Comprehensive model for a slag bath in electroslag remelting process with a current-conductive mould

A mathematical model was developed to describe the interaction of multiple physical fields in a slag bath during electroslag remelting （ESR） process with a current-conductive mould. The distributions of current density, magnetic induction intensity, electromagnetic force, Joule heating, fluid flow and temperature were simulated. The model was verified by temperature measurements during remelting 12CrMoVG steel with a slag of 50wt%-70wt% CaF2, 20wt%-30wt% CaO, 10wt%-20wt% A1203, and 〈10wt% SiO2 in a 600 mm diameter current-conductive mould. There is a good agreement between the calculated temperature results and the measured data in the slag bath. The calculated results show that the maximum values of current density, electromagnetic force and Joule heating are in the region between the comer electrodes and the conductivity element. The characteristics of current density distribution, magnetic induction intensity, electromagnetic force, Joule heating, velocity patterns and temperature profiles in the slag bath during ESR process with current-conductive mould were analyzed.

Calculation Model for Surface Tension of Slag Melt

Based on the coexistence theory of slag melt structure and Butler’s equation,a new calculation model has been proposed for the calculation of surface tension of slag melt.This model establishes a specific correlation between surface tension and mass action concentrations(activities) in the melt and on its surface on the basis of inner and surficial structures of slag melt.Calculated surface tensions of CaO-SiOand MnO-SiOslag melts are consistent with those measured.Furthermore,iso-surface tension lines of CaO-MnO-SiOslag melt have also been calculated.

Effects of several casting parameters on slag entrapment in mould( part A: water modeling)

The mechanism of slag entrapment in the mould was analyzed and the water modeling experiment was done according to the industrial manufacturing. The results show that the flow of the liquid steel becomes more active and the level fluctuation in the mould becomes bigger when the casting speed increases from 1.0 m/min to 1.2 m/min. So the control of slag entrapment in the mould becomes more difficult. When the depth of the nozzle increases from 30mm to 42. 5mm and the angle increases from 15~ downward to 30° downward, the level fluctuation in the mould becomes smaller and the slag entrapment in the mould also decreases. But the impact depth increases and the circumfluence vortex center moves downward, which is unfavorable for the flotation of gas bubbles and inclusions. Furthermore, the impact depth with side holes a （ 16.3 × 20mm2 ） and b （ 10 × 10 mm2 ） is almost equal, but a smaller level fluctuation can be obtained with side hole a.

Study on the separation process of non-metallic inclusions at the steel-slag interface using water modeling

The separation process of non-metallic inclusions at the steel–slag interface was simulated by physical modeling. Three different kinds of particles (octahedral, plate-like, and spherical) and three different oils (kerosene, bean oil, and pump oil) were used to model inclusions and slags, respectively. The effects of inclusion geometry (shape and size) and slag properties (viscosity and interfacial tension) on the separation process were investigated. The results revealed that the variation of surface free energy and the viscosity of the slag are two significant factors affecting the separation process of inclusions at the steel–slag interface. The variation of surface free energy helped inclusions enter the slag phase, whereas the decrease of slag viscosity shortened the separation time. The deformation of the steel–slag interface could give rise to the resistance force, which would resist inclusions passing through the interface. A liquid film formed on the inclusion as it passed through the steel–slag interface, which might be related to the inclusion’s shape. © 2017, University of Science and Technology Beijing and Springer-Verlag Berlin Heidelberg.

A model for estimating the rate constant between CO_2-CO gas and molten slag containing iron oxides using optical basicity

A simple model for estimating the rate constant between CO2-CO gas and molten slag containing iron oxides was developed using optical basicity only. In this model, the temperature dependence of the rate constant can be described by the Arrhenius law, and the activation energy can be expressed with a linear function of the slag＇s optical basicity. The model was applied to some molten slag systems, such as FeO, FeO-CaO, FeO-SiO2, FeO-Na2O, FeO-CaO-SiO2, FeO-SiO2-P2O5, FeO-SiOE-Na2O, and FeO-CaO-SiOE-P2O5. A comparison between the predicted results and measured data showed that the model worked well.

Effects of several casting parameters on slag entrapment in mould (part B:numerical modeling)

Based on the effects of several casting parameters on slag entrapment in the mould （ water modeling）, the numerical modeling was researched. The results show that the flow field with a submerged nozzle section dimension of 65 mm ×80 mm is better than that with a submerged nozzle section dimension of 40 mm × 40 mm and is favorable for avoiding slag entrapment. In this paper, low surface velocity, small level fluctuation and proper impact depth can be achieved with a nozzle of an outlet angle of 25° and an immersion depth of 150 mm, or with a prototype nozzle of an outlet angle of 15° angle and an immersion depth of 150 mm.

Calculation model of mass action concentrations for CaO-MgO-SiO_2-Al_2O_3-Cr_2O_3 penta-slag

Two calculation models of mass action concentrations for CaO-MgO-SiO_2-Al_2O_3-Cr_2O_3 penta-slag was presented whether 3CaO·Cr_2O_3·3SiO_2 was existence or not.Equilibrium mass action concentration of each element structure was gained.And the models results were compared with experimental activity.The final results illustrated the model without 3CaO·Cr_2O_33SiO_2 was suit for reality.The model could response the element structure of slag as well.

Prediction Model of Compressive Strength of Fly Ash-Slag Concrete Based on Multiple Adaptive Regression Splines

Accurate prediction of compressive strength of concrete is one of the key issues in the concrete industry. In this paper, a prediction method of fly ash-slag concrete compressive strength based on multiple adaptive regression splines (MARS) is proposed, and the model analysis process is determined by analyzing the principle of this algorithm. Based on the Concrete Compressive Strength dataset of UCI, the MARS model for compressive strength prediction was constructed with cement content, blast furnace slag powder content, fly ash content, water content, reducing agent content, coarse aggregate content, fine aggregate content and age as independent variables. The prediction results of artificial neural network (BP), random forest (RF), support vector machine (SVM), extreme learning machine (ELM), and multiple nonlinear regression (MnLR) were compared and analyzed, and the prediction accuracy and model stability of MARS and RF models had obvious advantages, and the comprehensive performance of MARS model was slightly better than that of RF model. Finally, the explicit expression of the MARS model for compressive strength is given, which provides an effective method to achieve the prediction of compressive strength of fly ash-slag concrete.

Electrochemistry of oxygen ion transport in slag

A systematic experiment relating to the electrochemistry of oxygen ion transport in slag has been studied in lab. An equivalent circuit has been used to describe ion transfer between metal and slag in this paper and a kinetic model with electrochemical characteristic representing oxygen ion immigration has been worked out. The different experimental phenomena can be explained generally by this model. It can be seen that the theoretical results are in good agreement with experiments. The comparison of experimental data with model calculation proved that the electrochemical model is right.

Leaching calcium from phosphogypsum desulfurization slag by using ammonium chloride solution: Thermodynamics and kinetics study

Phosphogypsum(PG) desulfurization slag is a calcium-rich residue from reductive decomposition of PG using sulfur as the reductant. We proposed a technology of preparation light calcium carbonate with PG desulfurization slag, which mainly contains two steps: leaching and carbonizing. In this work, we concentrated on the former, in which ammonium chloride aqueous solution was utilized as leaching agent to extract calcium from the slag, and conducted thermodynamics and kinetics study on it. Fact Sage software was employed to do thermodynamic and phase equilibrium diagram calculations. The influence of leaching conditions including agitation speed, initial concentration of leaching solution, reaction temperature, and liquid/solid ratio on the calcium leaching rate was discussed in detail by means of experiment optimal design. A kinetic model developed from the shrinking core model was given to describe the leaching process. The apparent kinetic activation energy(Ea) of the leaching reaction was calculated to be 10.58 kJ·mol^-1.

KINETICS OF DESULPHURIZATION IN PERMANENT CONTACT OF SLAG AND STEEL

The curve of % S vs reaction time is described quantitatively based on the electrochemical model directly deduced from the principle of electrochemistry as well as the given method for calculating the initial oxygen potential along slag/steel interface.The calculated data is in good agreement with the experimental results. During desulphurization,both L_s~* and L_s,the sulphur partition along the interface and that in the bulk,go up in association with the descending of oxygen potential along interface. The plot of L_s~* against reaction time follows a parabolic curve,while that of L_s is of hyperbola type.Correspondingly,on curves of driving force parameter vs reaction tone,either calculated or experimental,a hump occurs.

Electroreduction Kinetics for Molten Oxide Slags

The oxygen-ion conductor, the reducing agent, and the molten oxide slag containing electroactive matter were used as constituent of a galvanic cell. Metal was directly electroreduced from molten slag using a short-circuit galvanic cell. The following galvanic cell was assembled in the present experiment： graphite rod, [-O]Fe-C saturated ｜ZrO2 （MgO） ｜ Cu（1） ＋ （FeO）（slag） , and molybdenum wire. The FeO electroreduction reaction was studied through measuring short circuit current by controlling factors such as temperature, the FeO content in molten slags, and the external circuit resistance. An overall kinetics model was developed to describe the process of FeO electroreductiono It was found that the modeled curves were in good agreement with the experimental values. The new oxide reduction method in the metallurgy with controlled oxygen flow was proposed and the metallurgical theory with controlled oxygen flow was developed.

MATHEMATICAL AND PHYSICAL MODELING OF INTERFACIALPHENOMENA IN CONTINOUS CASTING MOULD WITH ARGONINJECTION THROUGH SUBMERGED ENTRV NOZZLE

The study on the fluid flow, meniscus oscillation, slag entrapment in continuous casting mould was conducted mathematically and experimentally. The results show that the injection of argon into submerged nozzle enhances the meniscus oscillation, thus increases the probability of slag entrapment, and the critical argon blowing flow rate, which will give rise to slag entrapment, is around 10l/min. The trajectory of bubble is affected by the bubble diameter and the molten steel flow, and the bubble diameter is dominant. The bubble with diameter 1.4mm floats fastest with 0.47m/s terminal velocity.

Physical Property Model of MnO-SiO_2 System

From the viewpoints of coexistence theory of the slag structure, the investigation on the structural units of MnO-SiO2 system and the chemical reactions between them has been carried out. The relationships between the physical propenies of the slag and the mass action concentrations of its have been set up at certain temperature and slag composition range, which based on the thermodynamic data of the chemtical reactions between the units and the method of linear regression. The calculated data from the model are in good agreement with the measured results. These calculated values are more accurate and systematic than those from other expirical and semi-expirical formulas used at present.

Oxidizing Capability of Refining Slags Containing BaO

According to the coexistence theory of slag structure melts, the oxidizing capability of the refining slag CaO-MgO-FeO- A12O3SiO2 is studied and the relationship between the mass action concentration of FeO (NFeO) and the activity of FetO (αFetO) for this slag is found to be as NFeo=0.656 1 αFetO. Furthermore, the calculating model of oxidizing capability of the refining slag BaO-CaO-MgO- FeOA12O3-SiO2 is established. A satisfactory result is obtained when using the above oxidizing capability relationship to calculate the desulphurizing capability of such refining BaO-slags.

Evaluation of Component Activity in Molten MnO-SiO_(2)-Al_(2)O_(3)-CaO System with Model SELF-SReM4

A sub-regular solution model SELF-SReM4 used to evaluate activity of the components in a homogeneous region of a quaternary system has been developed in Shanghai Enhanced Laboratory of Ferrometallurgy.The application of SELF-SReM4 in C-Mn-Fe-Si system without the SiC formation has been introduced in previous paper.It’s application for molten slag of MnO-SiO2-Al2O3-CaO was introduced in this paper.They provide a basis for the prediction of the metal-slag equilibrium conditions.

RATE OF SILICOTHERMIC REDUCTION OF TiO_2 IN TiO_2 CONTAINING SLAG MELT

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气化炉内熔渣流动特性预测模型的研究进展

双碳战略目标下,煤气化技术将会是我国未来煤炭领域的重要发展路线。在煤气化技术推广应用中,熔渣的流动行为严重影响气化炉的平稳运行时长,间接影响合成气的质量和炉壁的热量损失,有效求解流动参数的熔渣流动特性预测模型备受关注。本研究论述了现有的气化炉内熔渣流动特性的预测模型,并展望了预测模型的未来研究方向。综述当下,预测模型根据熔渣流动维数可分为一维预测模型和二维预测模型;一维稳态和非稳态预测模型均经历了构建和完善阶段;二维预测模型因无相关的数学公式描述和流动理念假设尚处于构建阶段;通过对液态熔渣的温度分布、附加应力的取舍,临界黏度的选取和熔渣黏度的处理方式等方面可以提高模型的计算精度。展望未来,一维预测模型的应用场景需更完善的规定,针对稳态和非稳态预测模型求解的参数需要更细致的辨析;二维预测模型的构建理论需更详细的突破,明确非稳态工况下熔渣在轴向和周向上流动的优先级;流动预测模型的计算精度需更全面的提升,熔渣性质的非恒定性、熔化的不均匀性、烟气流速的波动性等因素需要侧重考虑。

304不锈钢氩氧脱碳精炼过程中炉渣成分预测模型

针对304不锈钢氩氧脱碳(Argon-Oxygen Decarburization,AOD)精炼过程中存在炉渣成分难以测量等问题,本研究综合考虑了顶枪吹氧、供气比例变化、物料熔化速度以及初始渣量对渣-钢反应和精炼炉渣成分的影响,建立了炉渣成分预测模型,并用于计算精炼过程中的炉渣和钢液成分变化。此模型计算的渣成分与钢液硫含量与实测值吻合较好,AOD精炼终点渣中SiO_(2)含量平均偏差为1.434%,CaO含量平均偏差为1.848%,Cr_(2)O_(3)含量平均偏差为0.080%,MnO含量平均偏差为0.016%,钢液终点S含量平均偏差为0.002%。

铝粒尺寸及入炉高度对运动轨迹的影响

二次精炼过程中,铝是钢液进行脱氧及合金化的主要物料之一,但纯铝的密度小于钢液,能否穿越渣层与钢液接触及接触时间对铝的脱氧效果和钢中溶解铝的含量有直接影响。在忽略铝的熔化、溶解及化学反应的情况下,通过对铝粒运动过程受力分析,建立铝粒在气-渣-钢相内的三维运动数学模型,明晰铝粒尺寸及入炉高度对铝粒运动轨迹的影响。结果表明:在渣层厚度为70 mm且入炉高度为1~1.5 m的情况下,1 mm和5 mm的铝粒在渣钢界面处波动;入炉高度为1 m时,粒径为10 mm的铝粒停留在渣钢界面处,但在入炉高度为1.5 m及以上时可以进入钢液;20 mm及以上尺寸的铝粒可以进入钢液。在入炉高度为1 m时、30 mm尺寸的铝粒在钢液中的停留时间与深度相较于20 mm的基础上分别增加22.86%和50.00%;在铝粒尺寸为20 mm时、入炉高度为1.5 m时的铝粒在钢液中的停留时间与深度在1 m的基础上分别增加5.71%和10.00%。增加钢渣界面张力、减小钢铝界面张力或增加渣铝界面张力有利于铝粒进入钢液,而铝粒的尺寸大于20 mm,界面张力对铝块运动几乎没有影响;增大密度会使钢芯铝在钢液中停留更长时间,有利于钢液脱氧。