Computational Investigation of Inclusion Removal in the Steel-Refining Ladle Process

Xipeng Guo,Abhishek Bhansali,Joel Godinez,Chenn Q Zhou,Helmut Oltmann,Eugene Pretorius,Armin K Silaen,Vivek Thapliyal,Nicholas J Walla

doi:10.3390/pr9061048

Xipeng Guo, Abhishek Bhansali + Show 7 more

Open Access

https://doi.org/10.3390/pr9061048

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Journal: Processes	Publication Date: Jun 16, 2021
Citations: 10	License type: CC BY 4.0

Affiliation: Center for Innovation, Purdue University Northwest

Abstract

In a steel-refining ladle, the properties of manufactured steel can be notably degraded due to the presence of excessive inclusions. Stirring via gas injection through a porous plug is often used as part of the steel-refining process to reduce these inclusions. In this paper, 3D computational fluid dynamics (CFD) modeling is used to analyze transient multiphase flow and inclusion removal in a gas-stirred ladle. The effects of gas stirring with bubble-inclusion interaction are analyzed using the Euler–Euler approach for multiphase flow modeling, while the effects of inclusions aggregation and removal are modeled via a population balance model (PBM).

Highlights

In the control of steel cleanliness, non-metallic inclusion removal is largely accomplished (65–75%) through ladle operations
In 1975, Szekely et al [1] first modeled and studied the flow characteristic in a ladle based on a simplified water model
Gas was injected from the bottom of the ladle with an assumed constant bubble size, and all other boundary conditions were sourced from the physical experiment

Summary

Introduction

In the control of steel cleanliness, non-metallic inclusion removal is largely accomplished (65–75%) through ladle operations. Non-metallic inclusions can lead to excessive casting repairs and rejected castings These factors negatively impact U.S energy use and efficiency, infrastructure, economic competitiveness, and national security, because high-quality steel products are keystone parts of fundamental transportation, construction, communications, and defense systems. In 1975, Szekely et al [1] first modeled and studied the flow characteristic in a ladle based on a simplified water model. In 1978, DebRoy et al [2] improved Szekely et al.’s model by revising the bubble model from dispersed bubbles constrained in a single plume with a diameter related to volume fraction to injection based on gas flow rate. Johansen et al [3] performed experiments by using a bottom injection water model, discovering key interactions between bubble-generated turbulence and flow velocity in the bubble plume region

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