scholarly journals Mathematical Modelling and Simulation of liquid steel flow phenomena and temperature distribution in an optimized tundish design of a continuous caster

2021 ◽  
Vol 309 ◽  
pp. 01079
Author(s):  
Ankit Bhardwaj
Keyword(s):  
Fluid Flow ◽  
Liquid Steel ◽  
Flow Behavior ◽  
Continuous Caster ◽  
Flow Analysis ◽  
Metal Loss ◽  
Homogeneous Fluid ◽  
Ansys Fluent ◽  
Particle Tracking Method ◽  
Steel Flow

The objective of this study was to analyze the fluid flow of molten steel in a continuous casting tundish using numerical simulations for better inclusion floatation and its separation. The tundish geometry was designed using Autodesk FUSION 360 and the analysis were performed on ANSYS FLUENT. The investigations were done on steady-state as well as transient conditions. To scale back vortexing and turbulence within the tundish, turbo stoppers and flow modulators, e.g. dam and weirs were placed for an optimized and efficient flow inside the tundish and its behavior on the spacious flow structure was explored. The strategic placements of the flow modifiers produced higher turbulence in the recess region of the tundish resulting in better turbulent flow withinside the inlet region of the tundish. Thereby a more homogeneous fluid flow is formed with better conditions for particle separation. Analysing the flow behavior we have determined the inclusion floatation using particle tracking method form dense discrete phase modelling along with multiphase eulerian-lagragian model. Reduction in dead volumes was achieved in the spatial flow due to better intermixing which further reduced the metal loss and increased the yield of the tundish using the fluid flow analysis. Analyzing eddy formations in the spatial geometry of the tundish structure made it easy to evenly distributes the flow-induced shear. This determined the lesser turbulence on the free surface of the steel flow resulting in less reduction of the liquid steel surface.

Mathematical Modeling and Industrial Experiment of Liquid Steel Flow in the Three Outlets Continuous Casting Bloom Tundish

2013 ◽  
Vol 58 (4) ◽  
pp. 1077-1083 ◽  
Author(s):  
A. Cwudzinśki
Keyword(s):  
Liquid Steel ◽  
Mass Scale ◽  
Correct Process ◽  
Ansys Fluent ◽  
Industrial Experiment ◽  
Flow Control Devices ◽  
Working Volume ◽  
The Subject ◽  
Control Devices ◽  
Steel Flow

Abstract The dynamic development of the continuous steel casting (CSC) process has resulted in the application of this technology to the casting of steel semi-finished products on a mass scale. In the CSC process, before the cooling and solidification of liquid steel commences, the liquid metal dynamically flows through the steelmaking ladle, the tundish and the mould. Therefore, the control of steel flow is the key to the correct process. One of the metallurgical device in which the control of steel flow hydrodynamics is of crucial importance is the tundish. The subject of investigation within the present study was a three-nozzle tundish designed for casting of blooms. The software program Ansys-Fluent R was employed for the analysis of tundish operation. For the verification of the correctness of obtained results, an industrial experiment was carried out. For modification of the hydrodynamic conditions within the working volume of the tundish, two flow control devices were proposed, namely: a dam and a dam with an overflow window. The outcome of performed computer simulations were liquid steel flow fields and residence time distribution curves.

CFD Analyses of Flow in a Gas Turbine Combustor Swirl Cup

2017 ◽  
Author(s):  
Srinivasan Karuppannan ◽  
Bhirud Mehul ◽  
Gullapalli Sivaramakrishna ◽  
Raju D. Navindgi ◽  
N. Muthuveerappan
Keyword(s):  
Gas Turbine ◽  
Mass Flow ◽  
Flow Behavior ◽  
Flow Analysis ◽  
Operating Regime ◽  
Gas Turbine Combustor ◽  
Ansys Fluent ◽  
Turbine Engine ◽  
Downstream Flow ◽  
Cfd Analyses

Swirl cups (hybrid atomizers) are being widely employed in aero gas turbine engine combustors for their established merits in terms of achieving satisfactory atomization over the entire combustor operating regime. Even though several investigators have worked on development of these swirl cups, there is a scanty data reported in literature relevant to their design. In the present study, flow behavior in a swirl cup assembled in a confined chamber similar to a gas turbine combustor has been analyzed. Flow analysis has been carried out using ANSYS Fluent and turbulence has been modeled using Realizable k-ϵ model. Six swirl cup configurations have been analyzed; mass flow ratio between primary and secondary swirler and venturi converging area ratio have been varied. The effect of these parameters on downstream flow field has been studied by analyzing the profiles of axial, tangential and radial velocities downstream of swirl cup. The size and shape of the recirculation zone has been analyzed and reported for all configurations. Also, the mass flow recirculated by swirl cup has been estimated and compared amongst the configurations analyzed. Data thus generated is very useful in designing such swirl cups of gas turbine combustors.

scholarly journals Piv Method and Numerical Computation for Prediction of Liquid Steel Flow Structure in Tundish

2015 ◽  
Vol 60 (1) ◽  
pp. 11-17 ◽  
Author(s):  
A. Cwudziński
Keyword(s):  
Computer Simulations ◽  
Liquid Steel ◽  
Laboratory Experiments ◽  
Field Analysis ◽  
Ansys Fluent ◽  
Measuring Systems ◽  
Piv Method ◽  
Commercial Program ◽  
Flow Field Analysis ◽  
Steel Flow

AbstractThis paper presents the results of computer simulations and laboratory experiments carried out to describe the motion of steel flow in the tundish. The facility under investigation is a single-nozzle tundish designed for casting concast slabs. For the validation of the numerical model and verification of the hydrodynamic conditions occurring in the examined tundish furniture variants, obtained from the computer simulations, a physical model of the tundish was employed. State-of-the-art vector flow field analysis measuring systems developed by Lavision were used in the laboratory tests. Computer simulations of liquid steel flow were performed using the commercial program Ansys-Fluent¯. In order to obtain a complete hydrodynamic picture in the tundish furniture variants tested, the computer simulations were performed for both isothermal and non-isothermal conditions.

Optimization of Pulse-Step Method for Liquid Steel Alloying in One Strand Slab Tundish

2018 ◽  
Vol 941 ◽  
pp. 58-63 ◽  
Author(s):  
Adam Cwudziński
Keyword(s):  
Liquid Steel ◽  
Continuous Casting Machine ◽  
Casting Machine ◽  
Computational Grids ◽  
Time Interval ◽  
Step Method ◽  
Ansys Fluent ◽  
Pulse Charge ◽  
Steel Alloying ◽  
Steel Flow

Introduction to the Fe-C-X system: Si, Mn, Al and Nb, Ti, V, B allow the ultimate tensile strength and ductility of steel to be increased at the same time. Therefore, multiphase steels of the TRIP, DP, MART and CP are the steels of the future. The scientific aim of the researches were to obtain new basic information on alloying process of liquid steel in a tundish with the use of the pulse–step method. The facility under investigation was a single outlet tundish being a component of a slab continuous casting machine. Computer simulations of the liquid steel flow and alloy behaviour in turbulent motion conditions were done using the Ansys-Fluent computer program. For generating the computational grids, Gambit program was used. For pulse–step method optimisation two aspects were considered. At first numerical simulations were performed for the selection of the time interval between the pulse feed of the first alloy batch and the continuous feed of subsequent alloy batches in order to maintain the required homogenisation level. Next simulations were done for determination of the mass of the pulse charge that ensures not only the attainment of the 95% homogenisation level, but also the limitation of alloy concentration peaks occurring in the liquid steel and going beyond the 95% homogenisation zone. On the basis of numerical investigations the mixing curves and time mixing for different variants of pulse-step method optimization were obtained.

scholarly journals Investigations of Liquid Steel Viscosity and Its Impact as the Initial Parameter on Modeling of the Steel Flow through the Tundish

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5025
Author(s):  
Marta Ślęzak ◽  
Marek Warzecha
Keyword(s):  
Numerical Simulations ◽  
Liquid Steel ◽  
Dynamic Viscosity ◽  
Viscosity Coefficient ◽  
Ansys Fluent ◽  
Average Value ◽  
Wide Range ◽  
Profile Distribution ◽  
Predicted Values ◽  
Steel Flow

The paper presents research carried out to experimentally determine the dynamic viscosity of selected iron solutions. A high temperature rheometer with an air bearing was used for the tests, and ANSYS Fluent commercial software was used for numerical simulations. The experimental results obtained are, on average, lower by half than the values of the dynamic viscosity coefficient of liquid steel adopted during fluid flow modeling. Numerical simulations were carried out, taking into account the viscosity standard adopted for most numerical calculations and the average value of the obtained experimental dynamic viscosity of the analyzed iron solutions. Both qualitative and quantitative analysis showed differences in the flow structure of liquid steel in the tundish, in particular in the predicted values and the velocity profile distribution. However, these differences are not significant. In addition, the work analyzed two different rheological models—including one of our own—to describe the dynamic viscosity of liquid steel, so that in the future, the experimental stage could be replaced by calculating the value of the dynamic viscosity coefficient of liquid steel using one equation. The results obtained support the use of the author’s rheological model for the above; however, this model still needs to be refined and extended to a wide range of alloying elements, mainly the extension of the carbon range.

scholarly journals Intensification of liquid steel active flow volume in one-strand tundish using a modified ladle shroud

10.30544/458 ◽  
2020 ◽  
Vol 26 (1) ◽  
pp. 1-14
Author(s):  
Michał Bartosiewicz ◽  
Adam Cwudziński
Keyword(s):  
Numerical Simulations ◽  
Liquid Steel ◽  
Physical Simulation ◽  
Turbulence Models ◽  
Immersion Depth ◽  
Flow Volume ◽  
Ansys Fluent ◽  
The One ◽  
Steel Flow ◽  
Active Flow

This work presents the numerical and physical simulation results of the liquid steel flow in the one-strand tundish. The results obtained during the numerical simulations and the water modeling results were compared to each other. Six types of turbulence models were tested. Among tested turbulence models the BSL k-ω was turned out the best correlating with the results from the laboratory experiments. Besides, the ladle shroud modification was proposed by the authors and the influence of the modified ladle shroud immersion depth in the liquid steel on the hydrodynamic structure in the tundish was checked. The ladle shroud modification depended on the expansion, narrowing, and re-expansion of the liquid steel feed stream. The four tundish variants with the four different ladle shroud immersion depths (at 0.1, 0.2, 0.3 and 0.4 m) in the liquid steel were tested. The liquid steel flow volumes were calculated and according to the generated active flow volume, the most beneficial research case was indicated. The tundish variant with the ladle shroud immersion depth of 0.3 m in the liquid steel was characterized by the lowest stagnant flow volume. The numerical simulations were performed by using the Ansys-Fluent computer program.

scholarly journals Chemical Homogenization Of Liquid Steel Flowed Through Continuous Casting Slab Tundish During Alloying Process

2015 ◽  
Vol 60 (2) ◽  
pp. 561-565
Author(s):  
A. Cwudziński
Keyword(s):  
Liquid Steel ◽  
Mixing Time ◽  
Virtual Model ◽  
Ansys Fluent ◽  
Working Space ◽  
Continuous Casting Slab ◽  
Alloy Addition ◽  
Steel Flow ◽  
Mixing Curves ◽  
Metallurgical Processes

AbstractThis paper presents the results of research on the behaviour of an alloy addition in steel flowing through the tundish used for casting slabs. The device under examination is a wedge-shaped single-nozzle tundish of a capacity of 30 Mg. Due to the complexity of alloy addition dissolution and dispersion in metallurgical processes, a decision was made to use the Species Model available within the Ansys-Fluent®program. For describing the turbulence, the Realizable k-ɛmodel was chosen. By defining the heat losses on respective planes making up the virtual model, the non-isothermal conditions existing during the flow of liquid steel through the tundish were considered. From the performed numerical simulations, the fields of steel flow and steel temperature and alloy addition concentration in the tundish working space were obtained. In order to accurately illustrate the process of chemical homogenization in the tundish working space, mixing curves were recorded. Based on the obtained results (mixing curves), the mixing time needed for achieving the 95% level of chemical homogenization was calculated.

scholarly journals Interaction of Liquid Steel with Mould Flux in Continuous Casting Bloom Mould - Numerical Simulations and Industrial Experiences

2016 ◽  
Vol 61 (4) ◽  
pp. 2013-2020 ◽  
Author(s):  
A. Cwudziński ◽  
J. Jowsa ◽  
P. Przegrałek
Keyword(s):  
Numerical Simulation ◽  
Computer Simulation ◽  
Continuous Casting ◽  
Cross Section ◽  
Liquid Steel ◽  
Virtual Model ◽  
Ansys Fluent ◽  
Vof Model ◽  
Mould Flux ◽  
Steel Flow

Abstract The device under examination is a mould of a capacity of 0.5 Mg and with inner cross-section of 280×400 mm. The virtual model of the facility under investigation was made using Gambit, DesignModeler and Meshing programs. Computer simulation of the liquid steel flow and mould flux behaviour in turbulent motion conditions was done using the Ansys-Fluent® computer program. On the basis of earlier researches the volume of fluid (VOF) model was applied. Based on computer simulations carried out, steel flow and flux behaviour fields and curves of flux mould entrainment concentration were obtained. The results obtained from numerical simulation were compared with the data obtained during bloom casting under industrial conditions. Based on the obtained information on the interaction of steel with mould flux, the region was determined, in which conditions likely to favour the entrainment of slag portions into the forming bloom exist.

scholarly journals Influence of Hydrodynamic Structure on Mixing Time of Alloy Additions with Liquid Steel in One Strand Tundish

2016 ◽  
Vol 61 (1) ◽  
pp. 295-300 ◽  
Author(s):  
A. Cwudziński
Keyword(s):  
Liquid Steel ◽  
Mixing Time ◽  
Hydrodynamic Conditions ◽  
Step Method ◽  
Ansys Fluent ◽  
Working Space ◽  
Alloy Addition ◽  
Steel Flow ◽  
Mixing Curves ◽  
Active Flow

The knowledge of the hydrodynamic pattern aids in designing new and modernizing existing tundishes. The device under examination is an one-strand tundish of a capacity of 30 Mg. Computer simulation of the liquid steel flow, tracer and alloy addition behaviour in turbulent motion conditions was done using the Ansys-Fluent®computer program. The hydrodynamic conditions of steel flow were determined based on the distribution of the characteristics of tundish liquid steel residence time distribution (RTD). The alloy addition was introduced to the liquid steel by the pulse-step method. Based on computer simulations carried out, steel flow fields and RTD and mixing curves were obtained, and the shares of stagnant volume flow and active flow and the mixing time were computed. Dispersion of the alloy addition in liquid steel during its flow through the tundish is a dynamic process which is determined by the hydrodynamic conditions occurring in the tundish working space.

scholarly journals Numerical Prediction of Hydrodynamic Conditions in one Strand Tundish. Influence of Thermal Conditions and Casting Speed/ Numeryczna Prognoza Warunków Hydrodynamicznych W Jednozyłowej Kadzi Posredniej. Wpływ Warunków Cieplnych I Predkosci Odlewania

2014 ◽  
Vol 59 (4) ◽  
pp. 1249-1256
Author(s):  
A. Cwudzinski
Keyword(s):  
Computer Simulations ◽  
Casting Speed ◽  
Liquid Steel ◽  
Thermal Conditions ◽  
Hydrodynamic Conditions ◽  
Ansys Fluent ◽  
Working Space ◽  
Flow Control Devices ◽  
Pattern Forming ◽  
Steel Flow

Abstract This paper reports the results of computer simulations of the flow of liquid steel in a single-nozzle tundish, which describe the flow hydrodynamics, depending on the thermal conditions and casting speed. In this paper, five casting speeds, namely 0.3, 0.6, 0.9, 1.2 and 1.5 m/min., have been examined. In view of the fact that tundishes are being equipped with various flow control devices and the process of creating specific hydrodynamic conditions is influenced also by the temperature gradient, computer simulations of liquid steel flow under isothermal and non-isothermal conditions were performed. Computer simulations of liquid steel flow were performed using the commercial program Ansys-Fluent ®. In order to explain the phenomena occurring in the tundish working space, the buoyancy number (Bu) has been calculated. The next research step in the analysis of the flow pattern forming in different casting conditions was to record the E and F-type RTD characteristics and to describe the pattern of flow.

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