTD curves, inclusion removals, and the streaml...A conventional turbulence inhibitor is compared with a swirling chamber from the points of view of fluid flow and removal rate of inclusion in the tundish. Comparing the RTD curves, inclusion removals, and the streamlines in water model experiments, it can be found that the tundish equipped with a swirling chamber has a great effect on improving the flow field, and the floatation rate of inclusion is higher than the tundish with a turbulence inhibitor. Because of the introduction of the swirling chamber, the flow field and inclusion removal in a two-strand swirling flow tundish are asymmetrical. Rotating the inlet direction of swirling chamber 60 degree is a good strategy to improve the asymmetrical flow field.展开更多
The metallurgical effect of a round tundish used to cast heavy steel ingots in machine works at present was evaluated through water modeling experiments. The flow control devices of the improved oval tundish, which wa...The metallurgical effect of a round tundish used to cast heavy steel ingots in machine works at present was evaluated through water modeling experiments. The flow control devices of the improved oval tundish, which was used instead of the round tundish, had been optimized. The results show that the residence time of the round tundish is short, its inclusion removal efficiency is too low, and it has more dead zones and an unreasonable flow field. Compared with the round tundish, the improved oval tundish with the optimized weir and dam has a better effect： its minimum residence time is prolonged by 38.1 s, the average residence time is prolonged by 233.4 s, its dead volume fraction decreases from 26% to 15%, and the ratio of plug volume fraction to dead volume fraction increases from 0.54 to 1.27. The inclusion removal efficiency also increases by 17.5%.展开更多
The mechanism of inclusion aggregation in liquid steel in swirling flow tundish is analyzed by applying the theory of flocculation which was developed in the field of colloid engineering. The gas bridge forces due to ...The mechanism of inclusion aggregation in liquid steel in swirling flow tundish is analyzed by applying the theory of flocculation which was developed in the field of colloid engineering. The gas bridge forces due to the micro bubbles on hydrophobic inclusion surfaces were responsible for the inclusion collision and agglomeration, which can avoid the aggregation to breakup. The quantity of micro bubbles on hydrophobic inclusion particle is more than that on hydrophilic one. The trend of forming gas bridges between micro bubbles on particles is strong in the course of collision. The liquid film on hydrophobic particles is easy to break during collision process. Hydrophobic particles are liable to aggregate in collision. According to the analysis of forces on a nonmetallic inclusion particle in swirling chamber, the chance of inclusion collision and aggregation can be improved by the centripetal force. Hydropbobic particles in water are liable to aggregate in collision. Hydrophilic particles in water are dispersed although collision happens. The wettability can be changed by changing solid-liquid interface tension. The nonmetallic inclusion removal in swirling flow tundish is studied. The result shows that under certain turbulent conditions, the.particle concentration and the wettability between particles and liquid steel are the main factors to induce collision and aggregation.展开更多
Improper flow control devices in a multi-strand tundish can cause some problems, for example, liquid steel cannot reach every nozzle at the same time and the liquid steel in nozzles far away from the entry zone has a ...Improper flow control devices in a multi-strand tundish can cause some problems, for example, liquid steel cannot reach every nozzle at the same time and the liquid steel in nozzles far away from the entry zone has a lower temperature. The water model experiment of a six-strand tundish of Tianjin Iron ＆ Steel Co. Ltd. was performed, a new ＂U＂ type baffle was obtained, and its parameters were defined by perpendicular analysis. The ＂U＂ baffle can not only improve those imperfections, but also prolong the residence time of nonmetallic inclusions, which is good for their flotation and separation.展开更多
Fluid flow characteristics in a four-strand tundish with gas blowing were studied by water modeling experiments.It is found that gas blowing can greatly improve the flow characteristics in the tundish with a turbulenc...Fluid flow characteristics in a four-strand tundish with gas blowing were studied by water modeling experiments.It is found that gas blowing can greatly improve the flow characteristics in the tundish with a turbulence inhibitor.It dramatically increases the peak concentration time,and greatly decreases the dead volume,and reduces the minimum residence time.The gas blowing location,gas flow rate,and porous plug area greatly influence the flow characteristics in the tundish; the gas blowing location near the baffle,smaller gas flow rate,and smaller porous plug area are better for improving the fluid flow characteristics.Using gas blowing can reduce the difference of flows at the middle outlets and side outlets for the multi-strand tundish.Bubbles produced by gas blowing can absorb small inclusions and provide the condition for inclusion collision and aggregation.Therefore,introducing gas blowing into a tundish and combining the turbulence inhibitor can improve inclusion floating and removal,and the cleanness of molten steel can be advanced.展开更多
The optimization of flow control devices(FCDs) for a T-type five-strand billet caster tundish was carried out by water modeling and numerical simulation. In water modeling experiments, flow characteristics of the bare...The optimization of flow control devices(FCDs) for a T-type five-strand billet caster tundish was carried out by water modeling and numerical simulation. In water modeling experiments, flow characteristics of the bare tundish and tundish conf igurations with designed U-type baff les and a round turbulence inhibitor were analyzed using residence time distribution(RTD) curves. Mathematical models for liquid steel in the real plant tundish were established using the fluid dynamics software package Fluent. The flow field, the temperature field, and the RTD curves of liquid steel in the proposed tundish conf igurations were obtained. The results of numerical simulation and water modeling were validated with each other by the predicted and experimental RTD curves. The results of flow field and temperature field were used to ref lect the actual state of a real plant tundish and to choose the optimal FCD. Finaly, from the whole performance of the multi-strand tundish, the optimal scheme was determined by combining the results of water modeling and numerical simulation. With the optimal tundish equipped with U-type baffle with def lector holes and round turbulence inhibitor, not only was the flow characteristic of each strand improved, but also the difference of flow characteristics between multiple strands was smaller.展开更多
The solidified crust was harmful to Al-killed steel casting using a basic tundish flux. After sampling from an actual tundish, XRD, SEM and EDX examinations were carried out to analyze the microstructure of solidified...The solidified crust was harmful to Al-killed steel casting using a basic tundish flux. After sampling from an actual tundish, XRD, SEM and EDX examinations were carried out to analyze the microstructure of solidified crusts. The conclusions were obtained as follows： main crystallization phases existing in tundish crust were Ca12 A14 O23, Ca2SiO4 and a little spinel; spinel and Ca2SiO4 distributed between the grain boundaries of Ca12 A14 Oa3, which increased the connection strength of crystallization phases by pinning grain boundary, density or hardness of solidified crust maybe also significantly increases; when initial composition of tundish flux was located in spinel region of CaO-SiO2-Al2 O3-10 % MgO phase diagram, it was easier to precipitate spinel from molten slag; three approaches of spinel formation in flux were summarized. When flux was saturated with magnesia on the metal/flux interface, MgO in flux was reduced by dissolved aluminum and then formed spinel. On the interface of steel/refractory, with feasible aluminum content, it was also easy to form spinel, and spinel inclusions will be floated and captured by tundish flux.展开更多
The fluid flow and the interfacial phenomenon of slag and metal in tundish with gas blowing were studied with mathematical and physical modeling, and the effects of gas flowrate, the placement of porous beam for the g...The fluid flow and the interfacial phenomenon of slag and metal in tundish with gas blowing were studied with mathematical and physical modeling, and the effects of gas flowrate, the placement of porous beam for the generation of bubbles, and the combination of flow control devices on the flow and slag-metal interface were investigated. The results show that the position of gas bubbling has a significant effect on the flow in tundish, and the placement of porous beam and gas flowrate are the two main factors affecting the entrapment of slag in tundish. The closer the porous beam to the weir, the more reasonable is the flow, which is in favor of the control of slag entrapment in tundish.展开更多
For a multistream tundish,the uniformity among the streams plays a significant role in the quality of molten steel.How to analyze the uniformity quantitatively and optimize structures of a multistream tundish is an im...For a multistream tundish,the uniformity among the streams plays a significant role in the quality of molten steel.How to analyze the uniformity quantitatively and optimize structures of a multistream tundish is an important research content for a multistream tundish.A new approach was proposed to quantify the uniformity among the streams.And a physical study and a numerical study were carried out to optimize the structure of the diversion hole based on the prototype of a six-stream tundish in a steel plant.On the basis of average residence time,the uniformity of each flow was considered fully and then the optimal structure of the diversion hole was obtained by means of the comprehensive analysis of temperature field and velocity field.The results show that the optimum structural parameters adopted for diversion holes are height of 20 mm,angle of 15°and diameter of 80 mm.展开更多
A coupled mathematical model was developed to describe the flow field,temperature distribution of molten steel in the tundish with the channel type induction heating.The molten steel motion was dominated under the com...A coupled mathematical model was developed to describe the flow field,temperature distribution of molten steel in the tundish with the channel type induction heating.The molten steel motion was dominated under the combined effect of the thermal buoyancy and the electro-magnetic forces(EMFs)due to the channel type induction heating.The results indicate that the thermal loss of molten steel in the tundish can be compensated effectively by the channel type induction heating.In addition,the molten steel would flow upward under the thermal buoyancy which can reduce the erosion of refractory.Moreover,the upward flow would increase the residence time of the molten steel in the tundish which provide more opportunities for the inclusion to reach the top surface of the tundish.展开更多
The κ-ε two-equation model is used to simulate the fluid flow in the continuous casting tundish coupling with the effect of thermal buoyancy. The natural convection induced by the thermal buoyancy generates an upwar...The κ-ε two-equation model is used to simulate the fluid flow in the continuous casting tundish coupling with the effect of thermal buoyancy. The natural convection induced by the thermal buoyancy generates an upward flow pattern especially at the outlet zone, and has little effect on the fluid flow in the inlet zone. The maximum viscosity is 700 times larger than the laminar viscosity, which indicates the strong turbulent flow in the tundish. The maximum temperature difference in the whole tundish is 82 K. The temperature near the stopper rod and the short wall is obviously lower than that in the inlet zone. The existence of the stopper rod has a big effect on the fluid flow entering the SEN and the mold. All the characteristics of the tundish geometry should be considered to accurately simulate the fluid flow in the tundish.展开更多
基金the National Key R&D Program(No.2023YFB3709900)the National Natural Science Foundation of China(Nos.U22A20171 and 52104343)the High Steel Central(HSC)at North China University of Science and Technology and Yanshan Univ ersity,China。
文摘A 3D mathematical model was proposed to investigate the molten steel–slag–air multiphase flow in a two-strand slab continuous casting(CC)tundish during ladle change.The study focused on the exposure of the molten steel and the subsequent reoxidation occurrence.The exposure of the molten steel was calculated using the coupled realizable k–εmodel and volume of fluid(VOF)model.The diffusion of dissolved oxygen was determined by solving the user-defined scalar(UDS)equation.Moreover,the user-defined function(UDF)was used to describe the source term in the UDS equation and determine the oxidation rate and oxidation position.The effect of the refilling speed on the molten steel exposure and dissolved oxygen content was also discussed.Increasing the refilling speed during ladle change reduced the refilling time and the exposure duration of the molten steel.However,the elevated refilling speed enlarged the slag eyes and increased the average dissolved oxygen content within the tundish,thereby exacerbating the reoxidation phenomenon.In addition,the time required for the molten steel with a high dissolved oxygen content to exit the tundish varied with the refilling speed.When the inlet speed was 3.0 m·s^(-1)during ladle change,the molten steel with a high dissolved oxygen content exited the outlet in a short period,reaching a maximum dissolved oxygen content of 0.000525wt%.Conversely,when the inlet speed was 1.8 m·s^(-1),the maximum dissolved oxygen content was 0.000382wt%.The refilling speed during the ladle change process must be appropriately decreased to minimize reoxidation effects and enhance the steel product quality.
基金the National Natural Science Foundation of China(52004191)the China Postdoctoral Science Foundation(2022M711120)+1 种基金the Science and Technology Research Project of Education Department of Hubei Province(B2022020)Besides,the numerical calculation is supported by High-Performance Computing Center of Wuhan University of Science and Technology.
文摘A rotating stopper-rod technique was proposed to suppress the formation of free-surface vortex in the tundish.The large eddy simulation model coupled with volume of fluid model was developed to study the steel–slag–gas three-phase flow behavior.The critical slag entrapment height of the free-surface vortex and mass of residual steel were predicted at different rotating speeds(30,60,90 and 120 r/min)of the rotating stopper-rod.The numerical model was verified by water model experiment.The results showed that by rotating the stopper-rod in the opposite direction of the vortex above the submerged entry nozzle,the formation of vortex can be effectively disturbed and the critical height of the free-surface vortex can be reduced.Particularly for the 2nd strand,when the rotating speeds are 30,60,90 and 120 r/min,the critical height of the free-surface vortex above the 2nd strand is 7.3,4.7,6.3 and 7.4 cm,respectively.A reasonable rotating speed should be 60 r/min,which can reduce about 2 tons of residual steel.Other rotating speeds just can reduce about 1.6 tons of residual steel.
基金supported by grants from the National Natural Science Foundation of China(No.51774004)Anhui Province Outstanding Research and Innovation Team in Higher Education Institutions(No.2022AH010024).
文摘The external residence time distribution(RTD)curve is extensively used to characterise fluid flow within the single-strand continuous casting tundish.Dead volume fraction determination typically relies on the external RTD curve to reveal macroscopic fluid flow behaviour.Based on the external RTD to effectively assess dead volume fractions and other fluid characteristics under conditions of internal non-uniform flow,an internal RTD was introduced.In a smooth pipe under laminar flow conditions,the dead region occupies 25%of the total volume,which is defined as the space between the pipe wall and a radius of 0.866 R0(where R0 is the radius of pipe).Under turbulent flow conditions,the dead region only occupies 0.38%of the reactor’s internal volume,spanning from the pipe wall to a radius of 0.00189 R0.The results obtained using the external RTD method are consistent with the theoretical analysis.Experimental trials involving water were conducted to examine the flow of molten steel within a five-strand tundish.Subsequently,an analysis approach employing internal RTD was employed to evaluate fluid mixing within a multi-flow continuous casting tundish.Using the internal RTD method,the analysis revealed that the whole dead zone volume fraction of the intermediate package decreased from 26.9%to 18.9%after the addition of the flow control device.The dead volume fraction can be accurately depicted by utilising the internal mean RTD function.The association between the internal RTD function and the external average RTD can be effectively employed to scrutinise the response curve of the tracer within a system exhibiting uneven flow distribution.
基金funded by the National Natural Science Foundation of China(Nos.51874215 and 52204351)the China Postdoctoral Science Foundation(2022M722487).
文摘A three-dimensional mathematical model has been established for a novel metallurgy process coupling an annular gas curtain with swirling flow at tundish upper nozzle. The discrete phase model and volume of fluid model were applied to simulate the gas–liquid multiphase flow behavior in tundish and nozzle. The effect of argon flow rate on the migration behavior of bubbles and interface behavior between steel and slag was also investigated. The presented results indicate that the novel coupling process can significantly change the flow pattern in the stream zone of a tundish, prolong the average residence time of liquid steel, and reduce the dead fraction. A complete annular gas curtain is formed around the stopper rod of tundish. Under the action of drag force of liquid steel, a part of small bubbles enter the nozzle through the swirling grooves and gather toward the center of the nozzle by centripetal force. As the argon flow rate increases, the volume fraction of argon gas entering the nozzle increases, which enhances the swirl intensity and increases the concentration of bubbles in the nozzle. To avoid the formation of slag open eye in tundish, the argon flow rate should not exceed 8 L min−1.
文摘The research on tundish metallurgy has focused mainly on taking countermeasures to avoid and remove inclusions and the recent developments on tundish metallurgy were surveyed.The authers'advices for future development of tundish metallurgy were given in summary section.
文摘A detailed mathematical procedure of the optimization of the fluid flow in a tundish water model with and without flow control devices （weir and dam） was carried out using the commercial CFD eode FLUENT 6.0. The （k- ε） two-equation model was used to model turbulence. The residence time distribution （RTD） curves were used to analyze the behavior of the flow in tundish. The location of flow control devices in the tundish was studied. The results show that the flow modifiers play an important role in promoting the floatation of nonmetallic inclusions in steel. Comparing the three geometric configurations that are considered （bare tundish, weir, weir＋dam）, the tundish equipped with the arrangement （weir＋dam） is a best and optimal geometric configuration of tundish.
文摘The optimization of flow control devices in a single-slab continuous casting tundish was carried out by physical modeling, and the optimized scheme was presented. With the optimal tundish configuration, the minimum residence time of liquid steel was increased by 1.4 times, the peak concentration time was increased by 97%, and the dead volume fraction was decreased by 72%. A mathematical model for molten steel in the tundish was established by using the fluid dynamics package Fluent. The velocity field, concentration field, and the resi-dence time distribution （RTD） curves of molten steel flow before and after optimization were obtained. Experimental results showed that the reasonable configuration with flow control devices can improve the fluid flow characteristics in the tundish. The results of industrial applica-tion show that the nonmetallic inclusion area ratio in casting slabs is decreased by 32% with the optimal tundish configuration.
基金Item Sponsored by National High Technology Research and Development Plan of China(2007AA04Z194)
文摘A 1∶2.5 scale tundish model was set up in laboratory for a six-strand billet continuous casting tundish with different configurations to investigate fluid flow characteristics under different operational conditions by measuring residence time distribution curves.It was found that minimum residence time,maximum concentration time and average residence time of the three strands on the same side of the tundish with the former configuration under normal operation,that is,six strands were open,were small and non-uniform and the tundish had large dead volume fraction.Vortexes easily formed on the liquid surface in the pouring zone of the tundish.The fluid flow characteristics in the tundish with the optimal turbulence inhibitor and baffles were improved and became less non-uniform among the strands.Vortexes were not found on the pouring zone surface in the optimal tundish.For non-normal operation,that is,one strand was close,it was important to choose which strand to be closed for maintaining flow characteristics of the rest two strands.It was found from this investigation that fluid flow characteristics in the optimal configuration tundish with closing strand 2 were better than those with closing strand 3 on the same side.
文摘In the water modeling experiments, three cases were considered, i. e, , a bare tundish, a tundish equipped with a turbulence inhibitor, and a rectangular tundish equipped with weirs （dams） and a turbulence inhibitor. Comparing the RTD curves, inclusion separation, and the result of the streamline experiment, it can be found that the tundish equipped with weirs （dams） and a turbulence inhibitor has a great effect on the flow field and the inclusion separation when compared with the sole use or no use of the turbulent inhibitor or weirs （dams）. In addition, the enlargement of the distance between the weir and dam will result in a better effect when the tundish equipped with weirs （dam） and a turbulence inhibitor was used.
文摘A conventional turbulence inhibitor is compared with a swirling chamber from the points of view of fluid flow and removal rate of inclusion in the tundish. Comparing the RTD curves, inclusion removals, and the streamlines in water model experiments, it can be found that the tundish equipped with a swirling chamber has a great effect on improving the flow field, and the floatation rate of inclusion is higher than the tundish with a turbulence inhibitor. Because of the introduction of the swirling chamber, the flow field and inclusion removal in a two-strand swirling flow tundish are asymmetrical. Rotating the inlet direction of swirling chamber 60 degree is a good strategy to improve the asymmetrical flow field.
基金financially supported by the Key Special Project in the National Science & Technology Program during the Eleventh Five-Year Plan Period (No.2009ZX04014-061-7)
文摘The metallurgical effect of a round tundish used to cast heavy steel ingots in machine works at present was evaluated through water modeling experiments. The flow control devices of the improved oval tundish, which was used instead of the round tundish, had been optimized. The results show that the residence time of the round tundish is short, its inclusion removal efficiency is too low, and it has more dead zones and an unreasonable flow field. Compared with the round tundish, the improved oval tundish with the optimized weir and dam has a better effect： its minimum residence time is prolonged by 38.1 s, the average residence time is prolonged by 233.4 s, its dead volume fraction decreases from 26% to 15%, and the ratio of plug volume fraction to dead volume fraction increases from 0.54 to 1.27. The inclusion removal efficiency also increases by 17.5%.
文摘The mechanism of inclusion aggregation in liquid steel in swirling flow tundish is analyzed by applying the theory of flocculation which was developed in the field of colloid engineering. The gas bridge forces due to the micro bubbles on hydrophobic inclusion surfaces were responsible for the inclusion collision and agglomeration, which can avoid the aggregation to breakup. The quantity of micro bubbles on hydrophobic inclusion particle is more than that on hydrophilic one. The trend of forming gas bridges between micro bubbles on particles is strong in the course of collision. The liquid film on hydrophobic particles is easy to break during collision process. Hydrophobic particles are liable to aggregate in collision. According to the analysis of forces on a nonmetallic inclusion particle in swirling chamber, the chance of inclusion collision and aggregation can be improved by the centripetal force. Hydropbobic particles in water are liable to aggregate in collision. Hydrophilic particles in water are dispersed although collision happens. The wettability can be changed by changing solid-liquid interface tension. The nonmetallic inclusion removal in swirling flow tundish is studied. The result shows that under certain turbulent conditions, the.particle concentration and the wettability between particles and liquid steel are the main factors to induce collision and aggregation.
文摘Improper flow control devices in a multi-strand tundish can cause some problems, for example, liquid steel cannot reach every nozzle at the same time and the liquid steel in nozzles far away from the entry zone has a lower temperature. The water model experiment of a six-strand tundish of Tianjin Iron ＆ Steel Co. Ltd. was performed, a new ＂U＂ type baffle was obtained, and its parameters were defined by perpendicular analysis. The ＂U＂ baffle can not only improve those imperfections, but also prolong the residence time of nonmetallic inclusions, which is good for their flotation and separation.
文摘Fluid flow characteristics in a four-strand tundish with gas blowing were studied by water modeling experiments.It is found that gas blowing can greatly improve the flow characteristics in the tundish with a turbulence inhibitor.It dramatically increases the peak concentration time,and greatly decreases the dead volume,and reduces the minimum residence time.The gas blowing location,gas flow rate,and porous plug area greatly influence the flow characteristics in the tundish; the gas blowing location near the baffle,smaller gas flow rate,and smaller porous plug area are better for improving the fluid flow characteristics.Using gas blowing can reduce the difference of flows at the middle outlets and side outlets for the multi-strand tundish.Bubbles produced by gas blowing can absorb small inclusions and provide the condition for inclusion collision and aggregation.Therefore,introducing gas blowing into a tundish and combining the turbulence inhibitor can improve inclusion floating and removal,and the cleanness of molten steel can be advanced.
基金financially supported by the National Natural Science Foundation of China(51504002)
文摘The optimization of flow control devices(FCDs) for a T-type five-strand billet caster tundish was carried out by water modeling and numerical simulation. In water modeling experiments, flow characteristics of the bare tundish and tundish conf igurations with designed U-type baff les and a round turbulence inhibitor were analyzed using residence time distribution(RTD) curves. Mathematical models for liquid steel in the real plant tundish were established using the fluid dynamics software package Fluent. The flow field, the temperature field, and the RTD curves of liquid steel in the proposed tundish conf igurations were obtained. The results of numerical simulation and water modeling were validated with each other by the predicted and experimental RTD curves. The results of flow field and temperature field were used to ref lect the actual state of a real plant tundish and to choose the optimal FCD. Finaly, from the whole performance of the multi-strand tundish, the optimal scheme was determined by combining the results of water modeling and numerical simulation. With the optimal tundish equipped with U-type baffle with def lector holes and round turbulence inhibitor, not only was the flow characteristic of each strand improved, but also the difference of flow characteristics between multiple strands was smaller.
基金Item Sponsored by National Natural Science Foundation of China(50904017)
文摘The solidified crust was harmful to Al-killed steel casting using a basic tundish flux. After sampling from an actual tundish, XRD, SEM and EDX examinations were carried out to analyze the microstructure of solidified crusts. The conclusions were obtained as follows： main crystallization phases existing in tundish crust were Ca12 A14 O23, Ca2SiO4 and a little spinel; spinel and Ca2SiO4 distributed between the grain boundaries of Ca12 A14 Oa3, which increased the connection strength of crystallization phases by pinning grain boundary, density or hardness of solidified crust maybe also significantly increases; when initial composition of tundish flux was located in spinel region of CaO-SiO2-Al2 O3-10 % MgO phase diagram, it was easier to precipitate spinel from molten slag; three approaches of spinel formation in flux were summarized. When flux was saturated with magnesia on the metal/flux interface, MgO in flux was reduced by dissolved aluminum and then formed spinel. On the interface of steel/refractory, with feasible aluminum content, it was also easy to form spinel, and spinel inclusions will be floated and captured by tundish flux.
基金Item Sponsored by National Natural Science Foundation of China (50674020)Program for New Century Excellent Talents in University (NCET-04-0285)
文摘The fluid flow and the interfacial phenomenon of slag and metal in tundish with gas blowing were studied with mathematical and physical modeling, and the effects of gas flowrate, the placement of porous beam for the generation of bubbles, and the combination of flow control devices on the flow and slag-metal interface were investigated. The results show that the position of gas bubbling has a significant effect on the flow in tundish, and the placement of porous beam and gas flowrate are the two main factors affecting the entrapment of slag in tundish. The closer the porous beam to the weir, the more reasonable is the flow, which is in favor of the control of slag entrapment in tundish.
基金Funding was provided by National Natural Science Foundation of China(Grant No.51774179)the project of Science Department of Liaoning Province(2019-ZD-0269).
文摘For a multistream tundish,the uniformity among the streams plays a significant role in the quality of molten steel.How to analyze the uniformity quantitatively and optimize structures of a multistream tundish is an important research content for a multistream tundish.A new approach was proposed to quantify the uniformity among the streams.And a physical study and a numerical study were carried out to optimize the structure of the diversion hole based on the prototype of a six-stream tundish in a steel plant.On the basis of average residence time,the uniformity of each flow was considered fully and then the optimal structure of the diversion hole was obtained by means of the comprehensive analysis of temperature field and velocity field.The results show that the optimum structural parameters adopted for diversion holes are height of 20 mm,angle of 15°and diameter of 80 mm.
基金Item Sponsored by National Natural Science Foundation of China[No.50934008]National Natural Science Foundation of China[NO.50904014]
文摘A coupled mathematical model was developed to describe the flow field,temperature distribution of molten steel in the tundish with the channel type induction heating.The molten steel motion was dominated under the combined effect of the thermal buoyancy and the electro-magnetic forces(EMFs)due to the channel type induction heating.The results indicate that the thermal loss of molten steel in the tundish can be compensated effectively by the channel type induction heating.In addition,the molten steel would flow upward under the thermal buoyancy which can reduce the erosion of refractory.Moreover,the upward flow would increase the residence time of the molten steel in the tundish which provide more opportunities for the inclusion to reach the top surface of the tundish.
文摘The κ-ε two-equation model is used to simulate the fluid flow in the continuous casting tundish coupling with the effect of thermal buoyancy. The natural convection induced by the thermal buoyancy generates an upward flow pattern especially at the outlet zone, and has little effect on the fluid flow in the inlet zone. The maximum viscosity is 700 times larger than the laminar viscosity, which indicates the strong turbulent flow in the tundish. The maximum temperature difference in the whole tundish is 82 K. The temperature near the stopper rod and the short wall is obviously lower than that in the inlet zone. The existence of the stopper rod has a big effect on the fluid flow entering the SEN and the mold. All the characteristics of the tundish geometry should be considered to accurately simulate the fluid flow in the tundish.
