Numerical simulation on inclusion removal behaviours in refining processes of spring steel

Zhao, Jiaqi; Wang, Min; Qin, Deyue; Ma, Jianchao; Wang, Ning; Jiang, Haitao; Ma, Han; Bao, Yanping

doi:10.1080/03019233.2022.2160101

Cited by 3 publications

(2 citation statements)

References 24 publications

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“…The cleanliness of molten steel is becoming more and more important with the increasing demand for high-quality steel year by year [1,2]. The tundish, working as a buffer and distributor of molten steel between the ladle and continuous casting mold, plays a key role in ensuring continuous metal casting [3][4][5].…”

Section: Introductionmentioning

confidence: 99%

“…By imposing the A.C. magnetic field on the molten steel flowing in the tundish channel, the thermal loss of the molten steel in the tundish can be compensated effectively and the inclusions move towards the channel's inner wall by the electromagnetic force acting on them and are trapped on the channel inner wall. Thus, this method has two functions: (1) heat loss compensation by Joule heating and (2) inclusion removal by electromagnetic force. The A.C. magnetic field with a commercial frequency (50 Hz or 60 Hz) is generally used in the induction-heating system.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of the Circular Channel Size and the A.C. Magnetic Field Parameters for Application in a Channel-Type Induction-Heating Tundish

Zhang,

Xu,

Iwai

2024

Metals

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In this paper, the appropriate channel design and operating conditions for the simultaneous operation of the inclusion removal and the induction heating of the molten steel by imposing the A.C. magnetic field around the circular channel have been studied. (1) The effect of the lift force and the turbulence force on the inclusion in the transition zone of the channel has been computed; the results show that when the diameter of the inclusion is not less than 0.1 mm, both forces can be neglected because they are less than the electromagnetic pinch force, especially when the shielding parameter is not less than 5.0. (2) The minimal channel length to remove the inclusions out of the dead zone was computed without the lift force and the turbulence force; the shielding parameter of 10.0~15.9 is optimal to obtain the shortest channel length. Furthermore, the slow velocity of the molten steel is desirable. (3) The molten steel temperature increase per unit channel length by the induction heating can be controlled by the A.C. magnetic field frequency; a high frequency condition is better for the efficient thermal supply in this calculation condition. (4) When the flow velocity of the molten steel in the channel with a length of 1 m and a radius of 0.075 m is 0.1 m/s, the shielding parameter of 15.9 is the optimal parameter to simultaneously remove the inclusions and heat up the molten steel in the circular channel. And when the non-dimensional magnetic field intensity of the A.C. magnetic field is 31.7, the removal rate of the 0.1 mm inclusion in the channel can reach more than 95% and the molten steel temperature can be heated over 10 K.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Optimization of the Circular Channel Size and the A.C. Magnetic Field Parameters for Application in a Channel-Type Induction-Heating Tundish

Zhang,

Xu,

Iwai

2024

Metals

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Modeling of Motion of Inclusions in Argon‐Stirred Steel Ladles

Huang,

Duan,

Zhang

2024

steel research int.

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A 3D discrete phase model (DPM)‐ and volume of fluid–coupled model is developed to investigate the multiphase flow in a 260 ton argon‐stirred ladle. The flow field and interfacial behavior in the argon‐stirred ladle are accurately predicted. Then, the Lagrangian DPM is used to trace the motion of inclusions in the liquid steel. Residence time maps, which provided the residence time required for inclusions travelling from the bulk liquid steel to the steel–slag interface, are proposed and plotted as functions of inclusion diameter and percentage of inclusions. For inclusions smaller than 10 μm, the average residence time is size‐independent but decreases from 175 to 93 s with an increment in the gas flow rate from 50 to 400 NL min−1. With increasing the inclusion size, the average residence time is dependent on both gas flow rate and inclusion diameter. When the inclusion diameter increases to 1000 μm, the average residence time is almost independent of the gas flow rate. The current model overestimates the inclusion removal rate. However, this overestimation indicates that only appropriately considering the behavior of inclusions at the steel–slag interface can accurately predict the removal of inclusions in argon‐stirred ladles.

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Insight into the formation of slag eyes and the mechanism of slag entrapment in the steel-ladle refining process: Hydraulic modeling and numerical simulations

Lu,

Tang,

Zhao

et al. 2024

Physics of Fluids

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Slag eyes are the upper exposed areas of molten steel in a refining ladle that are formed due to excessive bottom argon bubbling. This phenomenon frequently occurs in the steel-refining process and can lead to slag entrapment and re-oxidation of molten steel. Taking a 150-t industrial steel ladle as the research object, the effects of a dual-plug gas-blown process on the slag-eye size were studied using hydraulic modeling and large-eddy simulations. The experimental results showed that at higher gas flow rates such as 9.1 and 11.7 normal liters/min (Nl/min), the relative central angle of the two porous plugs had a significant effect on the slag-eye size; conversely, at lower gas flow rates, its influence could be ignored. Due to the tendency of the two small slag eyes to merge, the 0.6R–45° (R being the bottom radius of the ladle) case resulted in a larger total slag-eye area compared to the cases with other angles. The 0.6R–135° case showed the most beneficial results for reducing the slag-eye size. Additionally, the numerical simulations helped us to visualize the bubble-uplifting and slag-eye formation processes, and they allowed an exploration of the slag-entrapment mechanism. The simulation results showed that the symmetric gas-blown mode can reduce slag entrapment when compared with the asymmetric mode for the 135°–11.7 Nl/min case; this will be favorable to control the cleanliness of the molten steel. Additionally, analysis of both liquid-level fluctuations and turbulent-kinetic-energy distributions further confirmed the advantages of the symmetric gas-blown mode for suppressing slag entrapment.

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Numerical simulation on inclusion removal behaviours in refining processes of spring steel

Cited by 3 publications

References 24 publications

Optimization of the Circular Channel Size and the A.C. Magnetic Field Parameters for Application in a Channel-Type Induction-Heating Tundish

Optimization of the Circular Channel Size and the A.C. Magnetic Field Parameters for Application in a Channel-Type Induction-Heating Tundish

Modeling of Motion of Inclusions in Argon‐Stirred Steel Ladles

Insight into the formation of slag eyes and the mechanism of slag entrapment in the steel-ladle refining process: Hydraulic modeling and numerical simulations

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