CSP中间包内腔优化的数值模拟

针对CSP中间包内冶金过程,建立中间包内钢水流场、温度场、夹杂物运动的数学模型,对不同挡墙和挡坝的5种组合方案的中间包钢水,从流动、传热和去夹杂能力等方面进行分析。结果表明:不同挡墙和挡坝的组合方案中,方案5效果最佳,其结构合理,钢液停留时间有效延长,利于夹杂物的上浮;没有明显的低温区域,中间包出口与入口的温差为5℃;对50μm的夹杂物能去除98.4%,对40μm的夹杂物去除率达到92.3%。     

Fluid Flow in Tundish Due to Different Type Arrangement of Weir and Dam

Tundish is an important metallurgical reactor in the continuous casting process,In order to control the fluid flow in tundish and thus take full advantage of the residence time available for the removal of inclusions from molten steel,the effect of weir and dam on the fluid flow has been studied in a water model based on the characteristic number Froude and Reynold number similarity criteria.The residence time distribution curves of the flow were measured by SG800,The optimum arrangement of dam and weir and the nonstationary flow in tundish were discussed.The results show that the comnbination of weir and dam is benefit for the flow pattern in tundish,weir can prevent the upper recirculating flow.dam can cut off the bottom flow and turn to upwards,it is advantageous to separate the nometallic inclusions.Furthermore,it is importnat to exceed the critical depth of bath during exchange ladles,not only for the inclusion floatation but also for avoiding tundish slag drainage earlier.     

Influence of flow control devices on metallurgical effects in a large—capacity tundish

The influence of flow control devices on metallurgical effects in large-capacity tundish has been studied carefully with elements tracing,sampling and theoretical prospecting,The results from the studies are(1) in the continuous casting of clean steel,bad control of tundish operation may deteriorate the cleanliness of steel;(2) the cleanliness of steel is deteriorated mainly at the unstady state;(3) large amount of macro inclusions come from the top slag and the refractory of tundish;(4) installing dam and weir can improve the cleanliness of steel and lighten the influence of steel fluctuation;and (5) the result of theoretical calculation suggests that the inclusions larger than the critical size of 92.6um can be floated out from the tundish bath completely.     

单侧孔长水口优化异型四流中间包流场

采用数值模拟方法研究了不同形式长水口下异型四流中间包的钢液流场和停留时间分布特征.数值结果表明：原型中间包存在较大的死区,各流流动情况存在着巨大的差异,而把直通型长水口替换成单侧孔型长水口之后,中间包死区比例减少,各流流动差异性基本上被消除.在挡墙的左侧产生了旋转流场,有利于夹杂物的碰撞聚合和去除.     

Dispersive bubble wall——a new method of flow control in tundish

Tundish is the last refractory vessel in the steelmaking process. The fluid flow phenomena in tundish have a strong influence on the separation of non-metallic inclusions. The dispersive bubble wall （DBW） is a new method in tundish metallurgy. A water model of a multi-strand tundish has been set up based on the Froude number and Reynold number similarity criteria. The effect of DBW＋weir on the flow pattern has been studied. The results show that this new structure of DBW＋weir is beneficial not only to uniform the temperature among different submerge entry nozzles but also to separate non-metallic inclusions from liquid steel. The DBW can capture the particles of non-metallic inclusions and make them float up to the surface.     

4145H钢的电炉连铸工艺生产

4145H钢是石油钻铤用钢,对钢水纯净度、非金属夹杂物含量、钢材的晶粒度、中心碳偏析等指标要求严格。采用电炉连铸工艺开展了4145H钻铤用钢的制备研究。结果表明,化学成分调整合格后,连铸过热度为25—35℃、铸速为0．4～0．6m／min、冷却水量为180m3／h时可以拉出280mm×280mm合格方坯。当加热炉出炉温度1160～1170℃、入轧温度965—975℃、缓冷时间46h、出坑温度100～150℃时,可以获得质量合格的西130的4145H轧制材。     

五流大方坯中间包流场优化

针对某钢厂五流大方坯中间包3流铸坯探伤不合格率较高的问题,采用数值模拟方法,研究不同结构中间包钢液的流场。结果表明,该钢厂现使用的中间包结构不合理,近流有短路流出现,且各流差异较大,不利于去除钢液中的夹杂物和提高各流间钢液的均匀性;采用大冲击区,挡墙中墙不开孔、侧墙开4个孔,设置2个坝的中间包结构最佳;中间包结构优化后,消除了近流的短路流,中间包钢液平均停留时间达652.9 s,各流示踪剂浓度的标准差仅为0.011 9,死区体积分数也仅为21.96%,既有利于夹杂物上浮去除,也保证了各流间钢液的均匀性。     

Dispersive bubble wall--a new method of flow control in tundish

Tundish is the last refractory vessel in the steelmaking process. The fluid flow phenomena in tundish have a strong influence on the separation of non-metallic inclusions. The dispersive bubble wall (DBW) is a new method in tundish metallurgy. A water model of a multi-strand tundish has been set up based on the Froude number and Reynold number similarity criteria. The effect of DBW weir on the flow pattern has been studied. The results show that this new structure of DBW weir is beneficial not only to uniform the temperature among different submerge entry nozzles but also to separate non-metallic inclusions from liquid steel. The DBW can capture the particles of non-metallic inclusions and make them float up to the surface.     

Numerical simulation of flow phenomena and optimum operation of tundish

1　INTRODUCTIONDuringthecourseofcontinuouscastingsteel,theflowofliquidsteelintundishwasafairlycomplexprocesscontainingmomentumtransfer,masstransfer,energytransferandphase changeofmultiphasecomponents .Ac cordingtoRefs.[1,2 ],someinfluencingfactorsincastingsteelwerefound ,includingthecompositionofliquidsteel,thetechnicalparametersoftundishandre oxidationofmoltenmetal.Theprocesswouldaffectdirectlysurfacedefectsandinternalstructureformationofthecastingsteelproductsaswellastherealizationofhig…     

板坯连铸中间包结构优化的研究

结合某公司双冲击点板坯中间包生产现状,利用水模实验对中间包内钢水流动特性进行了研究.结果表明：原中间包结构存在明显的短路流,钢水停留时间偏短,死区体积分率偏高,不利于夹杂物上浮去除.同时,由于在高度较大的两湍流控制器间钢水不能流出,影响金属收得率.这种具有双冲击点的中间包,应按照对称的两个单流板坯中间包进行结构优化.采用小高度湍流控制器加上下挡墙的控流方式时,由于钢水流经路径增长和全混流体积分率增加,响应时间增长,死区体积分率显著减小至15%以下,有利于夹杂物上浮去除.同时,将小高度湍流控制器和门式开孔导流坝相结合,残钢量显著减小,有利于提高金属收得率.     

宝钢板坯连铸机中间包三维流场数模研究

本文根据宝钢板坯连铸机中间包的形状和操作工艺参数,建立了一个钢液流动的三维数学模型,并利用数值计算结果,分析了宝钢中间包上、下挡墙结构对钢液流场的影响。结果表明,这种结构的中间包,有较合理的钢液流场。可避免钢渣卷入钢液流向水口进入结晶器,也有利于钢液内的夹杂上浮排除。     

中间包热态水模型研究

用热态水模研究了中间包内钢水的流动规律，结果表明，钢液由于温度变化导致密度不均匀，使自然对流影响钢液流动；同时，给出了不同控流装置和不同熔池高度下中间包内的温度分布，并讨论了它们对自然对流的影响．     

Numerical simulation on inclusion transport in continuous casting mold

Turbulent flow, the transpor＇t of inclusions and bubbles, and inclusion removal by fluid flow, transport and by bubble flotation in the strand of the continuous slab caster are investigated using computational models, and validated through comparison with plant measurements of inclusions. Steady 3-D flow of steel in the liquid pool in the mold and upper strand is simulated with a finitedifference computational model using the standard k-εturbulence rondel. Trajectories of inclusions and bubhles tire calculated by integrating each local velocity, considering its drag and buoyancy forces, A ＂random walk＂ model is used to incorporate the effect of turbulent fluctuations on the particle motion. The attachment probability of inclusions on a bubble surface is investigated based on fundamental fluid flow simulations, incorporating the turbulent inclusion trajectory and sliding time of each individual inclusion along the bubble surface as a function of particle and bubble size. The chunge in inclusion distribution due to removal by bubble transport in the mold is calculated based on the computed attachment probability of inclusions on each bubble and the computed path length of the bubbles. The results indicate that 6%-10% inclusions are removed by fluid flow transport. 10% by bubble flotation, and 4% by entrapment to the submerged entry nozzle （SEN） walls. Smaller bubbles and larger inclusions have larger attachment probabilities. Smaller bubbles are more efficient for inclusion removal by bubble flotation, so Inng as they are not entrapped in the solidifying shell A larger gas flow rate favors inclusion removal by bubble flotation. The optimum bubble size should be 2-4mm.     

Design optimization of flow control device for multi-strand tundish

The fluid flow phenomena in tundish have a strong influence not only on the uniform of composition and temperature of bath, but also on the separation of non-metallic inclusions, especially for the multi-strand tundish. A water model of a multi-strand tundish has been set up based on the Froude number and Reynold number similarity criteria. The effect of dam+weir and baffle on the uniform of composition and temperature of bath for different nozzles has been studied. The residence time distribution curves of the fluid flow were measured by SG800. Comparing the photos of the flow pattern in tundish, the optimum arrangement of baf-fle+dam was obtained. This new structure is benefit not only to uniform the temperature among different SENs (submerge entry nozzles) but also to separate the non-inclusions from the liquid steel, it can be widely used in multi-strand tundish.     

Orthogonal analysis of water model study on the optimization of flow control devices in a six-strand tundish

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.     

板坯连铸中间包内钢液流场和浓度场的数值模拟

采用FLUENT软件对板坯连铸中间包内的流场和浓度场进行数值模拟,分析中间包内有无挡墙以及挡墙参数变化引起中间包内流场、浓度场的变化情况。模拟结果表明,湍流控制器与挡墙的优化配合使中间包内钢液的平均停留时间由502 s延长至573 s,死区体积分数由29.7%降为14.4%,优化挡墙与挡坝参数有利于钢液温度和成份的均匀,及夹杂物的上浮去除。     

连铸中间包内流场控制优化水模实验研究

根据相似原理,研究了原设计方案和优化改进方案对中间包流场的影响。采用刺激-响应实验方法测得中间包流体的平均停留时间分布(RTD)曲线,并得到不同方案控流装置对中间包流体流动的影响,从而优化对中间包流场的控制。研究结果表明:方案4中活塞区体积分数增大了42.44%,钢液平均停留时间延长了500s左右,并且提高了中间包各流之间的钢液均匀性,从而促进夹杂物的上浮去除。     

二流连铸中间包内型优化水模试验

以相似原理为基础,用水模拟钢液研究中间包内的钢水流动特征,通过测定模型中间包内停留时间分布曲线(RTD),计算其平均停留时间及死区、活塞区和混合区的体积。试验表明,经过改进的中间包,其最短停留时间由20s增加到54s,平均停留时间由249s增加到305s,死区体积则由30．34％降低到14．74％,优化了中间包内的流场。     

两流非对称中间包内控流装置优化的水模型研究

通过水模型实验和数值模拟,研究了两流非对称中间包采用不同控流装置时流体流动的特性.结果表明：圆形湍流控制器与单挡墙组成的控流装置中间包两出口流体流动差异较大;非对称长方形湍流控制器和多孔挡墙组成控流装置的中间包,两流之间的平均停留时间差异是圆形湍流控制器和单挡墙组成控流装置中间包的2/3,且近长水口侧出口的平均停留时间延长7.5%.     

八流中间包内型优化水模实验

根据相似原理,利用水模拟钢液流动来研究中间包内流场的流动状况,通过调节中间包内挡墙位置及其开孔大小来改善和优化中间包内的流场。对比计算机采集的RTD数据及用墨汁作为示踪剂的照片寻求出最优化方案。得出经过改进的中间包各流平均停留时间增加50-90s,死区体积由25％～30％降低到14％～19％,活塞流的体积比从8％～13％增加到26％-27％,优化了中间包内的流场。