钢?渣界面非金属夹杂物运动行为研究进展

钢中夹杂物的去除一直是洁净钢研究的热点,对于提高钢材质量、保障产品性能具有重要意义。钢液中夹杂物主要通过上浮至顶渣被吸收而去除,这个过程可细分为夹杂物在钢液中长大上浮、在钢?渣界面穿越分离、在熔渣中被吸附溶解3个步骤。钢?渣两相的物性差异及界面特性导致不符合条件的夹杂物无法穿过界面与钢液分离,这使得该步骤成为夹杂物去除的决定性环节,且由于钢?渣两相周围快速的物性过渡、并行的物理化学现象以及高温、不透明等特性影响,使该步骤研究难度增大。近年来,随着数值模拟技术和高温实验设备的进步,夹杂物穿越钢?渣界面行为的研究取得了一些进展。经典的受力分析模型能够对夹杂物界面行为进行半定量的预测,且对于渣系优化等具有一定的指导作用;计算流体动力学（CFD）模型在研究夹杂物界面现象方面具有优势,但研究尚处于初期,未来有望适用于更大的尺度范围、更多的行为场景和相态;水模型与数值模型相结合是一种有效的研究界面行为的方法,随着实验技术进步,可进一步对微观尺度的界面行为进行研究;高温共聚焦原位观察是研究界面行为最为直接的方法,对于探究夹杂物界面行为极有帮助,有望通过设备改进,更加完整、深入地揭示夹杂物去除的关键机理。      

六流T型中间包夹杂物去除行为的数值模拟

以41 t圆坯连铸中间包为研究对象,运用ANSYS软件,结合流动模型、拉格朗日离散相模型模拟钢液流动和夹杂物行为。通过用户自定义函数为中间包钢渣界面的边界条件设置了一种新的判定标准,即根据夹杂物的受力情况判定夹杂物上浮去除或进入钢液。通过数值模拟计算中间包出口处夹杂物数密度,并与工业试验结果对比,发现新的判定标准较传统的捕捉(trap)边界条件具有更高的计算精度。基于上述模型计算了稳态浇铸过程中间包内不同粒径氧化铝夹杂物的上浮时间、上浮位置及去除率。上述结果为更好地研究中间包内夹杂物行为提供了支撑。     

六流T型中间包夹杂物去除行为的数值模拟

以41 t圆坯连铸中间包为研究对象,运用ANSYS软件,结合流动模型、拉格朗日离散相模型模拟钢液流动和夹杂物行为。通过用户自定义函数为中间包钢渣界面的边界条件设置了一种新的判定标准,即根据夹杂物的受力情况判定夹杂物上浮去除或进入钢液。通过数值模拟计算中间包出口处夹杂物数密度,并与工业试验结果对比,发现新的判定标准较传统的捕捉(trap)边界条件具有更高的计算精度。基于上述模型计算了稳态浇铸过程中间包内不同粒径氧化铝夹杂物的上浮时间、上浮位置及去除率。上述结果为更好地研究中间包内夹杂物行为提供了支撑。     

Modelling Effect of Circulation Flow Rate on Inclusion Removal in RH Degasser

Based on the similarity principles,a 1∶ 7 scale physical model was established to study the behavior of molten steel flow and inclusion removal in a 145 t Rheinsahl-Heraeus( RH) degasser.On the basis of the quantitative measurements of the circulation flow rate and inclusion removal under various lifting gas flow rates,the effect of circulation flow rate on inclusion removal was investigated in the RH degasser.The inclusion removal rate shows the trend of first increase and then decrease twice with increasing the circulation flow rate when the circulation flow rates are smaller than 104.7 L/min.Whereas,the inclusion removal rate increases again with the further increase in circulation flow rate when the circulation flow rate is larger than 104.7 L/min.At lower circulation flow rates,inclusions are mainly removed by Stokes flotation to the slag/steel interface after inclusions are transferred near the slag/steel interface by the circulation flow.At higher circulation flow rates,the collision and aggregation of inclusions improves the inclusion removal efficiency.With the further increase in the circulation flow rate,inclusions are mainly removed by following the turbulent fluctuation( turbulent diffusion)to the slag/steel interface after inclusions are transferred near the slag/steel interface by the circulation flow.     

板坯凝固过程夹杂物运动行为

 本文使用离散相模型,利用数值模拟的方法对结晶器中的钢液流动、传热、凝固以及夹杂物的运动进行了耦合计算。通过追踪夹杂物的运动轨迹,并在钢渣界面处对夹杂物进行采样分析,最终计算出夹杂物在结晶器中的上浮率。研究表明,夹杂物在结晶器中的上浮率与其尺寸及拉速的大小均有关系,但受夹杂物密度的影响很小。夹杂物越大、拉速越小,越有利于夹杂物上浮至自由液面。小颗粒夹杂在结晶器中并不能被有效去除。对于粒径为50μm的夹杂物,当拉速为1m/min时其上浮率仅为46%,有37%的夹杂物被凝固坯壳捕捉,主要分布在铸坯表皮下10~25mm处。夹杂物被宽面坯壳捕捉的位置多集中在宽面靠近窄面处,在水口下方被捕捉的夹杂物较少。以往的研究认为只要夹杂物上浮至钢渣界面就能够被保护渣吸收,J.Strandh等的研究表明,夹杂物能否被吸收还取决于保护渣的粘度和润湿性等因素。因此,对于粒径较小的夹杂物,必须在精炼后的软吹氩过程中适当增大钢液的静置时间,尽量减少钢液中小颗粒夹杂的数量。另外,结晶器保护渣的选用对钢液中夹杂物的去除也很重要,不仅要满足其对钢液的保温润滑作用,还要考虑其对夹杂物吸附的影响。     

RH去除Al2O3夹杂物的数值模拟及工艺分析

 RH已经成为炉外精炼的重要组成部分,以180 t RH设备参数为基础建立三维模型,通过工艺试验和数值模拟的方法分析夹杂物分布及去除情况。试验结果表明,RH净循环时间为300 s夹杂物去除效率最高,但是夹杂物去除净循环时间不超过850 s。数值模拟比较夹杂物直径60、40、20 μm去除行为影响因素情况,通过数值模拟与金相试验的方法相比较,两者质量分数相差15.8%,因此说明数值模拟的方法可以应用到RH炉外精炼工艺过程中指导生产实践的预测。     

Numerical simulation of inclusion movement in electroslag remelting process

A comprehensive three- dimensional mathematical model, which adopted the Euler- Lagrange approach, was developed to study the motion of inclusions in electroslag remelting (ESR) process. The gravity, buoyancy, drag, added mass, lift and electromagnetic pressure forces were taken into account for the solution of inclusion trajectories. Due to the great difference between the conductivity of non- metallic inclusion and molten metal, the non- metallic inclusion would be drove to migrate to the mold wall by the electromagnetic pressure force. The movement behavior and removal rate of inclusions with different diameters were investigated in detail while the current ranged from 1200A to 1800A. The results show that more than 90% inclusions are captured by the top surface of the slag pool and the slag/mold wall. Only a small part of the inclusions are still suspended in the slag, and less than 4% inclusions would pass through slag/metal interface and enter into the metal pool. The removal rate of inclusions with larger diameter is higher than that of smaller diameter in the remelting process. With the increase of the current intensity, the removal rates of the inclusions with all diameters increase.     

基于微细异相钢液洁净化技术研究进展

高纯净度钢的生产是钢铁企业面临的重大课题,在钢液中获得尺寸可控、弥散分布的气泡是去除细小夹杂物、生产高品质钢的重要手段。微细异相净化钢液技术是一种基于碳酸盐分解反应生产微小气泡与渣滴去除细小夹杂物的技术,近年来该技术的研发越来越受到冶金工作者的重视,部分新技术已被开发并趋于成熟。本文从微细异相净化钢水技术原理出发,详细介绍了微细异相净化钢水技术研究的最新进展,归纳总结了微细异相去除细小夹杂物、脱硫、脱磷、渣料迁移、RH快速脱碳及中间包长水口喷粉工艺特点及作用机理,并对其在工程领域应用亟待解决的问题及未来发展方向进行了展望。      

Numerical Simulations of Inclusion Behavior in Gas-Stirred Ladles

A computation fluid dynamics–population balance model (CFD–PBM) coupled model has been proposed to investigate the bubbly plume flow and inclusion behavior including growth, size distribution, and removal in gas-stirred ladles, and some new and important phenomena and mechanisms were presented. For the bubbly plume flow, a modified k-ε model with extra source terms to account for the bubble-induced turbulence was adopted to model the turbulence, and the bubble turbulent dispersion force was taken into account to predict gas volume fraction distribution in the turbulent gas-stirred system. For inclusion behavior, the phenomena of inclusions turbulent random motion, bubbles wake, and slag eye forming on the molten steel surface were considered. In addition, the multiple mechanisms both that promote inclusion growth due to inclusion–inclusion collision caused by turbulent random motion, shear rate in turbulent eddy, and difference inclusion Stokes velocities, and the mechanisms that promote inclusion removal due to bubble-inclusion turbulence random collision, bubble-inclusion turbulent shear collision, bubble-inclusion buoyancy collision, inclusion own floatation near slag–metal interface, bubble wake capture, and wall adhesion were investigated. The importance of different mechanisms and total inclusion removal ratio under different conditions, and the distribution of inclusion number densities in ladle, were discussed and clarified. The results show that at a low gas flow rate, the inclusion growth is mainly attributed to both turbulent shear collision and Stokes collision, which is notably affected by the Stokes collision efficiency, and the inclusion removal is mainly attributed to the bubble-inclusion buoyancy collision and inclusion own floatation near slag–metal interface. At a higher gas flow rate, the inclusions appear as turbulence random motion in bubbly plume zone, and both the inclusion–inclusion and inclusion-bubble turbulent random collisions become important for inclusion growth and removal. With the increase of the gas flow rate, the total removal ratio increases, but when the gas flow rate exceeds 200 NL/min in 150-ton ladle, the total removal ration almost does not change. For the larger size inclusions, the number density in bubbly plume zone is less than that in the sidewall recirculation zones, but for the small size inclusions, the distribution of number density shows the opposite trend.     

钢包底吹去除夹杂物的水力学模型

采用水力学模型方法对40t钢包单底吹去除钢水中夹杂物的行为进行了研究,分析了元件类型、渣层厚度、位置和流量等对夹杂物去除的影响规律。结果表明:在钢包底吹过程中钢水内夹杂物的去除率方面,弥散式透气砖均优于狭缝式底吹元件;底吹位置越靠近钢包中心时,去除夹杂物的效果越佳;在实验条件下渣层越厚,夹杂物去除率越高;底吹氩去除夹杂物存在一个最佳流量值。     

钢铁冶金过程中的界面现象

从界面润湿性的角度,对一些冶炼过程中的常见界面现象进行了详细分析.对于渣的泡沫化过程,主要分析了润湿性对渣的泡沫化指数的影响;对于铁水和钢液脱硫过程,主要分析了对脱硫速率和脱硫剂的利用率以及穿透钢液速率的影响;对于钢液与熔渣对耐火材料的侵蚀过程,主要分析了对耐火材料在熔渣中的饱和溶解度、熔渣在耐火材料中的侵蚀深度以及耐火材料的侵蚀速率的影响;对于钢中夹杂物的运动过程,主要分析了对钢中夹杂物的形核、聚集、去除、空间分布等影响.同时,本文总结得出了对于这些实际冶炼过程有利的界面润湿性.      

Investigation of inclusion re-entrainment from the steel-slag interface

The mechanism of inclusion elimination from continuous steel casting is investigated at the steelslag interface. Inclusion impact at the interface is considered under the concept of energy balance, with buoyancy forces, fluid dynamic forces, interfacial adhesion, and rebound forces determining whether the particle will pass through the interface or be retained by it. The effects of the inclusion, slag, and steel properties, as well as the effect of inclusion impact velocity, are considered at the interface. The interfacial tension between the slag and the inclusion should be smaller than that between the steel and the inclusion (negative wettability), so that the inclusions can pass into the slag layer and avoid re-entrainment. The inclusion particles that reach an equilibrium state at the steel-slag interface are subject to re-entrainment back into the steel, due to lift forces applied to them by the turbulent boundary layer at the interface. A removal criterion dependent upon the shear stress is introduced, and then the removal rates are calculated from the turbulent burst theory. It is found that the smaller diameter inclusions are trapped at the interface. Of the particles that remain at the interface, it is the larger ones that are more easily removed by the lift forces due to the turbulent shear stress. High slag viscosity is desirable, since it makes inclusion re-entrainment into the casting product more difficult.     

导电结晶器电渣重熔中非金属夹杂物的去除

导电结晶器电渣重熔渣池局部发热密度最高值在电极角部和结晶器壁附近,电极端部下方仍存在"高温区",对非金属夹杂物去除提供热力学与动力学条件。电渣重熔过程中非金属夹杂物的去除主要发生在自耗电极端头熔滴形成阶段以及熔滴穿过熔渣层阶段。综合自耗电极端部熔化至熔滴形成过程阶段、熔滴滴落并穿过渣池至金属熔池阶段和金属熔池至铸锭凝固非金属夹杂物的上浮阶段的去除率,导电结晶器电渣重熔去除非金属夹杂物的能力不低于传统电渣重熔。     

Effect of initial large-sized inclusion content on inclusion removal during electroslag remelting of H13 die steel

The current paper focuses on the influence of initial large-sized inclusion content in the consumable electrode on inclusion removal during electroslag remelting (ESR) of H13 die steel. Considering the relationship between the inclusion size and the interfacial energy change of the slag/inclusion/steel system during the inclusion transfer across the steel/slag interface, the thermodynamic conditions for inclusion removal from steel to the slag were put forward. The results showed that the content of large-sized inclusions in final ESR ingot was decreased by approximately 13.66% with the increase in large-sized inclusion content in the consumable electrode from 11.36?mg/10?kg to 16.50?mg/10?kg. The interfacial energy change of the slag/inclusion/steel system decreases with the increase in inclusion radius during the absorption process of inclusions by slag, which is beneficial for inclusion removal.     

30Cr1Mo1V汽轮机转子钢的精炼渣优化

摘要：为有效控制30Cr1Mo1V汽轮机转子钢中非金属夹杂物和有害杂质元素含量,利用热力学软件FactSage 8.1,计算了1873K下CaO-SiO2-Al2O3-5%MgO系精炼渣与30Cr1Mo1V钢液平衡时的等［O］线、等［S］线,以获得最优精炼渣成分范围。研究了不同精炼渣对钢中氧、硫含量,夹杂物特性的影响,继而揭示了钢中典型MgO·Al2O3夹杂物的热力学形成机制以及夹杂物与精炼渣之间的成分关系,并构建了“钢 渣”界面MgO·Al2O3夹杂物运动模型。实验和模型结果表明,优化渣系50.4%CaO-40-3%Al2O3-4.3%SiO2-5%MgO对钢液脱氧、脱硫和非金属夹杂物控制的效果明显,模型预测结果与夹杂物去除率对应关系良好。     

GCrl5轴承钢精炼渣对夹杂物祛除行为的研究

通过建立的夹杂物穿越钢渣界面运动模型,研究了精炼渣对夹杂物的吸附现象。结果表明,夹杂物 粒径、表面张力和熔渣粘度是影响夹杂物冲破钢渣界面的重要参数,大型夹杂物中粒径和熔渣粘度起决定作用,而 ≤ 20㎛ 级别的小型夹杂物中仅表面张力起决定作用;大型夹杂物冲破钢渣界面的能力远大于小型夹杂物。针对 小型夹杂物难以吸附的问题,运用了夹杂物运动模型和熔渣、钢液表面张力模型,研究了表面张力对吸附过程的影 响。结果表明,直径≤ 122.9 ㎛尺寸的夹杂物均无法穿越钢渣界面,回弹至钢液一侧,由此得出：无法通过调整精 炼渣用以吸附≤ 122.9 ㎛夹杂物以达到进一步降低钢中氧含量的目的。     

Upward Molten Flow for Optimization of Fluid Flow in Continuous Casting Tundish

Fluid flow pattern and buoyancy force support the motion of nonmetallic inclusions toward the tundish slag. Upward molten flow was investigated. To understand the fundamentals of the process, physical modelling was carried out with the utilization of a 1∶4 scale model. Numerical modelling was carried out in line with the physical modelling to examine details of the flow pattern and rotational effect caused by the upward flow with the commercial CFD (Computational Fluid Dynamics) package environment, FLUENT. The two-equation k-ε model was used to simulate the turbulence. Multiphase fluid flow was numerically simulated by using the Volume of Fluid (VoF) method. The simulation can predict free surface waves and other phenomena, which can be used to optimize these important metallurgical operations.     

Application of a Model for Liquid Inclusion Separation at a Steel‐Slag Interface for Laboratory and Industrial Situations

A mathematical model based on the equations of particle motion was used to predict inclusion behavior observed at steel‐slag interface in an in‐situ Confocal Scanning Laser Microscope. The results show that the model can be used to explain some phenomena observed in the experiments. In addition, a parameter study was done in order to illustrate how the model can be used to study the effect of physical properties on the inclusion behavior at the slag‐steel interface for some typical industrial ladle metallurgy conditions. Furthermore, to study the effect of steel temperature, sulfur and oxygen content in the steel, slag and inclusion density as well as initial inclusion velocity on the inclusions behavior at the slag‐steel interface. The results show that the temperature and initial velocity was of less importance and that the oxygen content in the steel had a larger influence on the inclusion behavior than the sulfur content in the steel.     

转炉出钢过程中涡流卷渣的数值模拟研究

为了提高转炉出钢挡渣效率,改善钢水质量,需要研发出更高效低耗的新型挡渣方法。利用CFD流体模拟软件Fluent6.3,通过基于压力的分离隐式求解器,采用k-ε双方程模拟出炉内钢液不同初始液位下静态出钢过程。通过对出钢过程的流场分析,从数学模拟的角度阐述了初始液位不同高度下的漩涡形成时间、漩涡的运动轨迹、出钢过程转炉内钢液的运动特征,针对涡流引起卷渣现象的研究,为今后研制新型挡渣方法提供了理论指导。     

钢中液态夹杂物聚并行为的数学物理模拟

基于相似原理,采用水模拟钢液,用有机试剂模拟钢液中液态非金属夹杂物,同时采用数值仿真方法共同研究了夹杂物种类、两相间界面张力及黏度对于液滴聚并过程的影响规律.结果表明,夹杂物液滴间的聚合趋势与其自身的物理性质有紧密联系,其中液滴相与连续相之间的界面张力会促进其相互聚并,而液滴相的黏度则正相反,在液滴聚并过程中起抑制作用.因此,通过改变液态夹杂物与高温钢液之间的界面参数以及黏度参数,有望达到聚合或分散的控制目标,进而实现夹杂物尺寸的灵活控制.