45 years of steel casting using slide gate systems in Russia

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Numerical Analysis of the Influence of the Modification of the Ladle Shroud on Fluid Flow Behavior in a One-strand Tundish during Continuous Steel Casting

A tundish is a device from which liquid steel is pour into a mold. Therefore tundish hydrodynamic conditions have a significant impact on solidification during continuous steel casting (CSC) process. Modification of ladle shroud workspace, allows for the modification of liquid steel movement in the tundish. In the following work, numerical simulations were performed which allowed the impact of the modification of the ladle shroud workspace on the liquid steel flow structure in a one-strand tundish to be determined. In order to assess the impact of the modification of the ladle shroud on the behavior of the liquid steel in the tundish, simulations were performed, on the basis of which the percentage share of stagnant, ideal mixing and plug flow zones were determined. In addition, the mixing parameters were determined, allowing the estimation of casting duration during sequential casting. The flow fields of liquid steel for each modification of the ladle shroud were performed. The average velocity of liquid steel flowing through the tundish, the Reynolds number and turbulent intensity were also described. The obtained results showed, among others, that the application of three cylinders with a diameter of 0.041 m into the ladle shroud with a diameter of 0.11 m increases the share of active flow in the tundish in relation to the tundish with Conventional Ladle Shroud. At the same time, applying a ladle shroud with a diameter of 0.11 m during casting is the most favorable in relation to the hydrodynamics of the tundish.

Mathematical statistics for measurement of steel temperature in steel-pouring ladle and tundish at steel continuous casting

The article considers the temperature distribution in steel during its continuous casting. Temperatures were measured sequentially in the steelpouring ladle (one measurement) and in the tundish (two measurements) using a platinum-platinum-rhodium thermocouple with an accuracy of ±4 °C. We have analyzed the results of 170 casts of two steel grades: 5SP and 35GS. The type of temperatures set distribution was verified on the basis of three goodness-of-fit criteria: Pearson’s χ-square criterion, λ Kolmogorov-Smirnov criterion and W Shapiro-Wilk criterion. The results obtained are consistent with the physical picture of steel casting. The metal in steel-pouring ladle is practically in a stable state and is subject only to natural cooling through the lining, top and ladle body. In the variant of analyzing a sample of temperature values in tundish at the first and second measurements, the hypothesis of normal distribution should be rejected. Here, the steel temperature depends on a number of parameters, including the feed rate and casting rate, feed time and composition of slag-forming and heat-insulating mixtures, etc. Attempts to establish the relationship between the steel temperatures of in steel-pouring ladle and tundish were unsuccessful. Considering the temperature measurement in tundish as two sequential data arrays, the first of which is an argument, and the second is a function, a linear relationship between these arrays was established. This relationship between the first and second temperature measurements in the tundish can be used to estimate the steel final temperature at thermocouple readout, including in the event of a failure. The results of the work can be used in development of a mathematical model of steel casting.

PROSPECTS OF APPLICATION OF LIQUID-MOVING SELF-CURING MIXTURES IN THE PRODUCTION OF THIN-WALLED STEEL CASTINGS

The method of manufacturing casting molds and cores for steel and iron casting from liquid self-hardening mixtures has been known since the 60s of the last century. The idea of the method is very simple - after preparation, the LSS is poured into the working cavity of the core box or onto the model installed in the flask, and then it is kept for some time until the foam falls, the core or shape hardens and the gas permeability is restored to operating values. Nevertheless, the method is not widely used in existing production due to a number of disadvantages. The aim of the work is to «revive» it, taking into account modern risks and challenges. Based on the results of the information and analytical review, a critical assessment was made. The directions of improvement and prospects of its use in innovative technology for the production of thin-walled steel casting for critical purposes are determined.

Health risk assessment of occupational exposure to heavy metals in a steel casting unit of a steelmaking plant using Monte–Carlo simulation technique

The present work aimed to evaluate the health risks of occupational exposure to heavy metals in a steel casting unit of a steel plant. To determine occupational exposure to heavy metals, personal air samples were taken from the workers’ breathing zones using the National Institute for Occupational Safety and Health method. Noncancer and cancer risks due to the measured metals were calculated according to the United States Environmental Protection Agency procedures. The results indicated that the noncancer risks owing to occupational exposure to lead (Pb) and manganese were higher than the recommended value in most of the workstations. The estimated cancer risk of Pb was also higher than the allowable value. Moreover, the results of sensitivity analysis indicated that the concentration, inhalation rate, and exposure duration were the most influencing variables contributing to the calculated risks. It was thus concluded that the present control measures were not adequate and further improvements were required for reducing the exposure levels.