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Definition of Steel

Principles of Clean Steel Production z Steel is a metallic material which consists


primarily of the element iron (Fe)
From Furnace to Mould
z The metallic elements are those which can
join together to form a block of material in
An Overview which the outer electrons are free to jump
from one atom to another

L.J. Heaslip
Atomic
J.D. Dorricott Arrangement
Examples
SOLID LIQUID

The Periodic Table of


Definition of Steel (Cont
(Contd)
the Elements
Inert
Metalloids Non-Metals
Metals Gases

z Steel is a mixture of elements (i.e. an alloy) -


iron is always the principal ingredient of steel
- but many other elements can be added
z Carbon (C) is one of the most important
ingredients of steel
z The higher the carbon content steel is
harder and stronger, but less ductile

Common Elemental Constituents


Definition of Steel (Cont
(Contd) of Steel - Categorized

z There are many categories or classes of steel ALLOYS DEOXIDIZERS RESIDUALS GASES

alloys: plain carbon steels, alloy steels, C (carbon) Si^ (silicon) S (sulfur) O (oxygen)
HSLA (high strength low alloy) steels, free- Mn (manganese) Al (aluminum) P (phosphorus) N (nitrogen)
V (vanadium) Ca* (calcium) Cu (copper) H (hydrogen)
machining steels, stainless steels, etc. Mo (molybdenum) Mg* (magnesium) Zn* (zinc)
Cr (chromium)
Ni (nickel)
z specific grades of steel often have stringent Ti (titanium)
chemical specifications Zr (zirconium)
B (boron)
Nb (niobium)
z The majority of steels manufactured contain * Very limited solubility in liquid steel
^ Silicon deoxidation is usually enhanced with manganese
more than 97% Fe by weight (i.e., contain
less than 3% total of other elements)
Role of the EAF in Steel
Temperature of Liquid Steel
Production
z Steel melting in an EAF allows multiple types of iron units
in many forms and qualities, such as; steel scraps z Pure liquid iron solidifies at approx. 2800 F
(bundled, shredded, turnings, etc.) DRI (pellets, and/or (1538 C). The addition of other ingredients
briquettes), pig iron and iron carbide: such as carbon reduces this temperature called
1. to be formed into a homogeneous metal mass (the
molten steel bath), and
the liquidus temperature (the temperature at
2. to be chemically refined (i.e. adjusted in chemistry
which the liquid steel begins to solidify).
from an often unknown or highly variable state to a
known, controlled, and desirable condition)
z The superheat of the liquid is the number of
z Subsequently, the steel can be further adjusted by
deoxidation and alloying to meet product chemical degrees by which the temperature of the molten
specifications and then cast into a semi-finished shape metal bath exceeds the liquidus temperature.
(billet, bloom or slab) suitable for further processing into
primary steel products (bars, coils, sheets, etc.)

The Iron - Carbon Characterization of


Phase Diagram Liquid Steel
z Dense - Hot - Reactive - Inhomogeneous
Max. C
content z Liquid steel is a dense liquid. Density is generally
of steel the range of 435 lb/ft3 (7 MT/m3) (approx. 7 times
greater than water)
Austenite
z Liquid steel rapidly radiates heat and yellow-white
light and will cool rapidly if it is not insulated
z As it cools, liquid steel becomes denser and
temperature stratification of a steel bath occurs
readily
Stirring of a steel bath is absolutely necessary to
obtain a uniformity of temperature and composition

Characterization of Critical Role of Oxygen in the


Liquid Steel (Cont
(Contd) Chemistry of Steelmaking

z Oxygen (O) readily combines with iron and many


z High Temperatures and High Chemical
other elements
Reactivity:
z Varying the chemical potential of oxygen is how
difficult to control liquid steel chemistry. iron and steel are made
Liquid steel is an excellent reactive solvent
Iron is naturally and most commonly found in the
(it readily reacts with, erodes, corrodes and Earths crust as an oxide (Fe2O3, Fe3O4)
dissolves its environment).
Oxygen is the principal refining agent in EAF
clean, chemically-stable, refractories and steelmaking
slag covers are essential in the control of Slag is formed by the combination of Fe and other
liquid steel chemistry metallic elements with oxygen to form oxides and
by the combination of these oxides with other
added oxides such as lime (CaO)
Critical Role of Oxygen in The Environment of
Steelmaking Chemistry (Cont
(Contd) Liquid Steel

Oxidation reactions are a very important fuel Steelmaking depends upon the control
(energy source) and thus oxygen usage can of the liquid steel environment
reduce the electrical energy consumption of the
EAF
The control of oxide inclusions or dirt in the steel
is essential for control of castability and in clean
steel production
z For all of the above reasons, oxygen is the The liquid steel bath reacts with each phase it
critical and controlling element in steelmaking contacts and the control of oxygen in each of
chemistry these phases is essential

The Chemical Stabilities


Solute Interactions
of Oxides
-25
Oxide Stability Increasing

2Cu2O
Free Energy of Formation (Kcal)

-75
2CO
2FeO

-125
2/3Cr2O3

2MnO
2NbO
-175 2VO
SiO2

2TiO
ZrO2
-225 2/3Al2O3

Oxygen control is essential in the control of 2MgO

2CaO
many other solute residuals in steel -275
500 700 900 1100 1300 1500 1700
Temperature (Deg. C)

Properties of the Properties of Slag and Refractory


Refractory Oxides Fluxing Components

MELTING DENSITY
OXIDE POINT (OC) (g/cm3)

Al2O3 2040 3.9


CaO 2560 3.3
Cr2O3 2400 5.2
MgO 2800 3.6
SiO2 1710 2.3
TiO2 1850 4.3
ZrO2 2715 5.6
Role of Oxygen in The Oxygen Map of Ironmaking
Steelmaking Chemistry and Steelmaking
Fe2O3, Fe3O4

HIGHER
z the most reactive forms of oxygen are: iron ore ~ 30 wt% O
oxygen gas (02)

Reduction Direction
oxygen in slag as iron oxide (FeO)

Oxidation Direction
O @ tap 3.
oxygen dissolved in liquid steel (O) 1. Blast

POTENTIAL
depends on C
Deoxidation Furnace

OXYGEN
& Alloying Ironmaking
each of these forms of oxygen is necessary and
desired for steelmaking refining, but precise 4.
control and reduction of active oxygen in the Reoxidation
Final O Ladle O

LOWER
steel and its environment is necessary when depends on deox. level
final chemistry is being reached and when steel 2. Steelmaking (typically 1 to 50 ppm)
BOF or EAF
cleanliness and castability' are determined
Steelmaking Pig Iron & Scrap
Charge 1-5 ppm O

Electric Furnace Basic Oxidizing Slag


Steelmaking (Basic Electric Arc Furnace Slag)
z Steelmaking is an OXIDIZING PROCESS z Lime (CaO) acts as a strong base in slag, while silica (SiO2) and
The furnace is primarily charged with iron units, lime (+MgO), and alumina (Al2O3) are common acidic slag ingredients. Silica and
alumina are contaminants in the charge or formed by oxidation of the
Carbon.
charge. Basic slag contains sufficient lime (CaO) such that it can
ELECTRICAL ENERGY IS INTRODUCED by arc discharge. neutralize and absorb the acid oxides.
A LIQUID METAL BATH FORMS which homogenizes the z A useful measure of the basicity of EAF slag is the ratio:
physical form of diverse types of iron units. %CaO
Basicity of EAF Slag (BEAF)=
OXYGEN GAS IS INJECTED into the furnace for chemical (%SiO2 + %Al2O3)
refining and to provide chemical energy (reducing electric
consumption). z Oxidizing slag contains iron oxide (FeO). Oxidized EAF slag will
MOLTEN SLAG FORMS that covers and insulates the metal bath generally have FeO levels in the range of 25% to 50%.
and collects the non-metallic products of oxidation. MgO (or dolomite) is often added to the furnace to raise the MgO

object is to form a highly oxidized liquid


content of EAF slag to reduce erosion of the furnace refractory.
The
Thus, typical EAF slag principally contains CaO, FeO, SiO2,
steel bath covered by basic oxidizing slag Al2O3, and MgO, and has a BEAF in the range of 1.8 to 3.0

Injection of Oxygen Oxidation Refining

z Oxygen and oxygen/carbon injection are essential z O2 gas, O , and FeO react with elements in the
components of EAF steelmaking: charge additional heating, aiding slag
to provide chemical energy and thus reduce KWH/ton forming and slag foaming, and providing
oxygen for refining reactions.
to oxidize slag (forming FeO) and oxidize the metal, thus
providing oxygen to remove elements from the metal Oxidation refining includes: removal of Al, Si,
having an affinity for oxygen (Al, C, P, Si, etc.) Ti, Ca, and P from the metal into the basic
to rinse the steel of undesired gases (H and N) oxidized steelmaking slag.
For example, aluminum and silicon removal:
to form CO gas to foam the slag, and thereby better
protect the bath from undesirable gases, stabilize the Si + 2O (SiO2)
arc, and protect electrodes and refractories from wear. 2Al + 3O (Al2O3)
Energy Benefit of
Oxygen Injection The Carbon Boil

REACTIONS THE CARBON BOIL REACTION


Fe + 0.5 O2 FeO HEAT RELEASED=0.17 KWH/SCF OXYGEN
C + O CO(g)
C + 0.5 O2 CO HEAT RELEASED=0.08 KWH/SCF OXYGEN

TYPICAL RESULT OF OXYGEN USAGE:


z The dissolved carbon content of liquid steel is
related to the dissolved oxygen content as a
HEAT RECOVERY IN EAF = 0.06 - 0.125 KWH/SCF OXYGEN
result of the carbon boil reaction.
EXAMPLE OF THE ENERGY EFFECT OF OXYGEN USAGE :
z As dissolved oxygen in steel increases,
WITH 800 - 1250 SCF OXYGEN/TON dissolved carbon is removed. Therefore, the
ELEC. POWER CONSUMPTION REDUCED BY 50 - 125 KWH/TON
higher the dissolved oxygen, the lower the
dissolved carbon and vice-versa.

Relationship between Carbon & Oxygen Influence of the


Dissolved in Liquid Steel Carbon Boil
2000

Carbon Boil Reaction at Equilibrium


z The carbon boil removes carbon and helps rinse-out
1600 C + O CO(g) nitrogen and hydrogen from the steel. The carbon
O dissolved in steel vs. C dissolved in steel boil reactions occur as follows:
Oxygen (ppm)

1200
PCO = 1 Atmosphere O2(g) 2O - Oxygen gas dissolves into the steel.
Temperature = 1600 Deg. C
C + O CO(g) - Then Carbon and Oxygen in the steel combine to
form CO gas which bubbles out of the steel.
800
- This helps foam the slag and remove Hydrogen and
Nitrogen which are carried out in the CO bubbles
400
z The carbon/oxygen relationship indicates that the
oxygen content of steel when the melt is ready for
0
0 0.05 0.1 0.15 0.2 0.25 0.3 tapping is generally determined by the carbon level ,
Carbon (Wt.%) but:

Influence of the Carbon


Functions of EAF Slag
Boil (Cont
(Contd)

Oxygen can be even higher than the range z Cover the Bath insulate the steel bath to
expected from the C/O relationship because reduce heat loss
slag/metal/gas equilibrium is not obtained in the
FOAMY SLAG

furnace. z Clean the Steel Absorb oxidation products


from the steel, Al2O3 , SiO2 and P2O5
The lower the carbon at tap, the higher the FeO in
the slag. z Cover the Arcs transfer heat to bath
protect lining, sidewalls & roof from arc flare
Stirring of the metal in the furnace: can improve
iron yield, and improve chemical and thermal z Protect the Steel from the pick-up of
homogeneity in the furnace. undesired gases (H and N)
EAF Slag Fluidity Foamy Slag & Fluidity

The Balanced Slag se


a
ph
nd
e co cl es
s i
re part
Mo

Slag Foaming
Performance
Balanced

Crusty
Watery

Crusty Watery
Apparent Slag Viscosity

Phase Diagram for


EAF Slag Deoxidation and Alloying

z Liquid Steel is normally deoxidized


CaO to control alloy recoveries
SiO2+Al2O3=2.5 Ideal Range: to prevent blowholes & pinholes in the cast
balanced for product
good foaming
Balanced over wide
range of FeO
z This is a reducing process and requires
EA

- saturated in
reducing slag (lower in FeO)
F
Sl

MgO for good


ag

refractory to protect the steel from oxygen


compatibility
to absorb the non-metallic particles produced by
After E.B. Pretorius and
R. Marr
deoxidation

Deoxidation Deoxidation Equilibria

z raising the quantities of Si or Si+Mn or Al in the steel


so that O will be removed.
z eg. Aluminum killing
Al(metal) Al aluminum dissolves into the steel
2Al + 3O Al2O3 aluminum oxide (Al2O3, alumina) appears
as solid particles suspended in the steel

z deoxidation and alloying are generally most


efficiently done in the ladle under basic reducing slag
z oxidized furnace slag entering the ladle should be
minimized
Figure: after Turkdogan
Contact Angle between Liquid Typical Contact
Steel and Non-
Non-Metallic Angles

Schematic of Liquid Steel Droplet in


Contact with a Solid Oxide Non-Metallic
Not-Wetting Wetting
High Contact Angle Low Contact Angle

Contact Angles affect Castability (Nozzle Higher contact angles imply an increased potential for
Clogging Potential of Oxides in Liquid Steel) sticking of the oxide inclusion to refractory surfaces

Lime Alumina
Phase Diagram Reoxidation

z the pick-up of oxygen by liquid steel after


deoxidation
z can be very detrimental to the production of a
clean quality product
z can cause large particles or droplets of dirt
z the closer the steel is to the mold when
reoxidized the more serious the problem of
inclusion pockets in the cast product

Levitation Melting Experiment


Experiment Reoxidation of Liquid Steel
Oxygen Pickup by a Steel Droplet Exposed to Air

Video:
Reoxidation of
Steel Droplets
and Steel Streams
Oxygen Pickup by a Comparison of Deoxidation and
Falling Steel Droplet Reoxidation Inclusions

After Greenberg and


McLean After Farrel, Bilek and Hilty

Residuals - Copper Residuals - Phosphorus

z P can be refined from the steel in the furnace by


z Cu can be a major problem in certain oxidation - P2O5 is an acid that dissolves readily in
steels basic oxidizing slag to form (4CaO.P2O5)
z P removal is favored by:
z Cu can not be refined from a steel
Oxidizing conditions
melt by oxygen
High slag basicity
z Cu in the furnace charge will therefore
Low temperatures
report as Cu residual in the steel
z carry-over of furnace slag containing P into the
ladle can cause P to revert into the metal when
reducing conditions are applied

Basic Reducing Slag


Residuals - Sulfur (Ladle Metallurgy Slag)
z Silica (SiO2) is an acid Lime (CaO) is a base. Basic
z Sulfur is most effectively refined and slags must contain more lime than silica.
removed from steel under basic z Basic slags have the potential to clean the steel by:
reducing slag Absorbing acid deoxidation inclusions from the
S + ( O2- ) ( S2- ) + O steel such as aluminates (inclusions containing Al2O3)
and silicates (inclusions containing SiO2)
z for each unit of sulfur removed by basic
slag, one unit of oxygen enters the steel Removing sulfur (S) from the steel
z Reducing slags are ones which will not contribute
for the reaction to go to low sulfur levels oxygen to the liquid steel and thus have a low content of
it is necessary to continually remove the FeO and MnO (typically reducing slags FeO+MnO 5%)
oxygen from the steel by deoxidation z To reduce refractory erosion, basic reducing slags
require a basic refractory slag-line in the ladle (MgO-C or
Dolomitic Refractories are typical for ladle slag-line)
Ladle Metallurgy Furnace Basicity of Slag
z Slags are Ionic Mixtures >>> The ionic form of the oxygen in
the slag is a determining factor of the chemical and physical
behavior of the slag
z Oxygen ions in the Slag are present in three forms

OF THE SLAG
INCREASING

INCREASING
O2- - free oxygen ion

ELECTRON

BASICITY
POWER
DONOR
O1- - terminal oxygen ion =
O0 - bridging oxygen ion
First Topics:
z The type and relative quantities of the cations in the slag (Ca2+,
Ladle Slag &
Ladle Slag-Line
Si4+, Mg2+, etc) govern the relative proportions of the three
Refractory forms of oxygen anions in the slag
For Clean Steels z The amount of free O2- ions in slag is the fundamental
measure of slag basicity and is related to Optical Basicity
Basicity

Desulfurization of
Optical Basicity Liquid Steel by Slag
z DEFINITION >>> z Sulfur is most effectively refined and removed from
steel under basic reducing slag
Electron Donor Power of the Slag
= z The reaction is: [S] + ( O2- ) ( S2- ) + [O]
Electron Donor Power of CaO
z for each unit of sulfur removed by basic slag, one
z CALCULATION >>> unit of oxygen enters the steel
for the reaction to go to low sulfur levels it is
Optical basicity values for the many oxides that are necessary to (1) provide sufficient basic reducing
found in slag can be found in a table and then a slag, to (2) stir the slag and the metal, and also to
tedious but simple calculation is performed: (3) maintain low dissolved oxygen levels in the steel
by good deoxidation
x1n11+x2n22+x3n33+..
Where:

= X1= mole fraction of oxide component 1


Note: [ ] means dissolved in liquid steel
x1n1+x2n2+x3n3+.. n1= # oxygen atoms per molecule of component 1
( ) means dissolved in molten slag
1= optical basicity of component 1

Sulfur Removal
Equilibrium Slag/Metal Sulfur Partition
z The equilibrium partitioning of sulfur between the
slag and the liquid steel is governed by the sulfur
capacity of the slag CS, the chemical activity of
dissolved oxygen in the steel aO, and the absolute
temperature T (K).
(S) 770
[S] = log CS - log aO + 1.3 - T
log
(S) is the sulfur content or activity in the slag
[S] is the sulfur content or activity in the metal

z Thus, the removal of sulfur from the steel requires


slag of high CS and steel with low oxygen content.
Prediction of Slag/Metal Basic Reducing Slags Saturated in
Sulfur Partition both CaO and MgO

z The sulfur capacity of the slag CS is determined z Ladle slags should be saturated in CaO to
by the slag chemistry. Optical basicity of provide the desired conditions for clean steel
slags has shown good correlation with CS. A production.
useful equation to determine CS using optical z Ladle slags should also be saturated in MgO
basicity () is as follows: to reduce the erosion of the ladle slag-line
refractories.
22690 54640.
Log CS = + 43.6. - 25.2 z Ladle slags should have a balanced fluidity
T
not-crusty and not-watery. Crusty slags will
is the optical basicity of the slag not absorb inclusions or sulfur and watery slags
attack refractory and can become emulsified in
T is the absolute temperature (K)
the liquid steel.

Ladle Slag Phase Diagram - CaO & MgO Saturated


CaO and MgO Saturation Basic Reducing Ladle Slags
%CaO 46.7 49.5 52.2 54.9 57.1 58.0 This diagram shows
SiO2
CaO-SiO2-MgO %SiO2 32.4 27.0 21.6 16.2 10.2 4.9 ladle slag compositions
%MgO 15.9 13.5 11.2 8.9 7.7 7.1 that have balanced
Phase Diagram Dual (CaO & MgO)
%Al2O3 5.0 10.0 25.0 30.0
Saturation Point 15.0 20.0
at 1600C fluidity and are both
0.712 0.727 0.743 0.759 0.777 0.791
%CaO 43.9 CaO & MgO saturated at
%SiO2 37.9 1600C.
Liquid Slag %MgO 18.2
Region
%CaO, %SiO2 & %MgO
are dependant on the
%Al2O3 in the slag.
CaO
Saturation O Si Optical basicity () of
O
MgO Ca 2
Line these slags increases as
Dual Saturation MgO Al2O3 increases. At
Point Moves as Saturation =0.71 the desulfurizing
Shown if Al2O3 Line
is Added
potential of the slag is
low, while at =0.78 the
CaO MgO
desulfurizing potential is
high.

CaO & MgO Saturated


Basic Reducing Ladle Slags Gases

z H can cause pinholes, blowholes, and


cracks in castings differences as small
as one ppm can have a substantial effect
z water vapor is the major source of H in steel
H2O(g) 2 +
z oxygen level affects hydrogen solubility
when O is high H is low
Appropriate for Si-killed steels Al-killed steels basic furnace slag can absorb water
But, weak de-S potential Good de-S potential
Potential for Spinel-type inclusions if this slag enters the ladle, H increases
Avoid De-Ox-Impregnated slag-line refractories
Effect of Oxygen on
Nitrogen Pick-
Pick-up in the EAF
Nitrogen Pick-
Pick-up

N pick-up is N pick-up is
enhanced by arcing hindered by foamy
After Greenberg and
McLean on a flat bath slag

Nitrogen Removal in the EAF Conclusion


The above presentation has provided a brief introduction to the
chemical metallurgy of modern steelmaking, including:
definition of the chemical nature of steel and the
characterization of liquid steel as a reactive metallic material
consideration of the critical role of oxygen and oxide
compounds in steelmaking chemistry:
the oxygen map of iron and steel production
the oxidation state of the liquid steel environment
oxygen refining, oxygen injection, carbon/oxygen
equilibria, and the making of basic oxidizing slag for the
electric arc furnace
deoxidation& alloying of steel and potential for subsequent
reoxidation
Nitrogen removal Nitrogen removal is
residual elements in steel - copper, phosphorus, and sulfur
is inhibited by flat enhanced with foamy
ladle metallurgy and basic reducing slags
bath conditions slag and carbon boil
gases in steel hydrogen and nitrogen

Ladle Stirring Water Modeling Methods

This presentation will concentrate on the A ladle of water was used to simulate a ladle
understanding of ladle stirring by inert gas filled with liquid steel
bubbling
Typical Height/Diameter Ratio of a ladle
A non-isothermal physical modeling is ~1.1 to 1
approach has been developed that allows
observation & characterization of ladle mixing at 1:1 scale = 13 MT ladle
by gas bubbling at 1:2 scale = 105 MT ladle
Influence of thermal effects on stirring at 1:3 scale = 360 MT ladle
performance is investigated
Appearance of Isothermal
Water Model Design Bubbling with One Stir Plug

Model Assembly Model Ladle 1 2 3

Side
Views

Up to
4 de
g.
Top
View

Isothermal Stirring by Flow Pattern of Isothermal


Gas Injection Ladle Bubbling

Bubble pile-up occurs at the leading end The bubble column rises
of the bubble column nearly vertically, but
Liquid inertia retards rise of leading with occasional swaying
bubbles toward wall and back
Following bubbles move quickly into the The top eye of the
wake of leading bubbles bubble column washes
Expected relationship: tm Q 1/3 the nearest ladle wall
Mixing time is inversely proportional A general overall
to the cubed root of the gas flow rate circulating flow pattern is observed.

Non Isothermal Stirring by Water Model


Gas Injection Thermal Simulation
Simulation of Initial Thermal Stratification
Simulation of an Initial Thermal Stratification
Ladle first filled to 1250 mm level with
cold water (8 to 10 oC). Before
stirring is
Thin plastic film placed over cold water. started the
colored hot
Hot water (48 to 54 oC) is used to fill upper water sits
part of the ladle to the 1420 mm level. quietly on
top of colder
Plastic film is removed causing negligible clear water
stirring.
Non-Isothermal
Stirring Flow Pattern Descent of warm colored fluid

Descending mixing Warmer Layer


column
surrounding the
rising bubble plume
Descending Plug
Flow Front

Upward pumping of Colder Layer


cold liquid by rising
bubble column

Non Isothermal Stirring by


Gas Injection Ladle Stirring - Results

During the removal of the thermal gradient 2.7

Cold liquid is carried upward within the bubble 5.4min


Stirring with Single Plug in Ladle Model
2.5
Log of Mixing Time - log(s)

column & mixes with hotter fluid layer above


2.3
A pulsating region of descending fluid is seen Non-Isothermal
2.3min
to tightly surround the rising bubble column 2.1
Critical Gas Flow
= ~50 l/min
Over the remainder of the ladle cross section - 1.9 Isothermal
warm fluid slowly descends in a nearly level tm Q 1/3 1.1min

1.7
front forming a downward plug flow -4.3 -4.1 -3.9 -3.7 -3.5 -3.3 -3.1 -2.9 -2.7

Log of Stir Gas Flow - log(cubic m/s)

Critical Stir Plug Gas Flow Rates for Ladle with Two or More Stir Plugs
Different Ladle Sizes Non-Isothermal Stirring Flow Pattern

Ladle Critical Gas


Ladle Critical Gas If stir plugs are more than 1.5
Capacity Flow
Scale Flow (l/min)
(metric T) (SCFM) bubble column diameters
1.00 13 50 1.9 apart, then each plug
1.25 26 87 3.2 Warmer Layer generally acts as an
1.50 45 138 5.1 independent pump that
1.75 70 203 7.5 conveys cold liquid upward to
2.00 105 283 10.5
mix with the warmer liquid
2.25 150 380 14.1 Very high ~2X One Plug
2.50 210 494 18.3 flows for one above. Thus two bubblers,
2.75 280 627 23.2 stir plug each at the same flow, are
3.00 360 779 28.9 Colder Layer approx. twice as effective at
achieving thermal
Critical Gas Flow is the flow required through a single stir
uniformity as a single
plug to overcome the non-isothermal conditions applied and bubbler at the same flow.
achieve relatively uniform mixing throughout the ladle.
Stir Plug Requirements Stir Plug vs. Stir Rod

Plug The stir plug is much


Ladle Critical Gas One Plug
Two Plug
Two Plug
Three Plug
Three Plug
Rod
Capacity Flow Mix Time
Gas Flow
Mix Time
Gas Flow
Mix Time Required # of Stir Plugs
more effective at
(SCFM (SCFM
(metric T) (SCFM) (min)
each)
(min)
each)
(min) pumping the cold fluid
13 1.9 1.1 1 off of the ladle bottom.
26 3.2 1.2 1 Warmer Because the rod does
45 5.1 1.4 1 Layer not reach all the way to
70 7.5 1.5 1
105 10.5 1.6 6.0 1.4 1 is OK, 2 are Better the bottom and since
150 14.1 1.7 7.5 1.5 2 gas bubbles have
210 18.3 1.8 10.0 1.6 7.5 1.4 2 are OK, 3 are Better
280 23.2 1.9 9.0 1.5 3
difficulty fully
360 28.9 2.0 10.5 1.6 3 detaching from rod,
particularly at the rod
Multiple stir plugs should be separated on the ladle
tip, a rod is not as
bottom by at least the max. bubble column diameter,
efficient a stirrer as a
estimated from 200mm (Max. SCFM/plug)0.33
stir plug.

Critical Stir Gas Flow Rates


Ladle Bubbling - Results Stir Plugs vs. Stir Rods
2.7

Stirring with Single Plug vs. Rod in Ladle Model These very high
Ladle Capacity
Critical Gas Flow (SCFM) gas flow rates
2.5 (metric T)
Log of Mixing Time - log(s)

Rod- indicate that it is


Non-Isothermal very difficult to
2.3 Plug-
Stir Plug Stir Rod achieve adequate
Non-Isothermal 3.0min
Rod- stirring in ladles
Isothermal 13 1.9 2.5
2.1 of 150T and
2.0min 26 3.2 4.4
larger with a
45 5.1 6.9
Plug- 1.5min 1.5min @ stirring rod
1.9 70 l/min 70 7.5 10.1
without severe
21 liter/min

Isothermal
1.1min @ 105 10.5 14.1 slag line
50 l/min
150 14.1 19.0 turbulence and
1.7
-4.3 -4.1 -3.9 -3.7 -3.5 -3.3 -3.1 -2.9 -2.7 210 18.3 24.7 opening of the
Log of Stir Gas Flow - log(cubic m/s) 280 23.2 31.4 slag cover.
360 28.9 39.0

LIQUID STEEL BEHAVIOR


DURING CONTINUOUS CASTING Stages of Ladle Draining

Vortexing Angular momentum in the draining flow


Final Stages of and asymmetries in the ladle outlet
Ladle Draining position and in the shape of the ladle
bottom lead to vortex formation. Slag
entrainment severity increases as vortex
strength increases
Surface Finally when metal depth in the ladle is
Collapse sufficiently low, the surface of the bath
collapses and at this moment the metal
flow is overwhelmed by the slag flow
Steel Residual at Ladle
Shut-Off Yield Improvement

To prevent excessive slag accumulation in the The dumping of steel from empty ladles after
tundish and to maintain cast steel quality, continuous casting is an expensive yield loss that can
easily cost a steel plant more than $1Million annually.
the ideal moment of ladle shut-off is the instant
when the proportion of slag/steel in the flow Thus, it is highly advantageous to retard the
entrainment of slag in the steel flow from the ladle
exceeds acceptable limits.
until all or very nearly all of the liquid metal is gone
However, even when flow is stopped at Two phenomena must be retarded or delayed:
the ideal moment, a significant quantity of
liquid steel can remain in the ladle due to formation of the draining vortex
vortexing and surface collapse collapse of the liquid metal bath surface.
The residual quantity of steel in ladles is often in Both computational analysis (CFD) and
the range of 1 to 5 tons or more, depending on water modeling have been used to
ladle size and casting rate. understand ladle draining phenomena.

Water Model -General Water Model Results Effect


Observations of Ladle Draining Rate
150
Final Stages of
Ladle Draining 125

1- Early (Intermittent) Vortex 100


Occasionally Observed
75
at 150 to 100 mm depth remaining
25
2- Full (Steady) Vortex 100
Very Usually Observed
at 100 to 50 mm depth remaining 75
25
3- Surface Collapse (Slag Flush)
Occurs when the depth remaining 75
is between 75 to 25 mm
25
(depending on drain rate)

Water Model Video CFD RESULTS


Final Draining Stages 6.4TPM FLAT BOTTOM LADLE
Show Video 200mm Remaining 100mm Remaining
Velocity (m/s)
TILTED LADLE BOTTOM - Tilted Ladle Bottom
SCHEMATIC 4degree Example

100mm
150mm 100mm
There is a natural volumetric reduction
of 33% at 150mm metal depth
remaining, due to the increase of
refractory thickness in the ladle bottom

DETRIMENTAL EFFECT OF Tilted Ladle Bottom Compared


LADLE BOTTOM TILT to Flat Bottom
Velocity Contours: 150mm Depth - 4.5 TPM
Max. Size of Entrained Slag Particles

150mm m
0 0m
Depth 1
om
ott + 33% Flat Ladle Bottom
te dB
Til
tom
(microns)

Bot
Flat
Tilted Ladle Bottom

Higher velocities with tilted bottom promote vortexing and therefore


33% displaced volume gain is lost.

TILTING TOWARDS THE OUTLET IS NOT THE ANSWER


Draining Rate (TPM) NEW LADLE BOTTOM CONCEPT IS REQUIRED

Ladle Yield Loss Summary


6.0
Flat Bottom Ladle The factors influencing steel yield during the
M final stage of ladle draining have been studied:
TP
5
4.5 7. M
Residual Tons

5
to TP Water Modeling & CFD (Computational Fluid
5
to Dynamics) Modeling have both been used with
2.5
3.0 M good correlations being found.
5 TP
<2.
Ladle Draining has 3 final stages:
1.5
Early vortex Full Vortex Surface Collapse
The steel depth in the ladle when these stages
0.0 occur is dependant on the draining (casting)
1.5 2.0 2.5 3.0 3.5
rate and the ladle bottom design
Ladle Bottom Diameter (m)
Summary (Contd) Summary (Contd)
When the full vortex develops before the slag
surface collapses (slag flush), there is still A tilted ladle bottom adversely affects the flow
residual liquid steel in the ladle. pattern of the draining flow by enhancing
surface velocity above the outlet
This residual in a flat bottom ladle can range from
1 to 3 tons at low draining rates (~2.5 TPM) Thus a tilted ladle bottom displays greater
increasing to as much as 5 to 6 tons at high inclusion contamination of the draining liquid
draining rates (5 to 7.5 TPM) in large ladles. steel as compared to a flat ladle bottom at
equivalent metal depth
The early vortex can entrains inclusions into
A tilted ladle bottom is less beneficial than
the steel resulting in a degradation of steel anticipated by the volume of steel removed.
quality entering the tundish before large
quantities of slag are entrained and before
the ladle is closed

The ELBY Design


Objectives (Enhanced Ladle Bottom Yield)

Development of ladle bottom design that Terraced Shape


Form Drainage Channel
control final stages of ladle draining: Decrease Residual Steel
Trap Slag
Retard the onset of vortexing
Enhance yield

Examine new features of ladle bottom design


and examine methods of detecting and
Drainage Channel
responding to the ideal MOMENT for ladle gate Alter the Draining Flow
closure : Pattern & Control the Steel
Flow Path
Enhanced Ladle Bottom Yield - ELBY Retard Vortex Formation
Automated Ladle Closure - RADAR Increase Yield

ELBY Design Features Water Modeling of ELBY Design

135mm Remaining - 6.4TPM ELBY

Porous
Impact Area

Plug Area
Drainage
Channel Outlet
Area

Area Raised for


Ladle Draining

No Early Vortex - 50% Less Residual Steel than Flat Bottom at


Formation of Full Vortex and Surface Collapse
ELBY Ladle Bottom - CFD ELBY Principle

Velocity Contours: 150mm Depth - 4.5 TPM


A ladle bottom design for enhanced yield
(ELBY) has been developed.
The early vortex is avoided and steel quality
in the tundish at ladle exchange is improved
Full vortex and slag flush are delayed, and ladle
shut-off can occur at residual steel quantities
~50% lower than with a flat ladle bottom

GAINING VALUABLE YIELD


Reduced but controlled surface velocities with much less steel
left in the ladle when vortexing or slag carryover is
experienced.

Computer Modeling Predictions CFD Model of Ladle Bottom:


Flat Ladle two ladle draining through-puts were used for the
bottom - ladle computation, 3.0 and 3.5T/min. This through-put range is
outlet region typical of this continuous casting machine.

Close-up around outlet


Single Strand Slab
160 Ton Heat
1,600,000 T/yr
10,500 Heat/yr
48 min typ.empty High definition mesh, particularly
3.3 T/min typ. around outlet

Comparison of Predictions Computer Prediction Summary


with Actual Performance Flat Bottom
5.0 Early Vortex can start during ladle draining around
4.5
STANDARD FLAT LADLE 110mm over the outlet, depending upon flow condition and
BOTTOM 3 to 3.5 t/min
Steel Residual Weight (ton)

4.0 slag viscosity.


110mm of steel 4.5T of residual steel,
3.5 Shut-Offs

3.0
Full Vortex is expected to be observed when the steel level
2.5 reaches a height of around 85mm over the outlet.
Early Vortex

2.0 ~85mm of steel 2.75T of residual steel,


Range

Average
1.75T
1.5
Full Vortex

Surface Collapse is expected to be observed when the steel


1.0 Surface
Collapse level reaches a height of around 60mm over the outlet.
0.5
~60mm of steel 1.3T of residual steel,
0 Actual plant ladle closures averaged 1.75T residual, correlating to
0 25 50 75 100 125 150
Bath Depth Over Outlet (mm) predicted full vortex / surface collapse phenomena
Full Monolithic
GENERAL ELBY CONCEPTS ELBY Ladle Bottom USA Plant
Low High elevation
elevation
2 different concepts have been developed:

-monolithic bottom: Full ELBY,


-a bricked ladle bottom with a special precast
insert: Mini-ELBY

Medium elevation

Video of CFD Simulation - CFD Prediction of ELBY


ELBY Ladle Bottom Ladle Bottom Performance
7050 2100

7000 1800
Density of Outflow (kg/m3)

Liquid Steel Remaining (kg)


6950 1500

Prediction
6900 1200
= ~600 kg
at shut-off
6850 900

6800 600

ELBY Ladle Bottom


6750 3.5 ton/min 300

6700 0
Time

Yield Savings Precast Insert


Value to Steelmaker Mini-ELBY Bottom
4500
The new Mini-ELBY features:
Residual Steel (pounds) at slag flush

4000
-flat upper terrace,
3500 Pred.
Approx. 0.75T 3000
Current Bottom-CFD
of steel can be 2500 -intermediate terrace, part of
saved from 2000 the mini-ELBY piece
each ladle 1500

1000
Pred.
-CFD
500 ELBY
0
2 2.5 3 3.5 4 4.5 5 5.5
La dle Em ptying Through-Put in T/m in
-lower channel for
vortex prevention and
15,000 Heats/Year * 0.75T = 11250 Tons/year
surface collapse
11250 Tons * US$125/Ton = approx. US$1.4 M/Year delay.
OR ~55 free ladles (almost 2 days production)
CFD Modeling CFD Modeling
Predicted Results Baseline vs Mini ELBY

ELBY vs Mini-ELBY
1.4 Baseline vs Mini-ELBY
3 Intermittent
Early Vortex
1.2 Baseline
0.9T Vortex
ELBY
Steel residual weight in Ton

2.5

Steel residual weight in Ton


1 Strong Vortexing
Strong Vortexing 2

0.8 Early Vortex 0.6T Stable Vortex


Surface Collapse 1.5
Surface Collapse
0.6
1 Surface
0.4
0.5T Collapse
Mini-ELBY 0.5

0.2 Mini-ELBY
0
0 20 40 60 80 100 120
0
Steel level residual over outlet in mm
0 20 40 60 80 100 120
Steel level residual over outlet in mm

Mini ELBY Concept vs Baseline Mini ELBY Ladle Bottom


Yield Gain Prediction In Trial
Early Vortex:
Increase of yield with the ELBY by (2.3-0.9=) 1.4T

Stable Vortex:
Mini ELBY installed,
Increase of yield with the ELBY by (1.4-0.6=) 0.8T preheated, and ready for
service
Surface Collapse:
Increase of yield with the ELBY by (0.8-0.5=) 0.3T
The New Mini ELBY design concepts can reduce the
average steel residual in each ladle by 40% or more

Automated Ladle Shut-


Shut-Off R.A.D.A.R.
Slag Detection Ladle Slag Detection System

z Factors affecting ladle draining and slag


entrainment
KEY FACTORS:
ACCURATE DETECTION Depth Remaining Net Effect:
Draining Rate Each ladle
RAPID RESPONSE
Slag Condition and Fluidity drain is
Ladle Bottom Geometry: somewhat
SOLUTION: - Wear Profile unique.
AUTOMATED LADLE GATE CLOSURE SYSTEM - Slope
- Impact pad
R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System

z Terminology z Principle
R.A.D.A.R.: Rapid Monitoring the vibra-acoustic emission of
Analysis liquid steel flow from ladle to tundish yields
Detection signals directly related to:
And steel flow rate
Response
changes in flow behaviour which precede
the onset of slag entrainment, and slag
carryover, including vortexing

R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System
z General Equipment Schematic z Mittal Inland Inc. No.1 Slab Caster

1 Sensor
2 Sensor Signal
3 Preamplifier Module
4 Analysis Unit
5 Digital Data
6 Logic Unit
7 Status Signals
8 Operator Panel
9 Auto Valve Closure
10 Ladle Weight / Level Signal
11 Tundish Level Signal
12 Ladle Gate Valve Position

R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System
z Sensor Location z Sensor Detail
R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System

z System at Nucor Steel Hickman


z System Description
The sensor signal is filtered, amplified, and
processed continuously within the analysis
unit. The logic unit interfaces with caster
process variables such as ladle weight,
tundish weight and ladle gate position.

R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System

z Operator Control Panel / Features Operator On-line


Control Panel Level 2 System
Sequence Sensor
Ladle Gate
LED Display Perform Pour Box Controller
% Gate Open
Maintenance
Gate Shut Off Horn Gate Shut Off
Set Gate Position Amplifier/
Slag Warning
Turn On System Conditioner Gate Position
System
Off On Closure Control 5 Second Calibration CONTROL UNIT
Operator System
Vortex Alarm Horn Detecting Detecting Light On
Slag Warning / Vortex Analysis Unit
Vortexing Light / Horn
Ladle Weight
Sensitivity Calibrating
Auto High Normal Shut Off Light / Horn
Reset Ready Operator Closes Gate Display Keyboard/
Or System Closes Gate Monitor Mouse Tundish Weight

R.A.D.A.R. Cumulative Frequency Distribution of slag alarm times


for RADAR system compared to electromagnetic
Ladle Slag Detection System system (181 heats)

Vibra-acoustic vs Electromagnetic
100%
z
90%
ELECTROMAGNETIC SYSTEM
ALARMED FIRST
80% 13.3% of time

; ThyssenKrupp Stahl AG, Germany 70%


Percentage of Heats take (%)

60%

Bruckhausen Works 50% RADAR SYSTEM SYSTEMS TIED 7.7% OF TIME


ALARMED FIRST
2 strand slab 40% 79% of time

30%

20%

Trial successfully completed June 2002 10%

0%
-20 -15 -10 -5 0 5 10 15 20
Time (seconds)
Cumulative alarm times of RADAR and
Electromagnetic systems compared to visual slag SLAG DETECTOR COMPARISON
(119 heats) Detection Capability
10
100%
9
90% Steel Residual in
Only vibra-
8 Ladle
acoustic can

Steel residual weight in Tons


80%
Current Slag
70%
For 25 of 119 heats (21%) the electromagnetic
7
Detector detect the early
Percentage of visual slag heats

system alarmed after slag was visually observed


60%
6 RADAR vortex
5
50% RADAR
electromagnetic
4

Collapse
40%

Surface

Early Vortex
Full Vortex
30% 3
0 seconds = visual slag
20% 2

10%
1

0%
-20 -15 -10 -5 0 5 10 15 20
0
Time (seconds) 0 50 100 150 200 250
Steel head over outlet in mm

Summary Summary

A ladle bottom design for enhanced yield An automated ladle gate closure system has
(ELBY) has been developed been developed
This design incorporates a terraced shape with This design utilizes vibra-acoustic sensing
drainage channel technology
The ELBY design alters the draining flow pattern The system detects the onset of vortexing and
so as to control the steel flow path and reduce can be programmed for optimized sensing of the
sub-surface velocities to alleviate vortexing ideal moment for ladle gate closure
In this way, the early vortex can be avoided, while Both enhanced ladle bottom design (ELBY)
full vortex formation and surface collapse occurs and automated ladle closure (RADAR), can
at residual steel quantities 50% lower than with a
flat ladle bottom.
provide substantial yield and quality benefits
to the steelmaker.

LIQUID STEEL BEHAVIOR Tundish Design Development


DURING CONTINUOUS CASTING What Does a Tundish Do?

Vital Functions
Tundish Act as a reservoir during ladle
Phenomena exchange
Distribution of flow between strands
Separation of non-metallic
inclusions
Control of casting speed
Tundish Design Development Tundish Design Development
How Must a Tundish Perform? How is a Tundish Optimized?

For Optimum performance the following must be A correctly designed tundish will
achieved Eliminate short-circuit flow and promote similar
Liquid steel must be uniformly distributed to each residence times for each strand on multiple outlet
strand casters
(thermally, chemically and dynamically) Control the propagation of turbulence from the ladle
Non-metallic inclusions and slag entrained within the stream inlet region down the tundish body
metal must be given time to separate by flotation Eliminate back mixing between the turbulent and
laminar flow regions of the tundish
Regions of stagnation resulting in temperature drop
and stratification must be eliminated Promote a quiescent surface condition and fluid flow
pattern for the flotation and elimination of inclusions

Tundish Flow Behavior


Tundish Technologies Without Refractory Insert Shapes

Weirs, Dams, and Baffles


Special Impact Pads
Vortex Killers
Skull Reducing Lining Geometries
Gas Diffusers (Bubbling) -High Tech Tundish

Variation in Tundish Stream Smoothness Rough Tundish Stream


of Poor Quality
SLAG ENTRAINMENT SCHEMATIC OF FLOW BEHAVIOUR
MECHANISM IN AN NON-OPTIMIZED TUNDISH

No Special Impact Pad Two Counter-Rotating


Cyclones Small Funnel-Shaped
Vortices

Short-Circuiting

Visualization of Slag Entrainment Tundish Furniture -


in a Tundish Water Model Weirs, Dams, and Baffles

Billet/Bloom
Caster
Slab Tundish
Caster
Tundish

Delta Shaped Billet Caster Tundish Tundish Flow Behavior


with Baffles With Refractory Insert Shapes
Smooth Tundish Stream Reduction of Slag Entrainment & Tundish
of Good Quality vs Poor Quality Impact Area Turbulence

Control of Turbulence with EVOLUTION OF THE


Special Impact Pad IMPACT PAD
2nd
Generation

1st
Generation

With Special No Special


Impact Pad Impact Pad

CURRENT SLAB CASTER


TUNDISH TECHNOLOGY TUNDISH SKULL SIZE
Current Technology: Low or No Raised Bottom
Current two strand or single strand slab Skull
tundishes have various furniture arrangements Height
20 Ton Skull
0.5m 0.28m 10 Ton Skull
2.5 3.5 m
Baffle
900 - 1100mm
New Technology: High Raised Bottom
75 to Skull Potential
100mm Height Turbulent 200 225mm
15 Ton Skull Zone
0.5m 0.28m 5 Ton Skull

Dam Impact Pad Low Raised


Bottom
Potential Bottom Line Savings:
Many have a flat bottom, but if they have a raised 1000 TDs/year X 5 Tons/Skull X $125/Ton
bottom, this raise is typically less than 100mm > $600,000/year per 1000 TDs
IMPACT ZONE TURBULENCE NEW TECHNOLOGY:
VIDEO THE PERFORMER PAD

Show Video The Performer Pad decelerates the


incoming flow and significantly inhibits
tundish turbulence
The Performer Pad has special lateral holes
to release flow outwardly & upwardly

Performer Pad

Plug Plug
Flow Flow

High Raised Sunken


Bottom Performer Pad

Baseline - Current Pad New Tundish - Performer Pad

t = 6 minutes t = 4 minutes
t = 50 s
Trap Zone

t = 110 t = 8 minutes t = 6 minutes


s

t = 115
s
t = 9 minutes t = 6.5 minutes
(a) Baseline - Current Pad (b) New Tundish - Performer Pad

Photo Series 12: Comparison of Baseline Current Pad and New Tundish Performer Pad, Drain Level = 15
t = 117 s
Photo Series 10: Comparison of Baseline - Current Pad and New Tundish Performer Pad, Drain Level = 15

CONTROL OF IMPACT ZONE Full Height Vortex in Full-Scale


TURBULENCE VIDEO Tundish Water Model
Show Video
CONTROL OF TUNDISH Tundish Vortex Killer
DRAINING Technology

Prevent Show Video


Vortex

Vortex
Killer

BENEFITS OF MULTISTRAND BILLET/BLOOM


NEW TUNDISH TECHNOLOGY TD CONFIGURATIONS

No Pad
Enhanced opportunities for inclusion flotation
- Reduced short-circuiting - Improved
residence time distribution = Cleaner Steel
Reduced turbulence in the impact zone - Less
slag entrainment = Improved Quality at Open End Ripple Pad

Ladle Exchange
Decreased skull size = $$$ in the Bank

FLOW PATTERN - STREAMLINES NO PAD


NO SPECIAL IMPACT PAD COLORED BY TEMPERATURE

VIDEO
The flow without Liquid steel is cooler in the tundish end and
impact pad is the far strand is 5C degrees (9F degrees)
swirling in nature. cooler than the inside strand.
This behavior leads
to a high potential
for slag entrainment,
thermal non-
uniformity between
strands, and short- Flo
Col wS
ore
d b tream
circuit paths for
yT l
inclusions to reach em ines
the strands. per
atu
re
IMPACT PAD FEATURES FLOW PATTERN-
OPEN END RIPPLE PAD

Open End Ripple Pad Flow from the pad Video


is distributed both
Ripple design momentum upwardly and also
dissipation reduce horizontally
turbulence toward the far
Directs flow to the meniscus strand. Short-
optimum inclusion flotation circuit flow to the
Open walls and ripple nearest strand is
configuration direct flow to far totally eliminated.
strands
Hotter steel flows
Provides a more homogeneous to the far strand.
temperature between strands

STREAMLINES OPEN END RIPPLE PAD BENEFITS OF


COLORED BY TEMPERATURE MULTISTRAND TD IMPACT PAD

Liquid steel is hotter in the tundish ends and


Special impact pads in multi-strand billet/bloom tundish
the strand temperatures are nearly equivalent. can alter tundish flow patterns in several beneficial ways:
Capturing, re-directing, and slowing-down the incoming
stream from the ladle to inhibit short-circuit flow and
stop turbulence from reaching the outlet strands to
prevent disturbance of the outlet streams
Forming more plug-like flow patterns in the tundish to
F
Col low S
improve slag and non-metallic inclusion flotation.
ore
d b tream Providing more homogeneous thermal distribution in
yT l
em ines the tundish and more uniform temperatures from
per
atu strand to strand.
re

Inert Gas Bubbling


Tundish Gas Diffusion
Applications
During casting, a controlled
flow of inert gas is introduced
to the TGD,
TGD forming a
TUNDISH GAS DIFFUSION - Enhanced
continuously renewed rising Inclusion Flotation
mechanisms of enhanced inclusion particle curtain of tiny gas bubbles
removal by gas bubble diffusion and through which the steel flow
passes.
guidelines for tundish gas diffuser
implementation The diffuse gas curtain
enhances inclusion removal
Controlled Flow of
and improves thermal
Inert Gas
homogeneity of the steel bath
in the tundish.
STUDY OF INCLUSION SEPARATION Principles of Enhanced Inclusion
BY TUNDISH BUBBLING Removal by Gas Bubbling
(Collision and Attachment)
Steel flow A inclusion must both collide and attach to a
from ladle bubble for a bubble/particle agglomeration to
Slag Layer be formed.
When a non-wetted particle collides with a
bubble there is a very high probability (>80%)
that it will attach. Thus, process efficiency is
dominated by the probability of collision.
Bubbles from Inlet Outlet Collision probability between a particle and
Inlet Concentration Porous Plug Gas Concentration bubble is greatly increased as bubble size
and Size Distribution and Size
Bubble
Bubble
of Inclusions
decreases, since particle streamline bending is
Distribution of
far less with tiny bubbles. Particle
Inclusions
Streamlines

Influence of Bubble Size on NUMERICAL PREDICTION OF


Particle/Bubble Collision INCLUSION SEPARATION
LB /L
Particle/Bubble Collision Probability 100% = 0.4 dp = 100m
increases exponentially with decreasing L
B /L
Collision Probability

=0
bubble size. 80% .2
L
Efficiency
Removal Efficiency

B /L
=0
Inclusion removal is dominated by the .1
60%
probability of particle/bubble collision, thus
inclusion removal is maximized with small
Separation

bubbles. 40%

L L /
B L T = 480
L B /L
=0 =0
Collision probability B /L .4 qG = 0.0005
20% dp = 20m =0 .2
increases with decreasing .1
bubble size
0%
0 1 2 3 4 5 6 7 8 9 10

Bubble Size Bubble Size (mm)

Bubbles Produced by the TGD Particle/Bubble Interaction

The TGD is
designed to
produce the
curtain of fine
bubbles
necessary to
maximize
inclusion
removal from
Diffuse Gas Curtain Before Diffuse Gas Curtain During
the tundish. Interaction with Particles Interaction with Particles
PARTICLE/BUBBLE Tundish Gas Diffusion
INTERACTION Model Results
Show Video 92m LLDPE particles in 1/3rd scale
100 water model, simulating 45m
inclusions in steel
90

Removal Efficiency (%)


80
95%
70
Simple TGD Enhanced
Flotation Only
60 Flotation
50
65%
40

30
45%
20

10

0
No TD Furniture Performer Pad Performer Pad
With TGD

BENEFITS OF LIQUID STEEL BEHAVIOR


NEW TUNDISH TECHNOLOGY DURING CONTINUOUS CASTING

Enhanced opportunities for inclusion flotation


by reduced short-circuiting and gas injection
and rinsing = Cleaner Steel
Reduced turbulence in the impact zone - Less Tundish-to-
Mold
slag entrainment = Improved Quality at Ladle Phenomena
Exchange (less downgrade)
Decreased skull size = $$$ in the Bank

NEW TUNDISH-TO-MOULD FLOW OFFSET BORE TUNDISH


REGULATION TECHNOLOGY GATE

Physical Modeling for Slide-Gate Development


Tundish Slide Gate: Advent Offset Bore System
Stopper Rod: Advent Ripple Rod System
TD Well
Nozzle (TWN)
Gate Top
Plate

Planar Illumination Throttle Plate


Offset Bore Gate Ripple Stopper Rod System Bottom Plate
OFFSET BORE TUNDISH OFFSET BORE TD GATE
GATE TOP VIEW

Steel Flow Behavior Simulation Central Axis of the System


Identifies Problems and Solutions

Typical Current Gate Stack-up Advent Offset Gate Stack-up Typical Current Gate Stack-up Advent Offset Gate Stack-up

OFFSET BORE TD GATE TOP NEW RIPPLE-STOPPER SYSTEM


Advent Novel Slide Gate
PLATE CONFIGURATIONS
Technology

Offset
Offset GateTop
TopPlate
Plate Examples
Designs Introduces turbulent mixing at regulation area
entrance to reduce build-up and plugging at
Ripple Stopper with
this critical point
Round Step TWN
Oval Reduces incidence of sudden dropping in
Orifice stopper rod position
Orifice

Promotes the formation of stable & uniform gas


bubble coverage of stopper tip below regulation
point to prevent non-metallic deposition
Eliminates pressure fluctuations in the
(a) Round Bore Design Delta-T
(b) Oval Bore Design RSEM1
Dramatically reduced clogging of well regulation region to prevent stopper vibration
and improve mold level control by reducing
nozzle, throttle plate, & SEN = stopper rod hunting
LONGER LIVES OF SEN & TUNDISH

RIPPLE STOPPER SYSTEM VIDEO LIQUID STEEL BEHAVIOR


DURING CONTINUOUS CASTING

Show Video

Mold Flow
Phenomena
NUMERICAL AND PHYSICAL NUMERICAL AND PHYSICAL
SIMULATION SIMULATION VIDEO

Show Video

Thin Slab
SEN A

Thin Slab
SEN B

MENISCUS FLOW - MENSICUS FLOW


UNDERSTANDING SIMPLE IMPROVEMENT

Show Video Prediction of off-corner Show Video


INFLUENCE OF
vortex formation causing
REFRACTORY
localized erosion of
OUTSIDE SHAPE ON
refractory
OFF-CORNER EROSION
Show Video

A good understanding of Field trial results


physical modeling and confirm influence of
CFD is required to
Square external shape
accurately predict flow
behavior

Double Insert Development Double Insert


Z1
Z1
Modulated Pressure
Sharp Pressure Drop Drop Below
to High Vacuum at Regulation Point
Regulation Point
Increasing
Flow
Z2 Z2
Pressure

Atmospheric Pressure
Pressure

Atmospheric Pressure

Z1 Z2
Z1 Z2 Z3
Constriction Zone
Control Zone

Z3
Control Zone
SEN Designs for Conventional Slab SEN vs.
Conventional Slab Casting Conical-Step Bore

Non-uniform flow in
Common Problems: the bore causes
non-uniform exit-jets
Clogging Build-ups in the
Bore & in the Ports Uniform flow in the
bore promotes
Wandering and
uniform exit-jets
Oscillation of the Exit-Jet
Flows

Straight Bore Conical-Step Bore

Conical-Step Bore and Conical-Step Bore - Boundary Layer


Clogging Potential Turbulence CFD Results

Regular Bore Conical-Step Bore CFD Model of Water Model of


Dye Injection
Conical-Step Bore Conical-Step Bore
into the
Boundary
Layer The Conical- The Conical-Step
Step Bore Diffusing Bore
Turbulent Kinetic Energy in m2/s2

restricts laminar geometry introduces


Dark dye layer sub-layer near-wall turbulence
shows the thick thickness and that reduces the
laminar sub-layer alters the laminar boundary layer
that develops on turbulence thickness and thereby
the bore wall, distribution alters the flow
allowing alumina along the bore character along the
particles to stick wall to reduce bore wall to reduce
and build up. clogging clogging

Advent Technology Clogging Reduction


Conventional Slab SEN Technology

Reduced Clogging
In SES with Conical-Section Bore Reduced Clogging
Standard SES Advent
bore in SEN/SES SES bore

with
Conical Diffusing
Standard Advent Advent
SES SES SES Standard Bore Advent
SES port SES port
Bore Clogging Quarter Section Photos Conventional Slab SEN
Clogging starts much higher in the
bore and builds thickness downwardly
on both broad and narrow faces

(Current SEN)
Problem = Oscillating Unstable Port Flow Swirling

The symmetric
flow pattern
Thickest clogging at shown here is
bottom of bore and
Severe clogging at top of port bottom of port
not achieved in Actually
typical SEN/SES
Lowest Bumper
Clogging on the broad
port designs.
face starts below the
(Advent Conical Section SEN)
lowest bumper
Instant A Instant B
Little or no clogging
found on the narrow
face The asymmetric influence of the flow regulation mechanism
combined with the unstable nature of turbulent flows causes
Bumpers clearly Little top of port clogging
Slightly reduced unsteady swirling of the SES exit-jets
bottom clogging
evident

Twin Twister (TT) Port Design


SEN COMPARISON
Conventional Slab SEN

TT port design creates twin, counter-rotating, flows


that significantly stabilize the jet and virtually
eliminate severe unsteady and jet swirling

Conventional SES SES with TT Port

Principle of Twin-Twister (TT) Port Design

Conventional Slab
SEN COMPARISON
SEN
STD SES Conical-Step & TT Port Problem = Poor Utilization of Port Area
Conventional ports are never fully
utilized. (Typically ~ 60% of port
used). Port clogging can be
substantial.
Jets and gas bubbles are free to
wander causing mold flow instability.
Mould powder can be deposited
outside and inside the SEN by
reversed flows at top of the ports.
Furthermore, the jets are poorly
diffused generating high
impingement velocity on narrow
faces.
Conventional Slab SEN Terrace Multi-Port SEN

The Terrace Multi-Port Design


Stable, symmetric mould flow
with ample and uniform heat
distribution across the
meniscus
High velocity and turbulence Back flow
throughout the SES to deter
clogging.
Optimized jet diffusion inside
the mould to decrease the
impact velocity on the narrow
faces. Much Improved Jet Diffusion
Improved Heat distribution
Reduction of Flow Fluctuation

Casting Nozzles Medium Advent Technology


Thickness Slab Thin Slab

Medium Thickness Slab Casting SEN Diffusive


Flow Bore
Geometry
Diamond-
Back
Section
Multi-stage
Flow
Division

SEN Development - Billet SEN Development - Billet


and Bloom Casting and Bloom Casting

Current SEN Straight-Thru Advent SEN 5 Port Radial

Diameter = 270 mm Speed = 1.2 m/min Subm. = 100 mm


5-Port Radial SEN Design Providing Rotational Surface (Similar to EMS)
Billet and Bloom Casting Billet and Bloom Casting
Multi-Port and Balanced Flow Design Multi-Port and Balanced Flow Design

FINAL SUMMARY FINAL SUMMARY (CONTD)

z THERMAL CONTROL
z LIQUID STEEL
Means Principally the Control of Bath
Is the Product of its Environment Temperature
z THE STEELMAKING ENVIRONMENT z PHYSICAL CONTROL
Consists of Slags, Refractories, and Gases Means Principally the Control of Fluid Flow and
Must be Controlled Thermally, Chemically, & Mixing Behavior
Physically z THESE CONTROLS ARE ALL LINKED
z CHEMICAL CONTROL Steel and Slag Stirring are Essential Components of
Is Strongly Affected by the Non-Metallic & Temperature and Chemical Control
Metalloid Elements Particularly Oxygen and Steel Refining Reactions, Slag/Metal Reactions, and
Carbon Re-Oxidation Phenomena are affected by the Flow

FINAL SUMMARY (CONTD) FINAL SUMMARY (CONTD)

z MANY PHENOMENA AFFECTING


PROCESS YIELD & STEEL QUALITY z STEEL FLOW BEHAVIOR IN THE
MOLD MUST BE CONTROLLED
Including such Factors as: Slag
Entrainment, Inclusion Formation & Otherwise Many Critical Factors are
Adversely Affected, Including:
Separation, and Nozzle Clogging
Meniscus Temperature Control and Steel
Are Influenced by the Forms of Refractory Shell Formation,
Components Such as: Uniformity of Molten Mold Powder Layer
& Resultant Mold Lubrication,
LADLE BOTTOMS & TUNDISH IMPACT PADS,
Capture of Non-Metallic Inclusions &
SLIDE-GATE VALVES & STOPPER RODS,
Cast Product Cleanliness.
CASTING NOZZLES (SEN & SES)

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