Research Progress on Anti-clogging Technology of Submerged Entry Nozzles for Continuous Casting

The causes, the formation process, and the prevention of submerged entry nozzle(SEN) clogging were introduced. The influence of electric field on the SEN clogging was focused on, including the basic theory and measurement of SEN charging,the preliminary research on SEN charging, the influence of molten steel on the wetting behavior of refractory materials in electric field, and the influence of electric field on the oxide inclusions in molten steel. Based on the influence of the hydrodynamics, chemistry and other factors on refractory materials, structure, inclusion particle transfer and adhesion, many anti-clogging researches have been carried out, such as optimizing process conditions, compositing anti-clogging inner lining materials, innovating SEN structure and applying physical fields, which solve the problem of SEN clogging to a certain extent.However, the problems of weak adaptability and superficial study on clogging mechanism are still prominent. The electric field control is a new technology to prevent clogging. Although it has achieved certain results in on-site continuous casting trials,some problems such as the method of applying electric field, the electric field parameters and the equipment still need to be gradually improved, and the surface characteristics of inclusions and SEN materials at high temperatures need to be further studied. It was pointed out that the combination of materials and applied electric field will become an important direction for SEN anti-clogging technology.

Velocity Monitoring of Molten Steel in a Continuous Casting Mold Using Three Submerged Entry Nozzle Designs

The horizontal and vertical velocity components of molten steel in a slab continuous casting mold produced by three different two-port Submerged Entry Nozzle (SEN) designs are monitored and compared using Computational Fluid Dynamics (CFD) simulations. These two ports designs correspond to a conventional cylindrical SEN, a plate SEN and an anchor-shaped SEN. Four monitoring points at the molten steel in the centered vertical plane were selected to track the horizontal and the vertical component of the velocity vector. Two of them are located near the free surface and the remaining two are located in the vicinity of the SEN discharge nozzles. Some statistical values of the time series of above the velocity components are analyzed and correlated with the Kelvin-Helmholtz instability and the Karman vortex streets, which cause mold powder entrapment in the molten steel.

Anchor-Shaped Design of a Submerged Entry Nozzle for the Continuous Casting of Steel

An anchor-shaped geometrical design for a Submerged Entry Nozzle for the slab continuous casting of steel is presented in this work. To evaluate its performance, transient 3D multiphase numerical simulations were carried out using the Computational Fluid Dynamics technique. The performance of the proposed nozzle is numerically compared with that of a conventional cylindrical nozzle. Computer results show that the chance of formation of Karman’s vortexes and powder entrapment becomes small for the anchor-shaped SEN.

Analysis of Corrosion Behavior of ZrO_(2)-C Slag-line Materials in Continuous Casting

In view of the service failure and low continuous casting production efficiency due to the corrosion of refractories at the slag-line in submerged entry nozzles,a submerged entry nozzle for low-carbon aluminum killed steel continuous casting in one steel plant was sampled and taken as the research object to analyze the causes and the mechanism of refractory corrosion at the slag-line.The results show that the core issue of the corrosion and necking of the slag-line materials is that the slag-line material are eroded,dissolved,and reacted by the mold flux gradually.Therefore,it is important to suppress or avoid the contact and reaction between the mold flux and slag-line materials.

Structure Design of SEN for High Efficiency Thin Slab Continuous Casting

Four-hole submerged entry nozzles （SEN） with dif- ferent structures were researched using the water simula- tion test by particle image velocimetry （PIV） and DJSO0 hydraulic measurement system to get suitable SEN for high efficiency continuous casting. The influences of the exit area ratio （2： 1：2, 3：2： 3, 1： 1：1 and 1：2： 1）, upper guide island angle θ （20°, 40°, 60° and 80°） , and lower guide island angle α （60°, 80°, 100° and 120°） on the vortex position in the mold and fluctuations were researched. The results show that the exit area ratio and the upper and low guide island angles have ob- vious influence on the flow field; the flow field in the mold is suitable at 1：2：1 of the exit area ratio, 80° of upper guide island angle, and 100° of lower guide island angle.

Damage Mechanism and Countermeasures of Carbon Bonded Refractories for Continuous Casting

The long nozzle,stopper,and submerged entry nozzle play an important role in continuous casting. They are of the similar composition and are mainly damaged by liquid steel thermal shock which leads to immediate cracks or fracture in their combined area because of the thermal mechanical properties mismatch,or damaged by corrosion on their interface. The failure mechanisms are the thermal shock damage and continuous reaction corrosion. High efficiency and long life of the long nozzle,stopper,and submerged entry nozzle can be realized by optimizing the thermal mechanical properties,the key erosion step,and the combination match.

Design of a submerged entry nozzle for optimizing continuous casting of stainless steel slab

To solve slag entrapment and casting slab defects in the process of stainless steel continuous casting,submerged entry nozzle(SEN)for slab casters operating at casting speed of 1 m/min was developed based on 3D numerical simulation and water modeling experiments by controlling the outlet shape and angle of original SEN with oval and 15°angle outlet under current industrial use.Mathematical simulations of fluid velocity at outlets with different shapes and angles of SENs have been carried out.The results showed that oval outlet with 5°and 15°angle led to asymmetric rotating flow pattern at outlet,as well as square outlet with 15°angle,but symmetric flow pattern formed at square outlet with 5°angle.The effect of these SENs on meniscus stability,flow field and slag entrapment behavior of stainless steel slab casting mold was further studied by water modeling experiments.The results showed that difficult floating fine droplets formed when the angle of outlet was 15°under the dual effect of vortex convection and shear force due to the strong swirling flow from outlet and rotating flow of outlet.However,outlet with 5°angle could lead to the formation of larger slag droplets,while the oval outlet with 5°angle could result in the scour to the mold wall.Thus,the square outlet with 5°angle was a relatively ideal solution for the submerged entry nozzle from the aspects of the stability of the mold and the slag entrapment behavior.After the design of a new SEN according to the experimental result,the solidification structure of continuous casting slab was obviously improved by industrial test.

CEMS在液化天然气接收站中的设计探讨

针对液化天然气接收站中浸没燃烧式汽化器(SCV)燃烧烟气中NO_(x)的特点,设计了烟气排放连续监测系统(CEMS),详细介绍了CEMS的组成,采样方式、分析仪的选取,烟气参数监测单元和数据采集与处理单元的设置等,对CEMS的安装和后期维护提出了相应的建议方案。该系统设计方案不但可以监控烟气排放是否达标,还可以监测烟气中的CO浓度来反映SCV低氮燃烧器的燃尽效率,有效降低生产维护费用。

Optimization of submerged entry nozzle parameters for ultra-high casting speed continuous casting mold of billet

Controlling the flow behavior in the mold in an appropriate way is the basis for realizing the billet ultra-high speed continuous casting.Based on the new proposed physical water modeling experiment considering the effects of solidified shell and hydrostatic pressure,the flow behavior in the mold with cross section of 160 mm 9160 mm during continuous casting of billet is regulated by optimizing the inner diameters and immersion depths of submerged entry nozzle at the ultra-high casting speeds of 5.0–6.5 m/min.The results show that under the premise of no slag entrainment,as well as uniform coverage and keeping good fluidity of liquid slag layer on the top free surface of the fluid in the mold,the appropriate parameters of submerged entry nozzle under the ultra-high casting speed of billet are 50 mm in inner diameter,95 mm in outer diameter and 180 mm in immersion depth.And on the basis of the obtained parameters of submerged entry nozzle,it can be known that the reasonable ranges of level fluctuation and impacting depth of the stream in the mold are about 0.82-1.11 and 593-617 mm,respectively.

A New Type of Submerged-Arc Flux-Cored Wire Used for Hardfacing Continuous Casting Rolls

It is expected that the welding hardfacing of continuous casting rolls has better welding performance and higher wear resistance. A new type of submerged-arc hardfacing flux-cored wire has been developed through nitrogen replacing part of carbon and addition of the nitrogen-fixing elements of niobium and titanium. And microstructure, degree of hardness and high-temperature wear resistance of its deposited metal samples were also investigated. It is found that the microstructure is martensite, residual austenite and carbonitride precipitates. As a result, the hardfacing metal with homogeneous distribution of very fine carbonitride particles had high hardness and excellent wear-re- sisting property during high-temperature wear, which could significantly extend the service life of continuous casting rolls.

ZrO_(2)-C质浸入式水口渣线耐火材料的侵蚀机制分析

针对目前连铸浸入式水口渣线部位耐火材料的侵蚀造成水口服役失效与连铸生产效率无法提升的难题,以某钢厂低碳铝镇静钢连铸常用的ZrO_(2)-C质浸入式水口为例,对其侵蚀后的水口渣线部位耐火材料进行取样,详细分析了水口渣线部位耐火材料的侵蚀原因与机制。结果表明:保护渣对水口外部渣线材料的冲刷、溶解与反应是导致浸入式水口渣线部位侵蚀和缩颈的核心问题。因此,如何有效防止或避免渣线部位耐火材料与保护渣间的接触与反应对抑制渣线侵蚀至关重要。

压力容器用埋弧焊丝钢H10Mn2-A盘条冶炼及轧制实践

根据客户特殊需求开发了压力容器用埋弧焊丝钢H10Mn2-A盘条,为了保证低倍组织质量,通过LF精炼进行窄成分和气体含量控制,连铸全程保护浇注,过热度≤30℃,拉速2.2 m/min。为了获得优良的成品力学性能,采用控轧控冷工艺,开轧温度1000±20℃,吐丝温度890±10℃,辊道速度15 m/min。经客户试用,H10Mn2-A盘条强度适中、塑性好,易拉拔,冲击韧性良好,满足压力容器用焊丝的拉拔和焊接性能要求。

Characteristics of SEN clogging and adhesive behavior of oxide inclusion during continuous casting of Ti-stabilized ultra-pure ferritic stainless steels

Submerged entry nozzle(SEN)clogging during continuous casting of Ti-stabilized ultra-pure ferritic stainless(Ti-UPFS)steels was systematically investigated via cross-sectional analysis and acid dissolution treatment.The SEN deposit profile was characterized as occurring in three major layers:(1)an eroded refractory layer;(2)an initial adhesive layer comprised an Al_(2)O_(3)-ZrO_(2) composite sub-layer and a dense Al_(2)O_(3)-based deposit sub-layer;and(3)a porous multiphase deposit layer mainly consisting of MgO·Al_(2)O_(3),CaO-Al_(2)O_(3),and CaO-TiOx.The MgO·Al_(2)O_(3)-rich inclusions did not adhere directly to the eroded refractory but were entrapped during the deposit growth.Results of inclusion characterization in the tundish revealed that the MgO·Al2O3-rich particles present in the tundish served as the primary source of clogging deposits.Furthermore,a novel cavity-induced adhesion model by circular approximation was established to explain the effects of complex inclusion characteristics and refractory material type on adhesion force.A high number of small MgO·Al_(2)O_(3) inclusions were expected to accelerate the buildup of clogging deposits.Improving the modification of MgO·Al_(2)O_(3)-rich inclusions in the size range of 2-4μm by Ca treatment was crucial to minimizing the risk of SEN clogging during the continuous casting of Ti-UPFS steels.

薄带连铸亚快速凝固行为热模拟研究的现状

薄带连铸是钢铁材料短流程绿色制造的前沿技术,具有资源消耗少、节能和对环境无害等特点。目前实验室热模拟研究的薄带连铸主要是熔滴凝固和浸入式测试技术。综述了熔滴凝固技术和浸入式测试技术的发明和发展、热模拟研究中涉及的凝固和传热问题、连铸薄带的组织和性能调控及这两项技术在高强钢等金属材料生产中的应用。

连铸水模型试验分体式旋流水口的设计与应用

在考察多个旋流水口技术的水模型试验中,制造加工传统单体浸入式水口的数量会随着试验条件数量的增加而增多,这会耗费大量的加工时间和成本。根据目前已有的旋流水口技术,文章提出一种全新的分体式旋流水口,将单体水口分为上、中、下三段,水口相邻两段采用螺纹旋拧的方式相互连接。水口上段保留传统水口特征;水口中段安装一个可拆卸的旋流转子;水口下段可选用直筒型或切向水口。这种分体水口结构不仅组装操作简单,降低了加工时间和成本,还有助于考察各旋流水口技术单独或耦合作用时的结晶器流场特征。

475 mm特厚板坯连铸结晶器浸入式水口优化数值模拟研究

特厚板坯连铸技术主要应用于特种装备制造领域,市场需求量较大。浸入式水口的结构是决定结晶器中流场流动行为的关键因素。本研究通过建立三维数值模型,研究浸入式水口侧孔倾角对475 mm特厚板坯结晶器内流场流动行为、温度场和凝固坯壳分布的影响。结果表明,水口侧孔倾角对钢液流动行为影响显著:当侧孔倾角由-20°调整至-10°时,射流冲击深度由660 mm减小至545 mm,结晶器自由液面平均温度升高4 K;此外,侧孔倾角的减小使凝固坯壳尤其是窄面坯壳厚度增加6 mm。综合考虑,当水口侧孔倾角为-10°时,结晶器性能最佳,此时的液面流动较活跃,结晶器保护渣和液面之间的传热性良好,出口处的壳体厚度均匀,足以满足生产需要,可有效避免漏钢现象发生。

富氧侧吹熔池熔炼-氧气底吹连续处理含铜电镀污泥与含铜物料工艺路线

我国电镀污泥产量大,富集大量有毒重金属,属于危险废物。本文介绍了各种电镀污泥处理工艺的原理及优缺点,基于目前工艺存在的问题,并针对多种含铜二次资源物料的特点,采用不同的处理工艺合并冶炼流程,提出了“富氧侧吹浸没燃烧熔炼-氧气底吹连续吹炼”的集成创新工艺。同时,并以某含铜二次资源综合利用项目为例,阐述了该工艺在含铜电镀污泥及含铜固废综合利用中的应用效果。该工艺发挥了侧吹浸没燃烧和底吹吹炼两种工艺的优点,协同处理各种含铜物料,具有原料适应性广、热效率高、投资较省、运行成本较低的优点,有效实现了工业固废的“减量化、资源化和无害化”,打造了固废处置行业的新标杆。

连铸板坯结晶器浸入式水口试验研究

结合某厂两种断面的结晶器内腔尺寸 ,采用 1∶ 0 .6水模型研究方法 ,系统地研究了浸入式水口结构参数、吹气量、拉速等工艺操作参数同结晶器液面波动、流股对结晶器窄面的冲击力及涡心高度之间的关系 ,得出了适用于两种断面的合理的凹型浸入式水口。并利用水模拟实验和工厂试验进行了对比研究 ,结果表明 ,应用凹型浸入式水口取得了良好的效果。

含钛不锈钢连铸浸入式水口结瘤的研究

为了解决含钛不锈钢连铸过程中浸入式水口的结瘤问题,采用扫描电镜和 X射线微区衍射等方法分析了AISI 321不锈钢连铸水口结瘤物的物相,探讨了浸入式水口的结瘤机理。结果表明:水口结瘤物中的物相主要有CaO·TiO2 -MgO·Al2O3 和金属,其中CaO·TiO2- MgO·Al2O3 主要来自于钢液中的夹杂物。喂钛线后吹氩搅拌过强使钢液面裸露和浇铸时的二次氧化会显著增加钢中CaO·TiO2- MgO·Al2O3 双相夹杂物的数量,导致结瘤层明显变厚。冶炼过程中采用低铝硅铁(ωAl=0 05%)还原,且不加铝、Ca- Si脱氧,或者在加 Ca Si后通过喂钛线前的吹氩弱搅拌尽可能排除钢中CaO- SiO2、CaO- SiO2 Al2O3 等夹杂物,严格控制二次氧化,可使喂入钛线后钢中CaO·TiO ·Al O 双相夹杂物数量明显减少,从而改善水口结瘤现象。