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.

Modeling study on fluid flow and inclusion motion in 6-strand bloom caster tundishes

The behavior of fluid flow and particle motion in a 6-strand bloom castertundish was investigated by a water model and numerical simulation. Compared with a device withoutflow control, the tundish with flow control has an important effect on the fluid flow pattern andinclusion removal. It is revealed that by non-isothermal process, which is real productioncondition, the fluid flow in tundish shows a strong buoyancy pattern, which drives particles to moveupwards. The particle removal was quantitatively studied by mathematical and physical simulations.

Flow Characteristics and Inclusion Removal in a Ten-strand Continuous Casting Tundish:Physical Modelling and Industrial Trials

The flow characteristics and inclusion removal in a ten-strand continuous casting tundish were investigated with physical modelling and industrial trials. The results show that, among the strands, the strand with the mini mum dimensionless time of the first appearance of tracer at the tundish exit appears to be the worst one for inclusion removal, while the strand with the maximum dimensionless mean residence time shows the best inclusion removal efficiency. The inclusion number decreases with increasing inclusion size for all strands. The inclusion number distri bution among strands is the same for all inclusion sizes and the descending order of inclusion number is basically con sistent with the ascending order of dimensionless mean residence time among individual strands. However, when the strand with the minimum dimensionless time of the first appearance of tracer at the tundish exit is not the same one with the minimum dimensionless mean residence time, the former seems to be inferior to the latter for inclusion re moval.

Non-metallic inclusions in electroslag remelting:a review

Non-metallic inclusion in electroslag remelting is a constant topic that has been studied for decades.Different results and conclusions are obtained on some of the subjects from these previous investigations.These differences originate in part from different experimental conditions,including original inclusion chemistries in consumable electrode,slag composition,oxygen level,liquid metal compositions,deoxidation schemes,and melting rates of electroslag remelting.The advances in the operating practices of inclusion control in electroslag remelting production are reviewed.Inclusion evolution during the electroslag remelting and related processing parameters are also reviewed and assessed.The role of the reoxidation of liquid steel during electroslag remelting on oxide inclusion composition is discussed.The generation of inclusions in remelted ingot is critically assessed.Perspective and remaining issues are noted.

Numerical model of inclusion separation from liquid metal with consideration of dissolution in slag

The transport of inclusion particles through the liquid metal/molten slag interface and their dissolution in the slag are two key processes of inclusion removal.Based on the latest version of inclusion transport model that takes into account full Reynolds number range and a dissolution kinetics model,a coupled model was developed to simulate the whole process of inclusion removal,from floating in the liquid steel to crossing the interface and further to entering and dissolving in the molten slag.The interaction between the inclusion motion and dissolution was discussed.Even though the inclusion velocity is a key parameter for dissolution,the simulation results show no obvious dissolution during moving state because the process is too short and most of the inclusions dissolve during its static stay in the slag side above the interface.The rate-controlling step of inclusion removal is the transport through the steel-slag interface for the small-size inclusion and static dissolution above the interface for the large-size inclusion,respectively.

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 circu- lation 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.

Motion and removal behavior of inclusions in electrode tip during magnetically controlled electroslag remelting:X-ray microtomography characterization and modeling verification

Detailed three-dimensional(3 D)microtomography characterizations of inclusions in electrode matrix,mushy zone(MZ)and liquid melt film(LMF)were performed to elucidate the motion and removal behavior of inclusions in electrode tip during magnetically controlled electroslag remelting(MC-ESR)process.A transient 2 D numerical model was also built to verify the experimental results and proposed mechanisms.The number and size of inclusions exhibited an obvious increasing trend from edge to mid region in LMF,while remained almost the same in electrode matrix and MZ.The inclusions in LMF migrated from edge to mid region of LMF,accompanied with removal process.In addition,the kinetic conditions for inclusion migrating to LMF/slag interface(LSI)were enhanced during MC-ESR process,thereby improving the inclusion removal efficiency in LMF.This work highlights the 3 D characterization and motion/removal mechanisms of inclusions in electrode tip,as well as sheds new light on preparing high purity materials.

Variation of Non-Metallic Inclusions Composition in X80 Pipeline Steel Refined by High Basicity Slag

The transformation of inclusions was studied when control technology of refining top slag in ladle furnace was used in X80 pipeline steelmaking.Sufficient amount of aluminum was added to experimental heats for final deoxidation during BOF tapping,and then the refining top slag with high basicity and strong reducibility was adopted to transform Al 2 O 3 to inclusions with low melting point.The results show that the composition of inclusions changes in order of "Al 2 O 3 → MgO-Al 2 O 3 system→ CaO-MgO-Al 2 O 3 system→ CaO-Al 2 O 3 system".And the inclusions after LF refining are liquid or semi-liquid state at the temperature of steelmaking,which are easily removable to obtain high cleanliness steel by collision,agglomeration and flotation.

Formation mechanism of interface reaction layer between microporous magnesia refractories and molten steel and its effect on steel cleanliness

The ceramic filter in continuous casting tundish can effectively improve the cleanliness of high-performance steel by regulating tundish flow field to promote the removal of inclusions and adsorbing or blocking fine inclusions in the molten steel into the mold.The interaction between microporous magnesia refractories used as tundish filter and molten interstitial-free(IF)steel at 1873 K was investigated to reveal the formation mechanism of their interface layer and its effect on steel cleanliness by laboratory research and thermodynamic calculations.The results show that the magnesium–aluminum spinel layer at the interface between the molten IF steel and the microporous magnesia refractories is formed mainly by the reaction of MgO in the refractory with the[Al]and[O]in the molten steel,significantly reducing the total O content,the size and amount of inclusions of the molten steel.In addition,the interparticle phases of microporous magnesia refractories at high temperature can adsorb Al_(2)O_(3) and TiO_(2) inclusions in the molten steel into interparticle channels of the refractories to form high melting point spinel,impeding the further penetration of the molten steel.As a result,the consecutive interface layer of high melting point spinel between microporous magnesia refractories and molten steel can improve the cleanliness of the molten steel by adsorbing inclusions in the molten steel and avoid the direct dissolution of refractories of the tundish ceramic filter immersed in the molten steel,increasing their service life.

Water Modeling of Swirling Flow Tundish for Steel Continuous Casting

A conventional turbulence inhibitor is compared with a swirling chamber from the points of view of fluid flow and removal rate of inclusion in the tundish. Comparing the RTD curves, inclusion removals, and the streamlines in water model experiments, it can be found that the tundish equipped with a swirling chamber has a great effect on improving the flow field, and the floatation rate of inclusion is higher than the tundish with a turbulence inhibitor. Because of the introduction of the swirling chamber, the flow field and inclusion removal in a two-strand swirling flow tundish are asymmetrical. Rotating the inlet direction of swirling chamber 60 degree is a good strategy to improve the asymmetrical flow field.

Novel Concept of Cleansing the Liquid Steel by the Fine In-Situ Phase Due to the Composite Ball Explosion Reaction in RH Ladle

The production of high purity steel is a major task for the iron and steel enterprises in the 21st century. To improve the quality of steel products and produce the cleanness steel, the key technique is to control inclusions in the molten steel. In the present investigation, a novel fine inclusion removal technology due to the dispersed in-situ phase induced by the composite ball explosion reaction was put forward. A composite ball with this function has been designed and the industrial experimental investigation was also carried out. The results indicate that feeding composite ball in RH ladle is a novel technology and the inclusion in the molten steel can be removed effectively. Compared with conventional inclusion removal technology, the number of the oxide inclusion can be decreased to a lower level and the inclusion size becomes much finer. Using this novel technology, the total oxygen in the as-cast slab can approach to 6ppm and the steel production cost for per ton can be reduced by 5 -12 RMB. This novel technology can be achieved without special facility and be realized in most steelmaking plant.

Effect of axial static magnetic field on cleanliness and microstructure in magnetically controlled electroslag remelted bearing steel

The effect of the axial static magnetic field(ASMF)on cleanliness and microstructure in magnetically controlled electroslag remelted GCr15 bearing steel ingots was investigated experimentally.The results show that a magnetically controlled spin-vibration induced by the interaction of the ASMFs and the remelting current exists at the consumable electrode tip,resulting in thinner liquid melt film and smaller droplets.With the increase in magnetic flux density,the optimization effect of ASMFs on electroslag remelting process increases and reaches the peak with a 40 mT ASMF,then decreases.The cleanliness of the ingots was improved,and the count of inclusions larger than 5μm was reduced.The microstructure of the ingots processed with a 40 mT ASMF was significantly refined.The depth of the metallic molten pool was reduced from 45.2 to 17.5 mm with the application of 40 mT ASMF.The tensile strength,impact toughness,and Rockwell hardness of the ingots obtained under the 40 mT ASMF were significantly improved.The mechanisms of the spin-vibration occurring at the electrode tip end were interpreted in detail to elucidate the effect of ASMFs.

Development of Clarification Technology for Molten-Al by a Combination of Cyclone and Electromagnetic Separation

Aluminum has high recyclability and promising future,so aluminum recycling is important for the future society.However aluminum recycling has some problems;one problem is inclusions remaining in final aluminum products.In this study,we have proposed a new separation process of inclusion particles from molten aluminum;it is the electromagnetic cyclone separator,which consists of the liquid cyclone and the electromagnetic separator.We carried out water model experiments,in which the magnetic separation was used instead of the electromagnetic separation.A theoretical model to estimate the separation efficiency was developed and the results agreed with the water model experiments.The theoretical model was used to estimate the separation performance of the electromagnetic cyclone separator for molten aluminum,and it was predicted that the separator was effective clarification process for aluminum recycling.