底吹中间包内钢液及夹杂物运动特性的数模研究

根据某厂实际中间包的操作工艺参数，采用欧拉两流体模型和拉格郎日随机轨道模型，模拟计算采用湍流控制器和气幕挡墙技术的中间包内的钢液流动特性及钢水中夹杂物的运动行为，研究结果表明，中间包底部吹气过程可以有效地改善钢液的流动状态，消除短路流，起到中间包档墙的作用，并且增大夹杂物在中间包内上浮排出率，大大提高了钢水的清洁度．     

透气砖对底吹中间包钢液流动特性影响的水力学模拟

采用不同性能参数的多孔透气砖进行中间包底部吹气水模实验，研究透气砖的气孔率、透气度、平均孔径对所形成的气泡大小和能形成有效气幕所需条件的影响，并分析使用不同透气砖时的RTD曲线，对使用不同透气砖时的吹气参数进行了优化。研究结果表明，透气砖的气孔率、透气度越小，形成的气泡越小，能形成有效气幕所要求的吹气量越大。采用中间包底部吹气技术，当控制的吹气参数合理时，可以有效地延长钢液的平均停留时间，降低死区体积；在中间包底部同一位置吹气时，气体通过的透气砖不同，要求的吹气参数不同。     

连铸中间包底吹气过程水模型实验研究

以宝钢集团梅山钢厂1台连铸中间包为原型,采用自行设计的吹气装置于底部吹气,用水模型的方法研究了吹气对中间包过程的影响。实验结果表明,底部吹气显著地改变了中间包内的流体流动特征;当不吹气时,通过上挡板下部的液流以层流形式贴近中间包的底部流动,然后从出口直接流出,在中间包的停留时间较短,死区体积较大,不利于夹杂物的去除;吹气以后,上升的气流起到了气幕挡墙的作用,通过上挡板下部的液流,被上升的气流抬起,贴近液面流动;吹气有利于增加平均停留时间,缩小中间包的死区体积,此外,上升的气流对中间包的液流具有一定的清洗作用,有利于夹杂物的去除;吹气用于中间包去夹杂过程,不需要较大气体流量。在气体流量相同时,在水模型实验装置中3个位置吹气对中间包的平均停留时间、中间包的死区体积分数、最短平均停留时间的影响大致相同,但总体上,中间位置的吹气效果要好于其他2个位置的吹气效果。     

单流板坯连铸中间包结构优化

通过对单流板坯连铸中间包的水模实验,研究了不同控流装置对中间包流动特性的影响.研究结果表明,堰、坝的尺寸和位置与湍流控制器(TI)的结构对中间包流动特性影响很大,在该中间包内使用不带顶檐的湍流控制器效果好于带顶檐的湍流控制器.与原方案中间包结构相比,优化后的中间包的流体流动特性得到很大改善,最小停留时间和峰值时间分别从64s和81 s提高到了81 s和163 s,平均停留时间从237s延长到了314 s,死区体积分数从35%降低到了14%,降低了60%.     

连铸中间包内夹杂物去除行为的水模型研究

通过选择乳状液滴模拟夹杂物和连铸中间包水模型实验,考察了控流装置、浇铸速度、夹杂物粒径对中间包内夹杂物去除行为的影响规律.结果表明:挡墙-挡坝组合控流夹杂物去除效果最佳,中间包内强湍流区夹杂物的碰撞聚合以及向上和表面流速的增加是主因;中间包注流区加入抑湍器,虽然其流体流动特征发生改变,但对夹杂物去除率的影响并不显著;较高的浇铸速度下,单纯靠控流装置的优化已不能很好地改善夹杂物的去除效果.     

连铸中间包控流装置优化的水模实验

通过对某厂板坯连铸中间包进行控流装置优化的水模实验,发现原中间包结构造成钢水在中间包内的最小停留时间过短,死区体积大;合理结构的挡墙和湍流控制器能够明显改善中间包内的流体流动特性,可以使钢包长水口注流区上方的液面更加平稳。     

两流T型连铸中间包结构优化

在实验室中以1∶2.5几何相似比建立了两流T型中间包钢液流动的物理模型,保持弗劳德数相等进行物理模拟实验.实验结果表明,原方案中间包结构的最小停留时间为35.00 s,峰值时间为103.75 s左右,平均停留时间约为273.42 s,活塞流体积分数约为17.88%,死区体积分数为29.53%.采用湍控器、一堰和两坝作为该中间包的控流装置,可以大幅度改善中间包的流体流动特性.结构改进后的中间包流体流动特性:最小停留时间达到151.75 s,峰值时间为281.25 s,平均停留时间为354.16 s,活塞流体积分数为55.80%,死区体积分数降低到8.73%.     

40t 单流中间包控流装置的优化配置

采用水模型和工业验证的方法针对40 t 单流中间包的控流装置进行优化配置研究.通过对单独湍流抑制器控流装置、湍流抑制器+下挡墙组合控流装置、湍流抑制器+下挡墙+上挡墙组合控流装置的研究表明,下挡墙在改善钢液流动形态和减少中间包内死区方面所起的作用大于上挡墙.平均停留时间随下挡墙与长水口的距离增加呈先增大后减小的趋势.确定了单流中间包以湍流抑制器+下挡墙的优化组合形式,死区比例由原来的25.9%降低到了13.6% .通过系统取样分析发现优化后中间包内 T. O 和 N 含量大幅降低,正常坯中的大型夹杂物质量分数也由原来的8.4×10-7降低到3.2×10-7 .     

兴澄特钢中间包结构优化

以兴澄特钢连铸中间包为工程背景,根据相似原理建立了中间包水模型系统,研究了4流不同结构的中间包的流体流动特性.研究表明:原结构的中间包同一侧的两流之间的流体流动特性存在很大差异,与内侧流相比,外侧流的最小停留时间、峰值时间小,死区体积大,造成中间包内钢液温度不均匀,夹杂物不能有效地上浮去除,不能很好地满足高质量特钢生产的要求.采用优化后的挡墙和坝组合的中间包控流装置,外侧和内侧的停留时间分布趋于一致,表明外侧流和内侧流之间流动特性相近.中间包结构优化后平均死区百分数由原结构的58.2%降低到10.9%.     

钢包在线底吹氩及夹杂去除的物理模拟研究

采用物理模拟的方法,研究钢包在线底吹氩时,钢包内钢液量、渣层厚度、底吹气体流量等参数对钢包顶部钢液裸露面积的影响,以及钢包在线底吹氩工艺对钢液中夹杂去除率的影响。结果表明,钢包临界卷渣底吹气体流量随着浇铸的进行而逐渐减小;在钢液量相同时,钢包顶部钢液裸露面积随着底吹气体流量的增加而逐渐增大;在底吹气体流量相同时,钢包顶部钢液裸露面积随着钢液液面高度的下降而逐渐减小;渣层越厚,钢液裸露面积越小;在底吹气体流量较小时,透气砖无堵塞与堵塞50%时造成的钢液裸露面积大小相近,但随着底吹气体流量的增加,透气砖堵塞50%时较无堵塞时造成的钢液裸露面积大;钢包在线底吹氩可以提高钢液中夹杂物的去除率。     

Uniformity evaluation and optimization of fluid flow characteristics in a seven-strand tundish

The effect of flow control devices (FCDs) on the uniformity of flow characteristics in a seven-strand symmetrical trapezoidal tundish was studied using both an experimental 1:2.5 hydraulic model and a numerical simulation of a 1:1 geometric model. The variation coefficient (CV) was defined to evaluate the flow uniformity of the seven-strand tundish. An optimized FCD configuration was proposed on the basis of the evaluation of experimental results. It is concluded that a turbulence inhibitor (TI) and U-type dam are essential to improve the uniformity of fluid flow in the seven-strand tundish. In addition, the configuration of inclination T-type dams with a height of 200 mm between the second and third strands and with a height of 300 mm between the third and fourth strands can minimize the proportion of dead zone. After optimizing the configuration of FCDs, the variation coefficient reduces below 20% of the mean value, and the average proportion of dead zone is just 14.6%; in addition, the temperature fluctuation between the strands could be controlled within 0.6 K. In summary, the uniformity of flow and temperature in the seven-strand tundish is greatly improved.     

湍流抑制器对中间包钢液流动的影响

采用水模拟试验研究湍流抑制器对中间包钢液流动特性的影响。结果表明,拉速变化时单层湍流抑制器对钢液流动影响程度较小,双层湍流抑制器能延长包内钢液平均停留时间;液位变化时双层湍流抑制器对钢液流动影响程度较小,相同液位下双层湍流抑制器使钢液在中间包内平均停留时间较之于单层湍抑器相应值至少增加20s;3种湍流抑制器对中间包流场的改善程度从大到小排序为:双层湍流抑制器,八角形湍流抑制器,单层湍流抑制器。     

非对称两流中间包内流体流动的对称化

采用数值模拟和水模型实验相结合的方法研究了不同控流方案下非对称两流中间包内流体流动行为,并将优化方案进行了工业实验.实验结果表明:采用经典组合方法计算各流的死区时,出现负死区现象,因此采用平均停留时间作为评价参数;原方案中靠近长水口侧出口的平均停留时间为194s,水口两流之间的平均停留时间之差为97s,两流之间钢液温度差为5℃.利用非对称长方形湍流控制器可以实现钢液在湍流控制器出口处流量的非对称分布.采用非对称长方形湍流控制器和多孔挡墙后,近长水口侧出口的平均停留时间为211s,水口两流之间的平均停留时间之差为34s,两流之间钢液温度差为3℃.     

Fluid flow in large-capacity horizontal continuous casting tundishes

The configuration of the tundish for a two-strand horizontal continuous caster was designed and optimized through water modeling. Three designs of the tundish were studied: the original tundish without any flow control devices, the tundish with a turbulence inhibitor at the bottom, and the tundish with an inlet launder and an inclined dam. The residence time, the location and size of the dead zone, and the fluid field pattern were investigated. At the same time, the asymmetry flow field and wavy inlet jet in the horizontal tundish were observed and the reasons for them were discussed. The results indicate that the tundish with an inlet launder and an inclined dam is the best of the three designs.     

Numerical investigation of the effect of transitory strand opening on mixing in a multistrand tundish

In a multistrand, the outlet near the inlet produces short circuiting flow. This leads to the formation of dead zones inside the tundish, and consequently, the mean residence time decreases. In the present study, numerical investigation of mixing inside a delta shaped tundish with sloping boundaries was carried out by solving the Navier-Stokes equation and employing the standard turbulence model. To decrease the dead zone volume inside the tundish, the effect of closing the outlet near the inlet for a small amount of time and further opening it on the mixing behavior of the tundish was studied. The outlets near the inlet were closed for varying amount of time, and the transient analysis of fluid flow and the tracer dispersion study were carried out to find the mixing parameters of the tundish, namely, mean residence time and the ratio of mixed to dead volume of the tundish. An optimum closure time of the near outlet has been found, which yields best mixing inside the tundish. The numerical code was validated against the experimental observation by performing the tracer dispersion study inside a multistrand tundish and the reasonably good match between the experimental and numerical results in terms of residence time distribution (RTD) curves. The results obtained from the present study confirm the strong role of choosing the right time for opening and closing the outlets to get improved characteristics for the fluid flow and mixing behavior of the tundish. The educational version of computational fluid dynamics (CFD) software PHOENICS was used to solve the governing equations and interpret the results in different forms.     

Optimization of flow control devices in a single-strand slab continuous casting tundish

The optimization of flow control devices in a single-slab continuous casting tundish was carried out by physical modeling, and the optimized scheme was presented. With the optimal tundish configuration, the minimum residence time of liquid steel was increased by 1.4 times, the peak concentration time was increased by 97%, and the dead volume fraction was decreased by 72%. A mathematical model for molten steel in the tundish was established by using the fluid dynamics package Fluent. The velocity field, concentration field, and the residence time distribution (RTD) curves of molten steel flow before and after optimization were obtained. Experimental results showed that the reasonable configuration with flow control devices can improve the fluid flow characteristics in the tundish. The results of industrial application show that the nonmetallic inclusion area ratio in casting slabs is decreased by 32% with the optimal tundish configuration.     

钢液精炼和连铸过程中物理去除夹杂物现状及展望

夹杂物去除是钢液精炼的重要任务之一。目前与去除夹杂物相关的工艺方法主要有:钢包-电磁搅拌和钢包底吹氩;RH及RH侧底复吹;中间包-控流装置、气幕挡墙和通道电磁感应加热;结晶器电磁搅拌与电磁制动和水口吹氩。本文总结了钢水精炼中各个反应器去除夹杂物的方法和机理,并分析了影响夹杂物去除效率的主要因素,为钢水二次精炼的夹杂物去除工艺优化提供理论依据和参考。     

连铸中间包内夹杂物去除行为的物理模拟

通过选择乳状液滴模拟夹杂物和连铸中间包物理模型实验,考察了换钢包过程中,中间包初始液面高度、长水口注入流量及控流装置对中间包内夹杂物去除行为的影响规律.结果表明:中间包初始液面高度从工作液面的1/4到3/4过程中夹杂物去除率提高较快,3/4工作液面为较理想的换钢包操作液面;夹杂物的去除率随长水口注入流量的增加而增大,注入流量超过2.5m3h-1时,夹杂物去除效果明显改善;挡墙挡坝组合控流装置的去夹杂效果较无控流装置有明显改善,在此基础上加入抑湍器后,去夹杂效果明显改善.     

Improvement of tundish shape and optimization of flow control devices for sequence casting heavy steel ingots

The metallurgical effect of a round tundish used to cast heavy steel ingots in machine works at present was evaluated through water modeling experiments. The flow control devices of the improved oval tundish, which was used instead of the round tundish, had been optimized. The results show that the residence time of the round tundish is short, its inclusion removal efficiency is too low, and it has more dead zones and an unreasonable flow field. Compared with the round tundish, the improved oval tundish with the optimized weir and dam has a better effect:its minimum residence time is prolonged by 38.1 s, the average residence time is prolonged by 233.4 s, its dead volume fraction decreases from 26% to 15%, and the ratio of plug volume fraction to dead volume fraction increases from 0.54 to 1.27. The inclusion removal efficiency also increases by 17.5%.     

70吨钢包底吹氩水模拟分析

对某钢厂70 t LF底吹氩精炼钢包建立了相似比为1∶3的物理模型,在全面考虑LF钢包的结构特点和工艺合理性的基础上,确定了3个径向方向上可供选择的9个吹氩孔。实验研究了吹氩流量、吹氩孔的位置、个数和相对分布对钢包混匀的影响。结果表明,在较小流量范围内,混匀时间随流量增加降低明显,流量增大到400 L/min左右和更大时,混匀时间的变化趋于平缓;相同流量下,透气砖个数由一个增加到两个并没有起到改善钢包混匀的效果;在原有0.55R透气砖位置基础上向外移动到0.67R处,能获得相对最好的钢包混匀效果。