Comparison of Thermo-electromagneto-hydrodynamic Multi-physical Fields in ESR Furnace with Vibrating and Traditional Electrodes

Wang, Fang; Wang, Qiang; Li, Baokuan

doi:10.2355/isijinternational.isijint-2016-436

Cited by 14 publications

(13 citation statements)

References 24 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…[36] used the rotating electrode method to improve production efficiency in the ESR process by over 25%, which cut power consumption and also improved the solidification quality of the ingot. Wang Fang and Chen Rui, et al [37][38][39][40] adopted a vibrating electrode remelting method to increase the electrode melting rate, which cut the power consumption by over 10% compared with the traditional method of ESR.…”

Section: Effect Of Melting Rate On Power Consumption In Esr Processmentioning

confidence: 99%

Factors influencing power consumption and power-saving measures in ESR process

2019

View full text Add to dashboard Cite

Since the USA patent of electroslag remelting (ESR) metallurgy was held by P. K. Hopkins in 1940, the ESR technology has now entered a relatively mature stage after a 70-year history of development. At present, the annual capacity of ESR steels around the world is approximately 2 million tonnes. ESR metallurgy emerged in China in 1958. Since then, electroslag furnaces were gradually installed in Chinese special steel plants. At present, there are more than 200 electroslag remelting furnaces in the metallurgical workshops of these steel plants with an annual production capacity of about 500,000 tonnes of ingots and components made of about 200 varieties of steels, including high quality steels and superalloys. This ESR technology is used as a special remelting and refining method for producing high quality steels and superalloys. However, traditional ESR technology has the disadvantages of environmental pollution and extremely high specific power consumption. High power consumption restricts, to a certain degree, the competitiveness of ESR steels in the marketplace. The measures of power saving in ESR have been researched in recent years. In this paper, some factors influencing power consumption, such as filling ratio, slag system, slag amount, melting rate and furnace structure are reviewed, and several new ESR technologies for power saving are proposed.

show abstract

Section: Effect Of Melting Rate On Power Consumption In Esr Processmentioning

confidence: 99%

Factors influencing power consumption and power-saving measures in ESR process

2019

View full text Add to dashboard Cite

show abstract

“…It is hard to decide the power efficiency accurately as to the complex physical and chemical process. Hence, a reasonable power efficiency 0.18 is chosen from literature [18].…”

Section: Boundary Conditions and Solution Proceduresmentioning

confidence: 99%

“…ln σ = −6769.0/T + 8.818 Liquidus temperature ( ∘ C) 1650 Top surface emissivity 0.6 parabolic shape, which had a 30 K superheat higher than the metal liquidus. Equivalent heat transfer coefficients are applied for the lateral and bottom walls [18,19]. The key geometrical and material properties together with controlling parameters are shown in Table 1.…”

Section: Boundary Conditions and Solution Proceduresmentioning

confidence: 99%

Investigation on the effect of electrode tip on formation of metal droplets and temperature profile in a vibrating electrode electroslag remelting process

Wang

Baleta

Wang³

et al. 2019

Open Physics

Self Cite

View full text Add to dashboard Cite

In the present work, a transient full-coupled modelling approach has been put forward to study the effect of electrode tip on formation of metal droplets and temperature profile in the electromagnetically-controlled electroslag-remelting furnace with vibrating electrode. The electromagnetic field, momentum and energy conservation equations are solved simultaneously based on the finite volume method. The interface of slag and metal is traced using the volume of fluid approach. The results show that in the case of cone tip electrode the average dimension of metal droplets is smaller compared to the flat tip electrode. In addition, the bigger and stretched metal droplets are not observed with the cone tip electrode. The temperature fields with the cone tip electrode are distributed in a prominent periodic pattern compared to the case with flat tip electrode. The maximum temperature zone with the cone tip electrode is located along the z axial in the upper part of slag, not in the lower part. When the frequency changes from 0.17 Hz to 1 Hz, the maximum temperature reduces from 2050 K to 1985 K and the peak value of velocity decreases from 0.20 m/s to 0.125 m/s. When the vibration amplitude varies from 3mm to 6mm, the maximum temperature in the slag cover drops by 3.9% and the peak value of velocity rises by 16.7%.

show abstract

“…It is well to achieve a typical U-shaped metal pool profile. Wang et al 30) carried out the numerical simulations about the ESR process with the vibrating and traditional electrodes. Their results showed that the horizontal vibrating ESR process could generate small droplets and the remelting rate could be increased, which were similar to our results, although the method was different.…”

Section: Features Of the Dropletsmentioning

confidence: 99%