Simulation of Fluid Flow and Inclusion Removal in Five-Flow T-Type Tundishes with Porous Baffle Walls

Abstract

To solve the instability of liquid steel in the continuous casting process and the inconsistent flaw detection of heavy rail steel, steel flow control was studied numerically in a tundish with a porous baffle wall by using the fluid dynamics software Fluent. The opening plan of the baffle wall was improved through orthogonal optimization of the design of the holes in the porous baffle wall. The test condition was set to a left inclination angle of α1 = 22°, a right inclination angle of α2 = 48°, an upward elevation angle of β = 30°, and an aperture of d = 70 mm. The simulation results of the optimization scheme showed that the uniformity of the flow and temperature fields had been significantly improved, and the flow in each strand became consistent. The maximum temperature difference was 21 K in the tundish, and the maximum temperature difference of three outlets was only 1.7 K. Dead zone volume was reduced by 10.0% compared to the original tundish, and plug flow volume was increased by 14.2%. Comparing the removal efficiency of Al2O3 inclusions of different size, the results showed that the removal efficiency of 10 μm and 30 μm smaller inclusions was above 87%. The removal rate of ≥50 μm larger inclusions also remained about 95%.