CFD Simulation of a Six-Strand Continuous Casting Tundish at - - PowerPoint PPT Presentation

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CFD Simulation of a Six-Strand Continuous Casting Tundish at - - PowerPoint PPT Presentation

Mar 18, 2023 600 likes •859 views

, CFD Simulation of a Six-Strand Continuous Casting Tundish at Georgsmarienhuette GmbH E. Runschke , Z. Cancarevic, H. Schliephake Georgsmarienhuette, Germany 1 Star Global Conference 2015 , San Diego, USA CONTENT , Company GMH

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CFD Simulation of a Six-Strand Continuous Casting Tundish at Georgsmarienhuette GmbH

  • E. Runschke,
  • Z. Cancarevic,
  • H. Schliephake

Georgsmarienhuette, Germany Star Global Conference 2015, San Diego, USA

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CONTENT

 Company  GMH Simulation Landscape  CFD Simulation:

  • Objective and Motivation
  • Setup
  • Simulation Results
  • Outlook
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COMPANY

 Manufacturer of quality

and engineering steels

 Market leader in Germany  Among Europe‘s top manufacturers  Key Data 2013:

  • 632 mil. Euro Turnover
  • 1,316 employees
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MARKET

 Fracture-split conrod  Piston  Steering rack  Knuckle  Camshaft  Crankshaft  Gear shaft  Cardan shaft  Wheel hub  Ball bearings  Common-Rail Injector Nozzle

Main Applications

ENGINE TRANSMISSION BEARINGS

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MARKET

References

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SIMULATION INFRASTRUCTURE

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SIMULATION INFRASTRUCTURE

 Windows-Cluster: Windows Server 2008 R2 @ 192 cores, 2.4 GHz, 24GB/Node

 Windows HPC Cluster Manager

 Linux-Cluster: RedHat ELS HPC @ 192 cores, 3.3 GHz, 64GB/Node  Fujitsu HPC Cluster Suite

SimSto SimWin SimLin

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TECHNOLOGY

DC electric arc furnace – 130 MW

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TECHNOLOGY

Tundish

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OBJECTIVE AND MOTIVATION

 Optimize the casting process to achieve a higher level of product quality  Develop a methodology for the design and optimization of tundish at GMH  Optimization of Tundish:  Furniture (Dam, Weir)  Tundish Working Space  Size (Larger Volume)  Shape (T-Shape, Delta, …)  Flow Control Devices (FCDs)  Tools:  CFD Simulation  Physical modeling

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GEOMETRY AND STATUS QUO

Real System 3D Model SIMULATION MESHING

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, 1 2 3 4 5 6

Type I (EXP)

Historical Data:

  • Shape,
  • Size,
  • Ultrasonic Immersion Testing

GEOMETRY AND STATUS QUO

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SIMULATION SETUP

5 10 15 20 25 30 35

500 1000 1500 2000 2500 3000

Weight [t]

Time [s] PARTICLES

LADLE CHANGE

PARTICLES FULL TUNDISH

600s 600s “STEADY STATE”

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  • Commercial CFD code: STAR-CCM+

Setup:

  • k-w SST (Menter’s Shear Stress Transport)
  • Mesh: Trimmer, Prism Layer, 3 mio. volume cells
  • Fluid: VOF (Volume of Fluid), Particle: Lagrangian Multiphase
  • Particles: 10 to 65µm, density 3900kg/m³
  • Strand 1 to 6: identical mass flow
  • Solution time 0 to 600s: “creation of fluid flow”
  • Solution time 600 to 600,2s: injection of 2600 particles
  • Solution time max. 2400s
  • Particles which left the system are counted
  • Temperature: 1530°C (Isothermal simulation)
  • The steel slag used in this work is chemically inactive and coalescence
  • f inclusions is not considered
  • Physical properties: VDEh – Ladle-Benchmark

SIMULATION SETUP

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SIMULATION SETUP

TYPE I VOF-Scene  Entrainment of slag during ladle change (during fill-up)

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COMPARISON: TYPE I VS. TYPE II

Type I (top) vs. Type II (bottom)

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, TYPE I 1 2 3 4 5 6

COMPARISON: TYPE I VS. TYPE II

Particles in the strands @ 2400s (before Ladle Change; Normalized)

1 2 3 4 5 6

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COMPARISON: TYPE I VS. TYPE II

TYPE II 1 2 3 4 5 6

Particles in the strands @ 2400s (before Ladle Change; Normalized)

1 2 3 4 5 6

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, Relative distributions of non-metallic inclusions in individual blooms Strand 3+4, Strand 2+5, Strand 1+6

EXPERIMENTS VS. SIMULATION

Ultrasonic Immersion Testing

Simulation

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  • The numerical modelling technique was successfully used for simulation of

steel flow and behavior of non-metallic inclusions in the tundish

  • “Small particles” (10µm)  FOLLOW THE STREAM-LINES
  • “Medium size particles” (20µm and 40µm)  MIXED BEHAVIOR
  • “Coarse particles” (65µm)  FLOTATION
  • The steel SLAG used in this work is CHEMICALLY INACTIVE and

COALESCENCE OF INCLUSIONS IS NOT CONSIDERED

  • ONLY Aluminum-Oxide Particles “generated” during the

LADLE CHANGE PROCESS are considered as non-metallic inclusions (Exogenous inclusions derived from external sources are not considered)

  • Start Configuration: UNEVEN DISTRIBUTION of particles along strands
  • After Optimization: BALANCED DISTRIBUTION of particles along strands
  • TRENDS of simulation results ARE WELL REFLECTED by the experiments

CONCLUSION

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OUTLOOK

  • 1. Partikel
  • 2. Partikel

Ladle Change

 Optimization of Tundish:  Furniture (Dam, Weir)  Tundish Working Space  Size (Larger Volume)  Shape (T-Shape, Delta)  Flow Control Devices (FCDs) CFD Simulation Physical modeling Experiments Calibration Validation Verification TO-DO LIST

  • Ladle Change Process
  • Emptying Process
  • Refilling Process
  • Grade Change
  • Isothermal vs. Non-isothermal
  • Coalescence of Particles
  • Slag Entrapment

Never Ending Story …

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OUTLOOK

 Continuous Casting

Source: Brian G. Thomas, University of Illinois at Urbana-Champaign

 Optimization of Tundish:  Furniture (Dam, Weir)  Tundish Working Space  Size (Larger Volume)  Shape (T-Shape, Delta)  Flow Control Devices (FCDs)

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Until we make steel transparent we must use simulation or physical modeling.

CONCLUSION 2.0

(Source: Dr. Z. Cancarevic, Georgsmarienhuette)

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