Abstract
A mathematical model was developed to study the effects of the flow control devices and the gas curtain on the steel cleanness in a single-strand tundish. The Eulerian–Lagrangian approach was applied to investigate the bubble flow and the behavior of the non-metallic inclusions in the system. Two modelling approaches were considered: (i) one-way coupling, where the influence of the micro-inclusion on the molten steel flow is neglected; and (ii) two-way coupling, where the momentum exchange between the molten steel and the bubbles is modelled. The model verification and validation (V&V) were carried out in order to establish confidence in the model predictions. Four different tundish configurations and the effect of various parameters, such as the inclusion size, the inclusion density and the gas flow rate, were investigated at the normal casting conditions. The results show that the flow control devices and the gas curtain reduce the extent of the dead volumes in the tundish and thus enhance the removal efficiency of the inclusions. Controlling the gas stirring intensity is important for tundish operation with the aim of removing the inclusions. Theoretical analysis suggests that small bubbles are preferable to increase the inclusion removal rate in industrial operations.
Highlights
The tundish, working as a buffer and distributor of liquid steel between the ladle and continuous casting molds, plays a key role in affecting the performance of casting and solidification, as well as the quality of final products, referred to as “Tundish Metallurgy”
The results show that the flow control devices and the gas curtain reduce the extent of the dead volumes in the tundish and enhance the removal efficiency of the inclusions
In terms of two gas injection cases, Case 3 and Case 4, the gas curtain generates small gas bubbles, which are beneficial for inclusion removal, and act as a ‘dam’, which redirects the downstream flow after the weir
Summary
The tundish, working as a buffer and distributor of liquid steel between the ladle and continuous casting molds, plays a key role in affecting the performance of casting and solidification, as well as the quality of final products, referred to as “Tundish Metallurgy”. With the continuing emphasis on superior steel quality, a modern steelmaking tundish is designed to provide maximum opportunity for the control of molten steel flow, heat transfer, mixing and inclusion removal. Tundish modelling studies can be categorized into three major groups: (i) physical modelling, (ii) mathematical modelling, and (iii) combined physical and mathematical modelling. These works have led to considerable improvements in our understanding of the various transport processes associated with tundish operations. A reliable mathematical model allows engineers to carry out full-scale predictions and useful engineering design and process calculations
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