The transient phenomena of re-oxidation and slag entrapment occurring in the tundish during the ladle change-over process have been proven detrimental to clean steel production.Therefore,an unsteady three-phase turbul...The transient phenomena of re-oxidation and slag entrapment occurring in the tundish during the ladle change-over process have been proven detrimental to clean steel production.Therefore,an unsteady three-phase turbulence model,coupling velocity,temperature,and phase field was established to study the effect of the ladle shroud immersion depth on the slag eye formation,slag entrainment,slag dragging,air dragging,and flow characteristics during the ladle change-over process of a two-strand tundish.The results showed that reducing the immersion depth decreases the high-velocity region area under the slag layer in the quasi-steady process.During the emptying stage,as the molten bath level gradually decreases,the outlet temperature exhibits a trend of initially decreasing and subsequently increasing across all three shroud immersion depths.However,under a 210 mm shroud immersion depth,molten slag and air are dragged into the shroud,forming slag droplets and causing significant fluctuations,with a maximum scalar velocity of 0.0764 m/s at the monitoring point.In the filling stage,air and molten slag are dragged into the molten bath,forming bubbles and slag droplets at an immersion depth of 210 mm.Bubbles are observed within the molten slag layer,which can readily cause an emulsification phenomenon,making it easier to be dragged as slag droplets.Additionally,the slag eye area measured under 210 mm immersion depth at 45 s is 0.303 m^(2),while the maximum scalar velocity of 2.4259 m/s is detected at 12 s.At an immersion depth of 360 mm,the average area of the slag eye is minimized to 0.06268 m2,with corresponding variances of 0.006753,representing the optimal immersion depth.展开更多
A new three-dimensional multiphase numerical model was built.The volume of fluid and k-ε turbulence models were used to investigate the hot metal ladle pouring process.During the pouring process,issues such as iron s...A new three-dimensional multiphase numerical model was built.The volume of fluid and k-ε turbulence models were used to investigate the hot metal ladle pouring process.During the pouring process,issues such as iron splashing,overflow,and significant heat loss are prevalent.To realize efficient and stable pouring,the effects of ladle tilting velocity,flow rate,and converter tilting angle on the pouring process were examined.The model was verified by comparing the actual pouring time with the numerical results.It is shown that there is a nonlinear relationship between pouring velocity and hot metal flow rate at the ladle mouth.As the mass flow increased and the converter tilting angle decreased,the impact point of the hot metal into the converter pool shifted from the side wall to the bottom,and the impact force increased accordingly.The pouring velocity curve was optimized by the volume difference of the ladle at different angles,and an empirical formula was derived.After the optimization of pouring speed,the flow rate was stabilized between 4000 and 6000 kg/s,and the pouring time was reduced by approximately 30 s.After applying this model in actual production,the hot metal temperature inside the converter increased by approximately 5℃statistically.This model is potential to enhance the production efficiency,stability,and safety of the pouring process between open containers.展开更多
Ladle furnaces are known for their high power consumption,making research on power-saving process crucial.In response to the defect of thin slag thickness in the industrial production of a 120-t ladle furnace at a ste...Ladle furnaces are known for their high power consumption,making research on power-saving process crucial.In response to the defect of thin slag thickness in the industrial production of a 120-t ladle furnace at a steel plant,with its production of ship plate steel DH36 as the focus,experiments involving adding the foaming agent and shifting power delivery gears were conducted.Based on the principle of measuring alternating current by Rogowski coils,the power consumption during the ladle furnace refining process was calculated theoretically,and the actual industrial power consumption matched with it basically,confirming the accuracy of the theoretical calculations.Additionally,the impacts of argon flow rate,foaming agents,and shifting power delivery gears on power consumption were studied.The results showed that adding 0.59 and 0.50 kg/t foaming agents in two batches improved the refining process of the ladle furnace,allowing for effective submerged-arc operations and saving electric energy of 7.2382 kWh per ton of steel.Similarly,utilizing a power supply mode of 7-step short arc during the refining process significantly enhanced the desulfurization rate of molten steel and saved electric energy of 11.6387 kWh per ton of steel.展开更多
The penetration of ladle slag into refractory linings is an essential process in service,and the mechanical properties of the refractory castables are affected by the location and content of slag in the refractory cas...The penetration of ladle slag into refractory linings is an essential process in service,and the mechanical properties of the refractory castables are affected by the location and content of slag in the refractory castables.In this work,ladle slag was added into Al_(2)O_(3)-Mgo refractory castables and its influence on the microstructure evolution,mechanical properties and thermal shock resistance of the castables was investigated.The phase composition and contents of the castables during the corrosion process were calculated by FactSage TM(6.2)and studied.The results indicate that the residual strength decreases as the ladle slag addition increases from 0 to 6 mass%.While the hot modulus of rupture of the castable with 6%ladle slag significantly decreases by approximately 80%compared with the one without ladle slag.The elastic modulus and CMOR of the castables decrease with slag-adding,which leads to the increase of liquid phase contents inside the samples.展开更多
The heat transfer analysis was performed for an industrial ladle furnace （LF） with a capacity of 55-57 t in Turkey. The heat losses by conduction, convection and radiation from outer and bottom surfaces, top and ele...The heat transfer analysis was performed for an industrial ladle furnace （LF） with a capacity of 55-57 t in Turkey. The heat losses by conduction, convection and radiation from outer and bottom surfaces, top and electrodes of LF were determined in detail. Finally, some suggestions about decreasing heat losses were presented.展开更多
Aiming at the characteristics of the practical steelmaking process, a hybrid model based on ladle heat sta- tus and artificial neural network has been proposed to predict molten steel temperature. The hybrid model cou...Aiming at the characteristics of the practical steelmaking process, a hybrid model based on ladle heat sta- tus and artificial neural network has been proposed to predict molten steel temperature. The hybrid model could over- come the difficulty of accurate prediction using a single mathematical model, and solve the problem of lacking the consideration of the influence of ladle heat status on the steel temperature in an intelligent model. By using the hybrid model method, forward and backward prediction models for molten steel temperature in steelmaking process are es- tablished and are used in a steelmaking plant. The forward model, starting from the end-point of BOF, predicts the temperature in argon-blowing station, starting temperature in LF, end temperature in LF and tundish temperature forwards, with the production process evolving. The backward model, starting from the required tundish tempera- ture, calculates target end temperature in LF, target starting temperature in LF, target temperature in argon-blo- wiag station and target BOF end-point temperature backwards. Actual application results show that the models have better prediction accuracy and are satisfying for the process of practical production.展开更多
In ladle furnace, the prediction of the liquid steel temperature is always a hot topic for the researchers. The most of the existing temperature prediction models use small sample set. Today, the precision of them can...In ladle furnace, the prediction of the liquid steel temperature is always a hot topic for the researchers. The most of the existing temperature prediction models use small sample set. Today, the precision of them can not satisfy practical production. Fortunately, the large sample set is accumulated from the practical production process. However, a large sample set makes it difficult to build a liquid steel temperature model. To deal with the issue, the random forest method is preferred in this paper, which is a powerful regression method with low complexity and can be designed very quickly. It is with the parallel ensemble structure,uses sample subsets,and employs a simple learning algorithm of sub-models. Then, the random forest method is applied to establish a temperature model by using the data sampled from the production process. The experiments show that the random forest temperature model is more precise than other temperature models.展开更多
The heat transfer in a steelmaking ladle was studied. The evaluation of heat transfer of the steel was performed by measuring steel temperature in points including all refining steel process. In the ladle, the tempera...The heat transfer in a steelmaking ladle was studied. The evaluation of heat transfer of the steel was performed by measuring steel temperature in points including all refining steel process. In the ladle, the temperatures in the refractories and the shell were also measured. To evaluate the thermal profile between the hot and cold faces of the ladle in the slag line position, an experiment which shows the importance of thermal contact resistance was carried out. Higher heat losses in the tapping and the vacuum were verified. The temperature measurements of the ladle indicate distinct thermal profiles in each stage of steel refining. Moreover, as each stage of the process depends on the previous one, the complexity of the ladle thermal control is incremental. So a complete model of heat losses in the ladle is complex.展开更多
In the electric arc furnace （EAF） steel production processes, scrap steel is principally used as a raw material instead of iron ore. In the steelmaking process with EAF, scrap is first melted in the furnace and then...In the electric arc furnace （EAF） steel production processes, scrap steel is principally used as a raw material instead of iron ore. In the steelmaking process with EAF, scrap is first melted in the furnace and then the desired chemical composition of the steel can be obtained in a special furnace such as ladle furnace （LF）. This kind of furnace process is used for the secondary refining of alloy steel. LF furnace offers strong heating fluxes and enables precise temperature control, thereby allowing for the addition of desired amounts of various alloying elements. It also provides outstanding desulfurization at high-temperature treatment by reducing molten steel fluxes and removing deoxidation products. Elemental analysis with mass balance modeling is important to know the precise amount of required alloys for the LF input with respect to scrap composition. In present study, chemical reactions with mass conservation law in EAF and LF were modeled altogether as a whole system and chemical compositions of the final steel alloy output can be obtained precisely according to different scrap compositions, alloying elements ratios, and other input amounts. Besides, it was found that the mass efficiency for iron element in the system is 95.93%. These efficiencies are calculated for all input elements as 8. 45% for C, 30.31% for Si, 46.36% for Mn, 30.64% for P, 41.96% for S, and 69.79% for Cr, etc. These efficiencies provide valuable ideas about the amount of the input materials that are vanished or combusted for 100 kg of each of the input materials in the EAF and LF system.展开更多
For further research on the control model of muhifunctional hot metal ladles between the ironmaking and steelmaking interface, the hot metal ladies of K steel plant were taken as the object to analyze the operation pr...For further research on the control model of muhifunctional hot metal ladles between the ironmaking and steelmaking interface, the hot metal ladies of K steel plant were taken as the object to analyze the operation process. The factors of blast furnace supply and basic oxygen furnace demand were proposed. According to the principle of supply and demand balance, the control model of hot metal was researched under the following factor conditions： equal to, greater than, and less than 1, respectively. The distribution model of the blast furnace, sleelmaking works, and online buffering was proposed. When the supply and demand factor is equal to ） , the turnover number of hot metal ladles equals 16 and the turnover cycle of hot metal ladles equals 512 min. When the factor is greater than 1, the total number of hot metal ladles is equal to the normal turnover number plus the turnover number of the cast iron machine. When the factor is less than 1, the total number of hot metal ladles is equal tO the normal turnover number plus the accumulating number. Satisfactory effects were obtained by applying the control model in produc tion. The numbers of turnover ladles and accumulating ladles were reduced.展开更多
To avoid slag sticking on the ladle immersion cover during the LATS refining and alloying process, the effect of Al2O3 on the melting point of the ladle slag was studied and the additives including CaF2, B2O3, Li2O, a...To avoid slag sticking on the ladle immersion cover during the LATS refining and alloying process, the effect of Al2O3 on the melting point of the ladle slag was studied and the additives including CaF2, B2O3, Li2O, and CaO were used to decrease the melting point of the ladle slag. The melting point was measured using the hemisphere method. The results show that the addition of Al2O3 to the ladle slag increases the melting point. The fluxing action is not remarkable if only CaF2 or CaO is used as the additive. The fluxing action of the composite additive obtained by the mixing of CaO and CaF2 in the mass proportion of ωCaO：ωCaF2=2 ： 1 is preferred. The fluxing action of B2O3 is also notable. When the B2O3 content in mass percent is in the range from 2% to 10%, the corresponding melting point is 1 380 ℃ to 1 290℃. The fluxing action of Li2O is the most remarkable. When the Li2O content is up to 5%, the melting point of the slag is lower than 1 300 ℃.展开更多
Fine bubbles will create when the inert gas is introduced to the high rapidsteel stream within the shroud nozzle between ladle and tundish. The collision and attachment amongthe bubbles and fine inclusions will promot...Fine bubbles will create when the inert gas is introduced to the high rapidsteel stream within the shroud nozzle between ladle and tundish. The collision and attachment amongthe bubbles and fine inclusions will promote the floatation efficiency of inclusions in the tundish.The behaviors of the bubbles, such as the dispersion in shroud, coalescence and floatation intundish, are studied. The results show that the maximum sizes of the bubbles in the water and steelflow within the shroud in the length of 1.2 m are 0.70-1.44 mm and 1.53-3.16 mm respectively whenthe flow rates are 0.006-0.016 m^3/s; the terminal velocities of fine bubbles in the water andmolten steel within the tundish are 0.02-0.2 and 0.05-0.6 m/s.展开更多
A rapidly air-cooled ladle furnace slag(RA-LFS), which is a type of steelmaking slag discharged from a steel mill, was used to synthesize CaCO_3 film. The CaCO_3 film with 35 cm^2 of surface area was synthesized under...A rapidly air-cooled ladle furnace slag(RA-LFS), which is a type of steelmaking slag discharged from a steel mill, was used to synthesize CaCO_3 film. The CaCO_3 film with 35 cm^2 of surface area was synthesized under atmospheric conditions, and the surface morphology of the CaCO_3 films was changed by using additives(CaCl_2 and ethylene glycol). Especially, the addition of CaCl_2 changed the surface morphology of CaCO_3 film with pore and induced new material properties, such as water adsorption. The(012) face of CaCO_3 film(calcite) was rapidly decreased by the addition of CaCl_2. The major components of RA-LFS were calcium(type of CaO, 53.9 wt%) and aluminum(type of Al_2 O_3, 37.9 wt%), and the major crystal phases of RA-LFS were C_3 S, C_(12) A_7, and C_3 A. The calcium extraction efficiency of RA-LFS was significantly increased after the CaCO_3 film synthesis. The material properties(hardness and elastic modulus) and the thermal characteristics of the CaCO_3 films were analyzed by nano-indentation and thermogravimetry–differential thermal analysis. The synthesized CaCO_3 films from RA-LFS and Ca(OH)_2(reagent) showed similarities in terms of their material properties and the decomposition temperature.展开更多
This study investigated whether the pouring ladle's outlet shape could reduce the porosity of aluminum alloy casting products and whether it could be applied to mass production of automotive brackets based on comp...This study investigated whether the pouring ladle's outlet shape could reduce the porosity of aluminum alloy casting products and whether it could be applied to mass production of automotive brackets based on computer simulations and experiment.The filling behaviors of the melt were simulated to compare the flow characteristics of the molten metal poured from the conventional ladle and the proposed ladle.Results show that for the conventional ladle,the pouring metal is V-shaped,while it is relatively circular and poured at a more constant rate in the proposed ladle.CT scans reveal that the proposed ladle reduces the porosity of the cast product.The proposed ladle resulted in an average of 30 fewer pores,a 299.56 mm3 smaller average total pore volume,and a 0.041% lower difference in average porosity.It is concludes that the proposed ladle can be used in the gravity casting process.By changing the ladle outlet shape can reduce the casting failure rate of massproduced automobile bracket.展开更多
Combined with the parameters of the production process of a steel factory, numerical simulations for a new ladle from preheating to turnover are conducted using the finite element analysis system software （ANSYS）. T...Combined with the parameters of the production process of a steel factory, numerical simulations for a new ladle from preheating to turnover are conducted using the finite element analysis system software （ANSYS）. The measured data proved that the simulated results are reliable. The effects of preheating time, thermal cycling times, and empty package time on steel temperature are calculated, an ideal preheating time is provided, besides, based on the analysis of a single factor and use the nonlinear analysis method, a steel temperature compensating model with di- versified coupling factors is proposed, with the largest error of the present coupling model at 1. 462 ~C, and the er- rors between actual and target steel temperature in tundish after the model is applied to practical production are basi- cally controlled within -4-6 ~C, which can meet the accuracy of the manufacturer and has a practical guiding significance for the production in steelmaking workshops.展开更多
Based on the two-phase fluid （Eulerian-Eulerian） model, a mathematical model about the gas-liquid flow and mixing behavior was developed to investigate the effect of the offset of dual plugs, the included angle of d...Based on the two-phase fluid （Eulerian-Eulerian） model, a mathematical model about the gas-liquid flow and mixing behavior was developed to investigate the effect of the offset of dual plugs, the included angle of dual plugs with a center point, and gas flow rate on the mixing time in a ladle with dual plugs. Numerical results indicate that two types of recirculation zones exist in the ladle. One is the middle recirculation between gas and liquid plumes, and the other is the sidewall recirculation between plumes and the ladle sidewall. The correction shows that the mixing time is in proportion to -0.2676 power of gas flow rate. There is a unique optimum offset of dual plugs with a particular included angle, in turn, a unique optimum included angle of dual plugs exits with a particular offset.展开更多
Steel 20Mn23AlV is a type of high aluminum steel with a very low ladle free-opening rate. The aluminum composition of 20Mn23AlV ranges from 1.6% to 2.45% ,which is significantly higher than other types of steel. Accor...Steel 20Mn23AlV is a type of high aluminum steel with a very low ladle free-opening rate. The aluminum composition of 20Mn23AlV ranges from 1.6% to 2.45% ,which is significantly higher than other types of steel. According to the real condition of 40 t ladle in steel-making plant of Baosteel Special Steel Company, previous works show that the key factors affecting the ladle free-opening rate of high aluminum steel in continuous casting are：sand material, accessories baking, ladle nozzle cleaning, the process and amount of adding sand, and the rate of argon stirring during refining. Therefore, improving the ladle filler sand quality, baking all of the raw materials, controlling the addition of ladle filler sand, cleaning the ladle nozzle, and optimizing argon stirring during the refining process can resolve the problem of a low ladle free-opening rate of high aluminum steel caused by the long ladle time of liquid steel.展开更多
In the prediction of the end-point molten steel temperature of the ladle furnace, the influence of some factors is nonlinear. The prediction accuracy will be affected by directly inputting these nonlinear factors into...In the prediction of the end-point molten steel temperature of the ladle furnace, the influence of some factors is nonlinear. The prediction accuracy will be affected by directly inputting these nonlinear factors into the data-driven model. To solve this problem, an improved case-based reasoning model based on heat transfer calculation(CBR-HTC) was established through the nonlinear processing of these factors with software Ansys. The results showed that the CBR-HTC model improves the prediction accuracy of end-point molten steel temperature by5.33% and 7.00% compared with the original CBR model and 6.66% and 5.33% compared with the back propagation neural network(BPNN)model in the ranges of [-3, 3] and [-7, 7], respectively. It was found that the mean absolute error(MAE) and root-mean-square error(RMSE)values of the CBR-HTC model are also lower. It was verified that the prediction accuracy of the data-driven model can be improved by combining the mechanism model with the data-driven model.展开更多
The composition control of molten steel is one of the main functions in the ladle furnace(LF)refining process.In this study,a feasible model was established to predict the alloying element yield using principal compon...The composition control of molten steel is one of the main functions in the ladle furnace(LF)refining process.In this study,a feasible model was established to predict the alloying element yield using principal component analysis(PCA)and deep neural network(DNN).The PCA was used to eliminate collinearity and reduce the dimension of the input variables,and then the data processed by PCA were used to establish the DNN model.The prediction hit ratios for the Si element yield in the error ranges of±1%,±3%,and±5%are 54.0%,93.8%,and98.8%,respectively,whereas those of the Mn element yield in the error ranges of±1%,±2%,and±3%are 77.0%,96.3%,and 99.5%,respectively,in the PCA-DNN model.The results demonstrate that the PCA-DNN model performs better than the known models,such as the reference heat method,multiple linear regression,modified backpropagation,and DNN model.Meanwhile,the accurate prediction of the alloying element yield can greatly contribute to realizing a“narrow window”control of composition in molten steel.The construction of the prediction model for the element yield can also provide a reference for the development of an alloying control model in LF intelligent refining in the modern iron and steel industry.展开更多
Hot metal ladle is an important part in continuous casting production line and its stress distribution has direct influence on its life. In the process of design and calibration of the large-sized hot metal ladle, it ...Hot metal ladle is an important part in continuous casting production line and its stress distribution has direct influence on its life. In the process of design and calibration of the large-sized hot metal ladle, it is of great significance to determine the stress distribution of each part of the ladle for safely and reliably running the device. Based on 100 t hot metal ladle which is designed by Baotou Iron and Steel Group, simulation of stress field was made by finite element software ANSYS 10.0 from different dumping angles. Through modeling, loading, restricting and calculating, strain and stress field distribution of the hot metal ladle were acquired. Finally, an assessment of strength and stiffness was made on the hot metal ladle. The results show that in the process of tipping for the hot metal ladle, maximum stress is 132 MPa and maximum strain is only 0. 064% ; maximum stress and strain have appeared in the stiffener plate which is located at the bottom of the trunnion, and strength and stiffness are qualified. The method, which is convenient and practical, reasonable and reliable, provides theoretical evidence for checking analysis and further optimal design of the hot metal ladle.展开更多
基金supported by the National Natural Science Foundation of China(Nos.52422408 and 52171031)the Liaoning Xingliao Talents-Top-notch Young Talents Project(No.XLYC2203064)+1 种基金the Excellent Youth Fund of Liaoning Natural Science Foundation(No.2023JH3/10200001)the Fundamental Research Funds for the Central Universities(No.N2425004).
文摘The transient phenomena of re-oxidation and slag entrapment occurring in the tundish during the ladle change-over process have been proven detrimental to clean steel production.Therefore,an unsteady three-phase turbulence model,coupling velocity,temperature,and phase field was established to study the effect of the ladle shroud immersion depth on the slag eye formation,slag entrainment,slag dragging,air dragging,and flow characteristics during the ladle change-over process of a two-strand tundish.The results showed that reducing the immersion depth decreases the high-velocity region area under the slag layer in the quasi-steady process.During the emptying stage,as the molten bath level gradually decreases,the outlet temperature exhibits a trend of initially decreasing and subsequently increasing across all three shroud immersion depths.However,under a 210 mm shroud immersion depth,molten slag and air are dragged into the shroud,forming slag droplets and causing significant fluctuations,with a maximum scalar velocity of 0.0764 m/s at the monitoring point.In the filling stage,air and molten slag are dragged into the molten bath,forming bubbles and slag droplets at an immersion depth of 210 mm.Bubbles are observed within the molten slag layer,which can readily cause an emulsification phenomenon,making it easier to be dragged as slag droplets.Additionally,the slag eye area measured under 210 mm immersion depth at 45 s is 0.303 m^(2),while the maximum scalar velocity of 2.4259 m/s is detected at 12 s.At an immersion depth of 360 mm,the average area of the slag eye is minimized to 0.06268 m2,with corresponding variances of 0.006753,representing the optimal immersion depth.
基金supported by the National Natural Science Foundation of China(Grant Nos.52104318 and 52374322).
文摘A new three-dimensional multiphase numerical model was built.The volume of fluid and k-ε turbulence models were used to investigate the hot metal ladle pouring process.During the pouring process,issues such as iron splashing,overflow,and significant heat loss are prevalent.To realize efficient and stable pouring,the effects of ladle tilting velocity,flow rate,and converter tilting angle on the pouring process were examined.The model was verified by comparing the actual pouring time with the numerical results.It is shown that there is a nonlinear relationship between pouring velocity and hot metal flow rate at the ladle mouth.As the mass flow increased and the converter tilting angle decreased,the impact point of the hot metal into the converter pool shifted from the side wall to the bottom,and the impact force increased accordingly.The pouring velocity curve was optimized by the volume difference of the ladle at different angles,and an empirical formula was derived.After the optimization of pouring speed,the flow rate was stabilized between 4000 and 6000 kg/s,and the pouring time was reduced by approximately 30 s.After applying this model in actual production,the hot metal temperature inside the converter increased by approximately 5℃statistically.This model is potential to enhance the production efficiency,stability,and safety of the pouring process between open containers.
基金The authors gratefully express their appreciation to the National Natural Science Foundation of China(51834002)for sponsoring this work.
文摘Ladle furnaces are known for their high power consumption,making research on power-saving process crucial.In response to the defect of thin slag thickness in the industrial production of a 120-t ladle furnace at a steel plant,with its production of ship plate steel DH36 as the focus,experiments involving adding the foaming agent and shifting power delivery gears were conducted.Based on the principle of measuring alternating current by Rogowski coils,the power consumption during the ladle furnace refining process was calculated theoretically,and the actual industrial power consumption matched with it basically,confirming the accuracy of the theoretical calculations.Additionally,the impacts of argon flow rate,foaming agents,and shifting power delivery gears on power consumption were studied.The results showed that adding 0.59 and 0.50 kg/t foaming agents in two batches improved the refining process of the ladle furnace,allowing for effective submerged-arc operations and saving electric energy of 7.2382 kWh per ton of steel.Similarly,utilizing a power supply mode of 7-step short arc during the refining process significantly enhanced the desulfurization rate of molten steel and saved electric energy of 11.6387 kWh per ton of steel.
基金Key Project of the National Natural Science Foundation of China(Grant No.U21A2058)China Postdoctoral Science Foundation(2023M740971)State Key Laboratory of Refractories and Metallurgy(Wuhan University of Science and Technology,G202209).
文摘The penetration of ladle slag into refractory linings is an essential process in service,and the mechanical properties of the refractory castables are affected by the location and content of slag in the refractory castables.In this work,ladle slag was added into Al_(2)O_(3)-Mgo refractory castables and its influence on the microstructure evolution,mechanical properties and thermal shock resistance of the castables was investigated.The phase composition and contents of the castables during the corrosion process were calculated by FactSage TM(6.2)and studied.The results indicate that the residual strength decreases as the ladle slag addition increases from 0 to 6 mass%.While the hot modulus of rupture of the castable with 6%ladle slag significantly decreases by approximately 80%compared with the one without ladle slag.The elastic modulus and CMOR of the castables decrease with slag-adding,which leads to the increase of liquid phase contents inside the samples.
文摘The heat transfer analysis was performed for an industrial ladle furnace （LF） with a capacity of 55-57 t in Turkey. The heat losses by conduction, convection and radiation from outer and bottom surfaces, top and electrodes of LF were determined in detail. Finally, some suggestions about decreasing heat losses were presented.
基金Item Sponsored by Fundamental Research Funds for Central Universities of China(FRF-BR-10-027B)
文摘Aiming at the characteristics of the practical steelmaking process, a hybrid model based on ladle heat sta- tus and artificial neural network has been proposed to predict molten steel temperature. The hybrid model could over- come the difficulty of accurate prediction using a single mathematical model, and solve the problem of lacking the consideration of the influence of ladle heat status on the steel temperature in an intelligent model. By using the hybrid model method, forward and backward prediction models for molten steel temperature in steelmaking process are es- tablished and are used in a steelmaking plant. The forward model, starting from the end-point of BOF, predicts the temperature in argon-blowing station, starting temperature in LF, end temperature in LF and tundish temperature forwards, with the production process evolving. The backward model, starting from the required tundish tempera- ture, calculates target end temperature in LF, target starting temperature in LF, target temperature in argon-blo- wiag station and target BOF end-point temperature backwards. Actual application results show that the models have better prediction accuracy and are satisfying for the process of practical production.
基金supported by the National Natural Science Foundation of China(61702070)
文摘In ladle furnace, the prediction of the liquid steel temperature is always a hot topic for the researchers. The most of the existing temperature prediction models use small sample set. Today, the precision of them can not satisfy practical production. Fortunately, the large sample set is accumulated from the practical production process. However, a large sample set makes it difficult to build a liquid steel temperature model. To deal with the issue, the random forest method is preferred in this paper, which is a powerful regression method with low complexity and can be designed very quickly. It is with the parallel ensemble structure,uses sample subsets,and employs a simple learning algorithm of sub-models. Then, the random forest method is applied to establish a temperature model by using the data sampled from the production process. The experiments show that the random forest temperature model is more precise than other temperature models.
文摘The heat transfer in a steelmaking ladle was studied. The evaluation of heat transfer of the steel was performed by measuring steel temperature in points including all refining steel process. In the ladle, the temperatures in the refractories and the shell were also measured. To evaluate the thermal profile between the hot and cold faces of the ladle in the slag line position, an experiment which shows the importance of thermal contact resistance was carried out. Higher heat losses in the tapping and the vacuum were verified. The temperature measurements of the ladle indicate distinct thermal profiles in each stage of steel refining. Moreover, as each stage of the process depends on the previous one, the complexity of the ladle thermal control is incremental. So a complete model of heat losses in the ladle is complex.
文摘In the electric arc furnace （EAF） steel production processes, scrap steel is principally used as a raw material instead of iron ore. In the steelmaking process with EAF, scrap is first melted in the furnace and then the desired chemical composition of the steel can be obtained in a special furnace such as ladle furnace （LF）. This kind of furnace process is used for the secondary refining of alloy steel. LF furnace offers strong heating fluxes and enables precise temperature control, thereby allowing for the addition of desired amounts of various alloying elements. It also provides outstanding desulfurization at high-temperature treatment by reducing molten steel fluxes and removing deoxidation products. Elemental analysis with mass balance modeling is important to know the precise amount of required alloys for the LF input with respect to scrap composition. In present study, chemical reactions with mass conservation law in EAF and LF were modeled altogether as a whole system and chemical compositions of the final steel alloy output can be obtained precisely according to different scrap compositions, alloying elements ratios, and other input amounts. Besides, it was found that the mass efficiency for iron element in the system is 95.93%. These efficiencies are calculated for all input elements as 8. 45% for C, 30.31% for Si, 46.36% for Mn, 30.64% for P, 41.96% for S, and 69.79% for Cr, etc. These efficiencies provide valuable ideas about the amount of the input materials that are vanished or combusted for 100 kg of each of the input materials in the EAF and LF system.
基金Item Sponsored by China Postdoctoral Science Foundation(2015M572647XB)Science Research Program of Yunnan Province Education Department of China(2014Y069)
文摘For further research on the control model of muhifunctional hot metal ladles between the ironmaking and steelmaking interface, the hot metal ladies of K steel plant were taken as the object to analyze the operation process. The factors of blast furnace supply and basic oxygen furnace demand were proposed. According to the principle of supply and demand balance, the control model of hot metal was researched under the following factor conditions： equal to, greater than, and less than 1, respectively. The distribution model of the blast furnace, sleelmaking works, and online buffering was proposed. When the supply and demand factor is equal to ） , the turnover number of hot metal ladles equals 16 and the turnover cycle of hot metal ladles equals 512 min. When the factor is greater than 1, the total number of hot metal ladles is equal to the normal turnover number plus the turnover number of the cast iron machine. When the factor is less than 1, the total number of hot metal ladles is equal tO the normal turnover number plus the accumulating number. Satisfactory effects were obtained by applying the control model in produc tion. The numbers of turnover ladles and accumulating ladles were reduced.
基金Item Sponsored by National Natural Science Foundation of China (50474037) Natural Science Foundation of Jiangsu Higher Education Institutions of China (04KJB430022 ,05KJD450043)
文摘To avoid slag sticking on the ladle immersion cover during the LATS refining and alloying process, the effect of Al2O3 on the melting point of the ladle slag was studied and the additives including CaF2, B2O3, Li2O, and CaO were used to decrease the melting point of the ladle slag. The melting point was measured using the hemisphere method. The results show that the addition of Al2O3 to the ladle slag increases the melting point. The fluxing action is not remarkable if only CaF2 or CaO is used as the additive. The fluxing action of the composite additive obtained by the mixing of CaO and CaF2 in the mass proportion of ωCaO：ωCaF2=2 ： 1 is preferred. The fluxing action of B2O3 is also notable. When the B2O3 content in mass percent is in the range from 2% to 10%, the corresponding melting point is 1 380 ℃ to 1 290℃. The fluxing action of Li2O is the most remarkable. When the Li2O content is up to 5%, the melting point of the slag is lower than 1 300 ℃.
基金The project is sponsored by the National Natural Science Foundation of China (No.50274007).
文摘Fine bubbles will create when the inert gas is introduced to the high rapidsteel stream within the shroud nozzle between ladle and tundish. The collision and attachment amongthe bubbles and fine inclusions will promote the floatation efficiency of inclusions in the tundish.The behaviors of the bubbles, such as the dispersion in shroud, coalescence and floatation intundish, are studied. The results show that the maximum sizes of the bubbles in the water and steelflow within the shroud in the length of 1.2 m are 0.70-1.44 mm and 1.53-3.16 mm respectively whenthe flow rates are 0.006-0.016 m^3/s; the terminal velocities of fine bubbles in the water andmolten steel within the tundish are 0.02-0.2 and 0.05-0.6 m/s.
基金supported by the Basic Research Project of the Korea Institute of Geoscience and Mineral Resources funded by the Ministry of Science, Information & Communication Technology and Future Planning of Korea
文摘A rapidly air-cooled ladle furnace slag(RA-LFS), which is a type of steelmaking slag discharged from a steel mill, was used to synthesize CaCO_3 film. The CaCO_3 film with 35 cm^2 of surface area was synthesized under atmospheric conditions, and the surface morphology of the CaCO_3 films was changed by using additives(CaCl_2 and ethylene glycol). Especially, the addition of CaCl_2 changed the surface morphology of CaCO_3 film with pore and induced new material properties, such as water adsorption. The(012) face of CaCO_3 film(calcite) was rapidly decreased by the addition of CaCl_2. The major components of RA-LFS were calcium(type of CaO, 53.9 wt%) and aluminum(type of Al_2 O_3, 37.9 wt%), and the major crystal phases of RA-LFS were C_3 S, C_(12) A_7, and C_3 A. The calcium extraction efficiency of RA-LFS was significantly increased after the CaCO_3 film synthesis. The material properties(hardness and elastic modulus) and the thermal characteristics of the CaCO_3 films were analyzed by nano-indentation and thermogravimetry–differential thermal analysis. The synthesized CaCO_3 films from RA-LFS and Ca(OH)_2(reagent) showed similarities in terms of their material properties and the decomposition temperature.
基金supported by the National Research Foundation of Korea(NRF)(2015R1A5A1037668)the Ministry of Trade,Industry and Energy(Grant N0002310)
文摘This study investigated whether the pouring ladle's outlet shape could reduce the porosity of aluminum alloy casting products and whether it could be applied to mass production of automotive brackets based on computer simulations and experiment.The filling behaviors of the melt were simulated to compare the flow characteristics of the molten metal poured from the conventional ladle and the proposed ladle.Results show that for the conventional ladle,the pouring metal is V-shaped,while it is relatively circular and poured at a more constant rate in the proposed ladle.CT scans reveal that the proposed ladle reduces the porosity of the cast product.The proposed ladle resulted in an average of 30 fewer pores,a 299.56 mm3 smaller average total pore volume,and a 0.041% lower difference in average porosity.It is concludes that the proposed ladle can be used in the gravity casting process.By changing the ladle outlet shape can reduce the casting failure rate of massproduced automobile bracket.
基金Item Sponsored by Technology Supporting Program During the 11th Five-Year Plan Period(BAE03A07)
文摘Combined with the parameters of the production process of a steel factory, numerical simulations for a new ladle from preheating to turnover are conducted using the finite element analysis system software （ANSYS）. The measured data proved that the simulated results are reliable. The effects of preheating time, thermal cycling times, and empty package time on steel temperature are calculated, an ideal preheating time is provided, besides, based on the analysis of a single factor and use the nonlinear analysis method, a steel temperature compensating model with di- versified coupling factors is proposed, with the largest error of the present coupling model at 1. 462 ~C, and the er- rors between actual and target steel temperature in tundish after the model is applied to practical production are basi- cally controlled within -4-6 ~C, which can meet the accuracy of the manufacturer and has a practical guiding significance for the production in steelmaking workshops.
基金supported by the National High-tech Research and Development Program of China (No.2009AA03Z530)the National Natural Science Foundation of China and Shanghai Baosteel (No.50834010)the Key Project of the Ministry of Education of China (No.108036)
文摘Based on the two-phase fluid （Eulerian-Eulerian） model, a mathematical model about the gas-liquid flow and mixing behavior was developed to investigate the effect of the offset of dual plugs, the included angle of dual plugs with a center point, and gas flow rate on the mixing time in a ladle with dual plugs. Numerical results indicate that two types of recirculation zones exist in the ladle. One is the middle recirculation between gas and liquid plumes, and the other is the sidewall recirculation between plumes and the ladle sidewall. The correction shows that the mixing time is in proportion to -0.2676 power of gas flow rate. There is a unique optimum offset of dual plugs with a particular included angle, in turn, a unique optimum included angle of dual plugs exits with a particular offset.
文摘Steel 20Mn23AlV is a type of high aluminum steel with a very low ladle free-opening rate. The aluminum composition of 20Mn23AlV ranges from 1.6% to 2.45% ,which is significantly higher than other types of steel. According to the real condition of 40 t ladle in steel-making plant of Baosteel Special Steel Company, previous works show that the key factors affecting the ladle free-opening rate of high aluminum steel in continuous casting are：sand material, accessories baking, ladle nozzle cleaning, the process and amount of adding sand, and the rate of argon stirring during refining. Therefore, improving the ladle filler sand quality, baking all of the raw materials, controlling the addition of ladle filler sand, cleaning the ladle nozzle, and optimizing argon stirring during the refining process can resolve the problem of a low ladle free-opening rate of high aluminum steel caused by the long ladle time of liquid steel.
基金financially supported by the National Natural Science Foundation of China (No.51674030)the Fundamental Research Funds for the Central Universities (Nos.FRF-TP-18-097A1 and FRF-BD-19-022A)。
文摘In the prediction of the end-point molten steel temperature of the ladle furnace, the influence of some factors is nonlinear. The prediction accuracy will be affected by directly inputting these nonlinear factors into the data-driven model. To solve this problem, an improved case-based reasoning model based on heat transfer calculation(CBR-HTC) was established through the nonlinear processing of these factors with software Ansys. The results showed that the CBR-HTC model improves the prediction accuracy of end-point molten steel temperature by5.33% and 7.00% compared with the original CBR model and 6.66% and 5.33% compared with the back propagation neural network(BPNN)model in the ranges of [-3, 3] and [-7, 7], respectively. It was found that the mean absolute error(MAE) and root-mean-square error(RMSE)values of the CBR-HTC model are also lower. It was verified that the prediction accuracy of the data-driven model can be improved by combining the mechanism model with the data-driven model.
基金supported by the National Natural Science Foundation of China(No.51974023)State Key Laboratory of Advanced Metallurgy,University of Science and Technology Beijing(No.41621005)。
文摘The composition control of molten steel is one of the main functions in the ladle furnace(LF)refining process.In this study,a feasible model was established to predict the alloying element yield using principal component analysis(PCA)and deep neural network(DNN).The PCA was used to eliminate collinearity and reduce the dimension of the input variables,and then the data processed by PCA were used to establish the DNN model.The prediction hit ratios for the Si element yield in the error ranges of±1%,±3%,and±5%are 54.0%,93.8%,and98.8%,respectively,whereas those of the Mn element yield in the error ranges of±1%,±2%,and±3%are 77.0%,96.3%,and 99.5%,respectively,in the PCA-DNN model.The results demonstrate that the PCA-DNN model performs better than the known models,such as the reference heat method,multiple linear regression,modified backpropagation,and DNN model.Meanwhile,the accurate prediction of the alloying element yield can greatly contribute to realizing a“narrow window”control of composition in molten steel.The construction of the prediction model for the element yield can also provide a reference for the development of an alloying control model in LF intelligent refining in the modern iron and steel industry.
文摘Hot metal ladle is an important part in continuous casting production line and its stress distribution has direct influence on its life. In the process of design and calibration of the large-sized hot metal ladle, it is of great significance to determine the stress distribution of each part of the ladle for safely and reliably running the device. Based on 100 t hot metal ladle which is designed by Baotou Iron and Steel Group, simulation of stress field was made by finite element software ANSYS 10.0 from different dumping angles. Through modeling, loading, restricting and calculating, strain and stress field distribution of the hot metal ladle were acquired. Finally, an assessment of strength and stiffness was made on the hot metal ladle. The results show that in the process of tipping for the hot metal ladle, maximum stress is 132 MPa and maximum strain is only 0. 064% ; maximum stress and strain have appeared in the stiffener plate which is located at the bottom of the trunnion, and strength and stiffness are qualified. The method, which is convenient and practical, reasonable and reliable, provides theoretical evidence for checking analysis and further optimal design of the hot metal ladle.
