Transient Thermo-Mechanical Analysis of Steel Ladle Refractory Linings Using Mechanical Homogenization Approach

Mahmoud Ali,Alain Gasser,Thomas Sayet,Eric Blond

doi:10.3390/ceramics3020016

Abstract

Mortarless refractory masonry structures are widely used in the steel industry for the linings of many high-temperature industrial applications including steel ladles. The design and optimization of these components require accurate numerical models that consider the presence of joints, as well as joint closure and opening due to cyclic heating and cooling. The present work reports on the formulation, numerical implementation, validation, and application of homogenized numerical models for the simulation of refractory masonry structures with dry joints. The validated constitutive model has been used to simulate a steel ladle and analyze its transient thermomechanical behavior during a typical thermal cycle of a steel ladle. A 3D solution domain and enhanced thermal and mechanical boundary conditions have been used. Parametric studies to investigate the impact of joint thickness on the thermomechanical response of the ladle have been carried out. The results clearly demonstrate that the thermomechanical behavior of mortarless masonry is orthotropic and nonlinear due to the gradual closure and reopening of the joints with the increase and decrease in temperature. In addition, resulting thermal stresses increase with the increase in temperature and decrease with the increase in joint thickness.

Highlights

Steel ladles are industrial vessels that are used in the steel industry for liquid steel transportation and refinement
The main objective of the present study is to investigate the thermomechanical response of a steel ladle during complete thermal cycles of the steelmaking process
In order to validate the developed homogenized equivalent material model, comparisons between experimental and numerical results of the mortarless masonry structure subjected to biaxial compression have been carried out

Summary

Introduction

Steel ladles are industrial vessels that are used in the steel industry for liquid steel transportation and refinement. Normal operating conditions of steel ladles include high operating temperatures (around 1700 ◦ C), high thermal stresses, slag corrosion, and degradation of layers in contact with liquid steel. To withstand these severe operating conditions, steel ladle design is based on the concept of multi-layer design. The most critical layer in the steel ladle is the working lining layer in contact with liquid steel, as its temperature values are the highest within the ladle This layer is usually subjected to thermal shock and a severe chemical environment, leading to thermomechanical degradation [1]

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