Application of Cooling Water in Controlled Runout Table Cooling on Hot Strip Mill

The controlled runout table cooling is essential in determining the final mechanical properties and flatness of steel strip. The heat of a hot steel strip is mainly extracted by cooling water during runout. In order to study the heat transfer by water jet impingement boiling during runout, a pilot facility was constructed at the University of British Columbia. On this pilotfacility, the water jet impingement tests were carried out under various cooling conditions to investigate the effect of processing parameters, such as cooling water temperature, water jet impingement velocity, initial strip temperature, water flow rate, water nozzle diameter and array of water nozzles, on the heat transfer of heated strip. The results obtained contribute to the optimization of cooling water during runout.     

喷雾转筒冷却机喷雾冷却性能

 喷雾转筒冷却机是转底炉生产线上的关键设备之一。为了提高冷却机的冷却性能,针对转筒外喷雾冷却系统换热特性,应用CFD数值模拟技术建立传热过程耦合模型,研究了喷嘴数量、间距以及偏移量等布置参数对换热的影响。结果表明,数量过多、间距过小或数量过少、间距过大均不利于传热,合适的数量和间距对设备冷却性能具有积极作用,喷嘴平行四边形排列在一定程度上优于矩形排列。最后通过具体工程应用试验验证了研究成果的正确性。     

A measuring method for quick determination of local heat transfer coefficients in spray water cooling within the range of stable film boiling

Within the framework of research investigations described in this paper, a measuring method for the determination of heat transfer coefficients in the range of stable film boiling has been developed for water spray cooling in the secondary cooling zone of continuous casting machines. Based on investigations by ³), a water cooled test sample with a measuring field of 20 × 20 mm² was constructed. For this sample geometry, a special evaluation method has been developed which permits quick evaluation in on-line procedure. Result of measurements are sections for the heat transfer coefficient arising from different spray water distributions. On the one hand, these can be used as calculation figures for the determination of the solidification profile and the solidification rate. On the other hand, the measuring results serve as an assessment basis for nozzle constructions. Practical use of the measuring results confirms the usefulness of the measuring method on a laboratory scale. In addition, the validity of the measuring results has been demonstrated by comparing them with an unsteady state method in accordance with ²).     

高温表面喷雾冷却传热系数的理论分析

以池内膜态沸腾为基础，将喷雾颗粒的冲击作为一种扰动，对喷雾冷却过程进行了建模，分析了水流密度、高温表面温度、雾滴尺寸、雾滴冲击速度对喷雾冷却换热系数的影响。并以一种全锥喷嘴为例，利用该模型进行了计算、分析，结果证实该模型对实际应用具有一定的指导作用。     

攀钢板坯连铸机二冷区喷嘴特性测试

对连铸二冷区喷嘴的冷态特性进行了研究。测定了不同喷水条件下喷嘴的压力一流量关系,喷水密度分布以及喷射角和喷雾粒度分布。分析了国内外喷嘴的特性曲线,为国内厂家生产喷嘴提供了更为合理的参数。     

喷嘴喷淋距离对连铸小方坯二冷均匀性的影响

研究了不同喷淋距离下连铸小方坯二冷喷嘴的水量分布,建立了凝固传热模型分析了82B钢连铸坯的热行为。该模型特别考虑了二冷区铸坯表面宽度方向的水流密度分布,并根据铸坯表面测温结果进行了模型校正。采用凝固传热模型研究了喷嘴喷淋距离对连铸二冷均匀性的影响。结果表明:喷嘴喷淋距离的增加有助于提高二冷水横向分布的均匀性,导致铸坯表面温度横向均匀性降低、纵向均匀性提高。这些效果有助于改善铸坯内部裂纹,但是会对角部裂纹产生不利影响。在二冷区前段喷嘴采用低喷淋距离,二冷区末段采用高喷淋距离,既可以提高铸坯角部温度,又能降低表面最大回温速率,有助于同时改善连铸坯角部和内部裂纹。在此基础上,提出了一种连铸小方坯二冷喷嘴布置方式,即二冷区每段喷嘴喷淋距离沿拉坯方向逐渐增加,该方法有助于提高连铸坯“纵?横”冷却均匀性。      

Two-dimensional heat transfer model for secondary cooling of continuously cast beam blanks

Abstract

A two-dimensional heat transfer model was developed for the secondary cooling system during beam blank continuous casting. The finite element method was used to calculate the heat transfer. Accurate cooling boundary conditions in the secondary cooling zone are involved, including spray water cooling, water evaporation cooling, radiation cooling and roll contact cooling in the casting direction and non-uniform distribution of spray water flow density in the cross-section. The causes of longitudinal crack at the fillet during Q235 steel continuous casting were analysed on the basis of the simulation of the developed model, and then the spray water flow and the transverse nozzle layout were optimised. Practical results show that the surface quality of the beam blank improved after optimisations. Numerical results from the present model were validated using previous experimental measurements, which show good agreement.     

喷淋结晶器传热特性的实验研究

喷淋结晶器是一种新型结晶器，它是用特殊的喷嘴将水喷淋到结晶器的铜板表面上进行铸坯冷却的，这种冷却方式具有较高的传热速度，便于调节结晶器的热流密度，可以提高拉坯速度和铸坯质量，喷淋结晶器的传热现象是很复杂的，本文通过建立传热实验台，对喷淋冷却过程进行较细致的实验研究，找出喷水量和换热系数的关系等，为设计喷淋冷却结晶器提供必要的参数。     

连铸板坯二冷高温区传热均匀性研究与优化

在板坯连铸过程中,二冷区传热的均匀性对铸坯表面与内部质量均有重要的影响。首先对国内某钢厂二冷各区的喷嘴进行了喷淋性能测试,根据各冷却区喷嘴的布局及2 000 mm×250 mm断面包晶桥梁钢板坯连铸生产过程的各区水量分布,建立了铸坯三维凝固传热有限元计算模型,模拟分析了铸坯在二冷区内的动态凝固传热行为。在此基础上,优化调整了连铸二冷高温区的喷嘴布局。结果表明,某钢厂原二冷区喷嘴布局条件下,其高温区的铸坯表面温度沿其横向波动较大。典型生产工艺下,二冷4区出口处的铸坯宽面表面横向温差最大,即距角部313 mm处的宽面表面温度最高为1 073 ℃,而距角部873 mm处的宽面表面温度最低为996 ℃,温差达77 ℃。而当铸坯进入二冷弧形区时,铸坯表面的横向温度分布逐渐趋于均匀。将二冷2区的喷嘴安装高度由距铸坯表面170提升至200 mm、3区和4区的喷嘴安装高度由距铸坯表面200提升至240 mm,可使铸坯在高温区内的表面横向温差最大值降至30 ℃以下,大幅改善铸坯表面温度分布的均匀性。     

Experimental study of heat transfer in process of rolls cooling in rolling mills by water jets

The paper summarizes results obtained by carrying out a large set of experiments that studied cooling of rolls. The experiments are based on the cooling of a steel plate by a set of flat nozzles from a starting temperature of 615 °C. The temperature histories measured in 39 points of the test plate are the inputs to the evaluation procedure. The sensor distribution covers a surface of a size of 450 × 110 mm. Classical Beck's inverse task was extended for the 3-dimensional area. The inverse task computes the surface distribution of heat transfer coefficient history, heat flux history and surface temperature. The results have pointed out a non-homogeneity in cooling by means of flat jets and provide us with a comparison of the flat and the full cone jets. The possibility of the intensification of the cooling by non-rectangular spray angle is discussed. It is shown that a certain point of saturation exists in the experimental pressure range from 0.4 to 1.2 MPa and increasing the pressure has a negligible influence on the cooling intensity.     

Atomized Spray Quenching as an Alternative Quenching Method for Defined Adjustment of Heat Transfer

In Atomized Spray Quenching, water is atomized to a fine spray by compressed air and sprayed onto the hot metallic surface. On the surface, the single drops partially evaporate. Afterwards they are taken away by the superposed airflow. Thus a water film cannot form. By quenching one edge, it is shown that an undefined water film collapses at the edges and corners; roughness, as known from Water Spray Quenching, does not occur. In this way a defined adjustment of heat transfer including quality improvement is possible. The influence of impingement density, spray characteristics, drop velocity, drop diameter and surface temperature on heat transfer was investigated. The heat transfer was measured with infrared thermography. The spray characteristics were measured with a combination of 2D‐Phase‐Doppler‐Anemometer and Patternator. Heat transfer coefficients up to 3000 W/(m² K) were measured.     

高碳钢线材轧后水冷换热过程的有限差分模拟

根据82B和72A钢Φ5.5～12.5mm高速线材轧后水冷传热特点,将水冷过程分成3个区域,并在水冷箱区域中根据环形喷嘴的开关状态,分别采用了水对流换热和水蒸气对流换热两种形式传热模型,建立了水冷过程按喷嘴个数分段处理的边界条件,通过有限差分模拟得出轧后水冷系统中线材断面的温度分布。通过实测温度值校正高碳钢线材水冷过程中水的对流换热系数,模拟结果表明,精轧机入口和吐丝机的预报和实测线材表面温度均值的绝对误差在±20℃以内。     

Ultra Fast Cooling of a Hot Steel Plate by Using High Mass Flux Air Atomized Spray

In the current research, the ultra fast cooling (UFC) of a hot stationary AISI‐304 steel plate has been investigated by using air atomized spray at different air and water flow rates. The initial temperature of the plate, before the cooling starts, is kept at 900°C or above. The spray was produced from a full cone internal mixing air atomized spray nozzle at a fixed nozzle to plate distance; and the average spray mass flux was varied from 130 to 370 kg m^?2 s by selecting different combinations of air and water flow rates. The surface heat flux and surface temperature calculations have been performed by using INTEMP software and the calculated results have been validated by comparing with the measured thermocouple data. The heat transfer analysis indicates that the cooling occurs in the transition boiling regime up to surface temperature of 500°C and thereafter it changes to nucleate boiling regime. The superposed flow of air on the hot plate enhances the cooling in the temperature range of 900–500°C by sweeping the partially evaporated droplets from the hot surface. However, due to the high percentage of fine water droplets in the resultant spray produced at higher air flow rates, the maximum cooling rate is achieved at the medium air flow rate of 30 N m³ h^?1. The cooling rate (182°C s^?1) produced by an air atomized spray is found to be in the UFC regime of a 6 mm thick steel plate. The findings of this research can be considered as the basis for the fabrication of cooling system in the run‐out table of a hot strip mill.     

喷嘴射流特征对连铸二冷区蒸汽膜穿透行为的影响

 连铸二冷区铸坯表面温度通常高于900 ℃,此时喷淋液滴接触高温铸坯时不会湿润铸坯表面,仅在其上形成一层蒸汽膜,阻碍了液滴与铸坯表面接触传热。针对以上问题,以国内某钢厂连铸二冷区的扁平型水喷嘴为原型,建立了喷嘴射流仿真计算模型,并对所建模型进行了理论和实验室验证;采用数值模拟的方法研究了喷嘴自由射流区的流场分布,运用连铸喷嘴冷却检测系统测量获得了射流液滴粒径演变规律;结合数值模拟和实验室测定结果,定量分析了喷嘴在不同水流量下射流液滴冲击铸坯表面蒸汽膜深度的变化规律。结果表明,该喷嘴的最大射流速度在喷嘴出口处,射流在喷嘴出口附近出能维持较大的射流速度,且随着水量的增加,射流保持高射流速度的距离也增长;整体射流的轴向速度占比均在80%以上。当喷淋水量越大时,射流液滴粒径变得越小;随着距喷嘴出口距离的增加,射流中心处的液滴粒径逐渐增大并达到最大值;当水流量为9和12 L/min时,液滴粒径基本相同,这表明当水流量增加到一定值时,冷却水量的增加不影响液滴粒径分布。在不同水流量下,随着喷淋距离的增加,液滴穿透铸坯表面蒸汽膜深度呈先增大后略微减小的变化规律,在喷射距离为100~200 mm范围内时,液滴穿透深度最大,这表明喷射高度在该范围时,喷淋冷却效果最好。     

Development of accelerated cooling for new plate mill

Abstract

The aim of the paper is to design the new wide plate mill. The work on the new cooling technology was supported by extensive laboratory testing while a simulator with full scale testing of cooling units was used. The principal objective of the investigation was to establish the design specification of equipment for accelerated cooling, particularly with respect to the product dimensions and steel grades. The possibilities of accelerated cooling are limited by technical parameters of cooling equipment such as thickness of water layer, flowrate, spray height, position of cooled surface to the nozzles and water or plate speed. These parameters were studied for different product temperatures and water impingement densities from 50 to 110 l s^?1 m^?2. The heat transfer coefficient was determined and compared for each case. There were three recognised significant cooling regions: water layer region, impinging jet region without water layer and impinging region with water layer, which must be taken into account. The application of the new cooling technology showed better flatness product and productivity higher than previous accelerated cooling system, even shorter cooling length. The rejection ratio by flatness problem of new mill was nearly half of the previous one.     

热轧带钢层流冷却过程温度场研究

 建立了热轧带钢层流冷却过程中温度场的三维有限元模型,对3 mm厚带钢轧后冷却过程带钢温度场进行模拟计算,得出卷取温度比现场测量值低9.5 ℃,相对误差为1.42%,验证了模型和假设的合理性。研究了上喷嘴直径对带钢温度的影响,带钢上表面宽度方向上存在2种不同的冷却区域：位于喷嘴正下方层流冷却过程中交替经过冲击区和平流区的区域和位于两喷嘴之间层流冷却过程中只经过平流区的区域,这造成带钢宽度方向上温度分布不均匀。计算结果表明,喷水量保持不变的情况下,存在一个最佳喷嘴直径,使带钢宽度方向上温度分布更均匀。喷水速度保持不变,增加喷嘴的直径有利于带钢宽度上方温度均匀,但增加了喷水量,降低了带钢的卷取温度。     

板坯二冷区喷嘴布置的数值模拟分析及优化

  在板坯连铸中,二冷区的喷嘴布置对铸坯的凝固冷却有重要影响。通过建立的三维稳态传热凝固模型对不同喷嘴布置下铸坯的冷却情况进行了模拟分析。通过优化喷嘴布置,消除了铸坯横断面“眼镜形”双热节现象,铸坯凝固情况得到改善。模拟结果与现场情况符合较好,证明了模型的可靠性及实用性。     

大方坯径向水口旋流效应及其对凝固的影响

通过改变水口侧孔钢水流动方向可以控制结晶器内钢水流动与换热。采用流体动力学与凝固模拟方法对比研究了浸入式四分径向水口不同出流方向对大方坯连铸结晶器内流动、传热和凝固行为的影响。结果表明,侧孔方向对浇注过程结晶器内钢水的流动与凝固行为有显著影响。当水口侧孔水平旋转角度为30°时,结晶器内形成较好的水平旋流,可以有效降低侧孔出流钢水对坯壳的冲刷作用,并有利于结晶器内自由液面过热度的提高。比较不同侧孔出流角度发现,利用普通径向四分水口在一定安装角度下的旋流效应不仅对于初生坯壳的均匀生长以及自由液面的冶金效果产生有利影响,还可能在不改变水口结构条件下获得类似结晶器电磁搅拌的旋流效应。     

A parametric study of the accelerated cooling of steel strip

To gain insight into the effects of various parameters controlling the thermal behaviour of a quenched steel strip during the process of accelerated cooling by an array of planar water jets, a parametric study has been performed using a previously developed and validated mathematical model. The behaviour of the strip was characterized by its coiling temperature, top and bottom surface temperature variations and heat extraction in the jet impingement region, top surface heat extraction in the film boiling region, and top and bottom surface thermal penetration depths. Parametric variations included cooling system design conditions, such as the top and bottom nozzle widths, and operating conditions such as the top nozzle discharge velocity, the cooling water temperature, and the ratio of volumetric water flow rates applied at the top and bottom surfaces. The effects of steel strip parameters such as strip thickness and strip velocity were also considered.     

On the development of a three-dimensional transient thermal model to predict ingot cooling behavior during the start-up phase of the direct chill-casting process for an AA5182 aluminum alloy ingot

The control of the heat transfer during the start-up phase of the direct-chill (DC) casting process for aluminum sheet ingots is critical from the standpoint of defect formation. Process control is difficult because of the various inter-related phenomena occurring during the cast start-up. First, the transport of heat to the mold is altered as the ingot base deforms and the sides are pulled inward during the start-up phase. Second, the range of temperatures and water flow conditions occurring on the ingot surface as it emerges from the mold results in the full range of boiling-water heat-transfer conditions—e.g., film boiling, transition boiling, nucleate boiling, and convection—making the rate of transport highly variable. For example, points on the ingot surface below the point of water impingement can experience film boiling, resulting in the water being ejected from the surface, causing a dramatic decrease in heat transfer below the point of ejection. Finally, the water flowing down the ingot sides may enter the gap formed between the ingot base and the bottom block due to butt curl. This process alters the heat transfer from the base of the ingot and, in turn, affects the surface temperature on the ingot faces, due to the transport of heat within the ingot in the vertical direction. A comprehensive mathematical model has been developed to describe heat transfer during the start-up phase of the DC casting process. The model, based on the commercial finite-element package ABAQUS, includes primary cooling via the mold, secondary cooling via the chill water, and ingot-base cooling. The algorithm used to account for secondary cooling to the water includes boiling curves that are a function of ingot-surface temperature, water flow rate, impingement-point temperature, and position relative to the point of water impingement. In addition, a secondary cooling algorithm accounts for water ejection, which can occur at low water flow rates (low heat-extraction rates). The algorithm used to describe ingot-base cooling includes both the drop in contact heat transfer due to gap formation between the ingot base and bottom block (arising from butt curl) as well as the increase in heat transfer due to water incursion within the gap. The model has been validated against temperature measurements obtained from two 711×1680 mm AA5182 ingots, cast under different start-up conditions (nontypical “cold” practice and nontypical “hot” practice). Temperature measurements were taken at various locations on the ingot rolling and narrow faces, ingot base, and top surface of the bottom block. Ingot-based deflection data were also obtained for the two test conditions. Comparison of the model predictions with the data collected from the cast/embedded thermocouples indicates that the model accounts for the processes of water ejection and water incursion and is capable of describing the flow of heat in the early stages of the casting process satisfactorily.