Search Results (24)

Mixing time, as a key parameter for evaluating ladle refining efficiency, has long attracted extensive attention from researchers. In typical experimental studies, salt solution tracers are introduced into ladle water models to assess the degree of mixing within the ladle. Previous studies have demonstrated that the volume of tracer can significantly influence the measured mixing time. However, the gas flow rates employed in these studies are generally relatively high, whereas, in industrial operations, especially during final composition adjustments, lower gas flow rates are often applied. To systematically investigate the effect of the salt solution tracer volume on the mixing efficiency in a ladle water model under asymmetrical gas stirring with a low gas flow rate, a 1:3-scaled water model was developed based on a 130-ton industrial ladle. The mixing behaviors corresponding to different tracer volumes were comprehensively analyzed. The results indicate that the relationship between tracer volume and mixing time is non-monotonic. As the tracer volume increases, the mixing time first decreases and then increases, reaching a minimum at 185 mL. When the tracer volume was small, the dimensionless concentration curves at Monitoring Point 4 exhibited two distinct patterns: A parabolic profile, which was when the tracer initially moved through the left and central regions and then slowly crossed the gas plume to reach the monitoring point. A sinusoidal profile, which was when the tracer predominantly circulated along the right side of the ladle. When the tracer volume exceeded 277 mL, the concentration curves at Monitoring Point 4 consistently exhibited a sinusoidal pattern. Compared with moderate gas flow conditions (8.3 L/min), the peak concentration at Monitoring Point 3 was significantly lower under a low gas flow (2.3 L/min), and the overall mixing time was longer, indicating reduced mixing efficiency. Based on the findings, a recommended tracer volume range of 185–277 mL is proposed for low gas flow conditions (2.3 L/min) to achieve accurate and efficient mixing time measurements with minimal disturbance to the flow field. It was also observed that when the tracer concentration was relatively low, the mixing behavior throughout the ladle became more uniform. Full article

In this study, through RH water model simulation experiments, the effects of precipitation bubbles on the two-phase flow pattern, liquid steel flow behavior, and flow characteristics in an RH reactor during the whole decarburization process were comparatively investigated and analyzed by using quasi-counts that reflected the similarity of the precipitation bubble phenomenon. The experimental results show that an increase in precipitation bubbles is positively related to an increase in circulating flow rate, a reduction in mixing time, and an increase in gas content and negatively related to the residence time of liquid steel in the vacuum chamber. The two-phase flow pattern of the rising tube under the influence of precipitation bubbles includes bubble flow, slug flow, mixing flow, and churn flow. Under the influence of precipitation bubbles, the liquid surface spattering inside the vacuum chamber is reduced, the fluctuation amplitude is reduced, the efficiency of liquid steel processing is improved, it is not easy for cold steel to form, and the fluctuation frequency is increased, which is conducive to increasing the surface area of the vacuum chamber; the bubbles’ rising, aggregating, and crushing behavior increases the stirring effect inside the vacuum chamber, which is conducive to improving the decarburization and mass transfer rate. Under the influence of the precipitated bubbles, the concentration gradient between the ladle and the vacuum chamber is increased, which accelerates the mixing speed of the liquid steel in the ladle, and the volume of the dead zone is reduced by 50%. The lifting gas flow rate can be appropriately reduced in the plant. Full article

In the quest to design reactors with a higher productivity, their mixing efficiency should be highly improved. The mass transfer coefficient is a parameter that measures the rate of the refining rates and has been extensively investigated in the past; however, most of the correlations developed in steelmaking are based on the effect of the gas flow rate or its alternative form, stirring energy. The gas flow rate can play a big role in mass transfer but there are many more variables involved. This work has investigated the combined effect of five variables on the mass transfer coefficient due to bottom gas injection with two injection devices: the gas flow rate, the radial position and the separation angle of the porous plugs, the slag thickness, and the ladle aspect ratio. A novel expression in a dimensionless form has been developed, which accurately predicts the mass transfer coefficient. The expression proposed indicates that increasing the gas flow rate, the slag thickness, the ladle aspect ratio, and the separation angle also increases the mass transfer coefficient. On the contrary, increasing the radial position away from the center affects mass transfer, especially at high gas flow rates. Based on the experimental data and their practical application, an optimum layout for the injection of gas is suggested to optimize both mass transfer and the mixing intensity of liquid steel. Full article

The measurement of mixing time in a water model of soft-stirring steelmaking ladles is practically facing a problem of bad repeatability. This uncertainty severely affects both the understandings of transport phenomenon in ladles and the measurement accuracy. Scaled down by a ratio of 1:4, a water model based on an industrial 260-ton ladle is used. This paper studies the transport process paths and mixing time of salt solution tracers in the water model of eccentric gas-stirred ladles with a low gas flow rate. After a large number of repeated experiments, the different transport paths of the tracer and the error of the mixing time in each transport path are discussed and compared with the numerical simulation results. The results of a large number of repeated experiments on the water model show that there are five transport paths for the tracer in the ladle. The tracer of the first path is mainly transported by the left-side main circulation flow, which is identical to the numerical simulation results. The tracer of the second and third paths are also mainly transported by the left-side circulation flow, but bifurcations occur when the tracer in the middle area is transported downward. In the third path, the portion and intensity of the tracer transferring to the right side from the central region is higher than in the second path. The fourth path is that the tracer is transported downward from the left, middle, and right sides with a similar intensity at the same time. While the tracer in the fifth path is mainly transported on the right side, and the tracer forms a clockwise circulation flow on the right side. The mixing times from the first transport path to the fifth transport path are 158.3 s, 149.7 s, 171.7 s, 134 s and 95.7 s, respectively, among which the third transport path and the fifth transport path are the maximum and minimum values among all transport paths. The error between the mixing time and the averaged mixing time at each monitoring point in the five transport paths of the tracer is between −34.7% and 40.9%. Furthermore, the error of the averaged mixing time of each path and the path-based average value is between 5.5% and 32.6%. Full article

In previous research simulating steelmaking ladles using cold water models, the dosage/volume of the salt tracer solution is one of the factors that has been overlooked by researchers to a certain extent. Previous studies have demonstrated that salt tracers may influence the flow and measured mixing time of fluids in water models. Based on a water model scaled down from an industrial 130-ton ladle by a ratio of 1:3, this study investigates the impact of salt tracer dosage on the transport and mixing of tracers in the water model of gas-stirred ladle with a moderate gas flow rate. A preliminary uncertainty analysis of the experimental mixing time is performed, and the standard deviations were found to be less than 15%. It was observed in the experiments that the transport paths of tracers in the ladle can be classified into two trends. A common trend is that the injected salt solution tracer is asymmetrically transported towards the left sidewall of the ladle by the main circulation. In another trend, the injected salt solution tracer is transported both by the main circulation to the left side wall and by downward flow towards the gas column. The downward flow may be accelerated and become a major flow pattern when the tracer volume increases. For the dimensionless concentration curve, the sinusoidal type, which represents a rapid mixing, is observed at the top surface monitoring points, while the parabolic type is observed at the bottom monitoring points. An exception is the monitoring point at the right-side bottom (close to the asymmetric gas nozzle area), where both sinusoidal-type and parabolic-type curves are observed. Regarding the effect of tracer volume on the curve and mixing time, the curves at the top surface monitoring points are less influenced but curves at the bottom monitoring points are noticeably influenced by the tracer volume. A trend of decreasing and then increasing as the tracer volume increases was found at the top surface monitoring points, while the mixing times at the bottom monitoring points decrease with the increase in the tracer volume. Full article

Ladle metallurgy serves as a crucial component of the steelmaking industry, where it plays a pivotal role in manipulating the molten steel to exercise precise control over its composition and properties. Turbulence in ladle metallurgy influences various important aspects of the steelmaking process, including mixing and distribution of additives, alongside the transport and removal of inclusions within the ladle. Consequently, gaining a clear understanding of the stirred flow field holds the potential of optimizing ladle design, improving control strategies, and enhancing the overall efficiency and steel quality. In this project, an advanced Particle-Tracking-Velocimetry system known as “Shake-the-Box” is implemented on a cylindrical water ladle model while compressed air injections through two circular plugs positioned at the bottom of the model are employed to actively stir the flow. To mitigate the particle images distortion caused by the cylindrical plexi-glass walls, the method of refractive matching is utilized with an outer polygon tank filled with a sodium iodide solution. The volumetric flow measurement is achieved on a 6 × 6 × 2 cm domain between the two plugs inside the cylindrical container while the flow rate of gas injection is set from 0.1 to 0.4 L per minute. The volumetric flow field result suggests double gas injection at low flow rate (0.1 L per minute) produce the least disturbed flow while highly disturbed and turbulent flow can be created at higher flow rate of gas injection. Full article

Argon bottom stirring is commonly practiced in secondary steelmaking processes due to its positive effects on achieving uniform temperatures and chemical compositions throughout a steel melt. It can also be used to facilitate slag metal refining reactions. The inter-mixing phenomena associated with argon gas injection through porous plugs set in the bottom and its stirring efficiency can be summarized by evaluations of 95% mixing times. This study focuses on investigating the impact of different plug positions and ratios of argon flow rates from two plugs on mixing behavior within a 110-tonne, elliptical-shaped industrial ladle. A quasi-single-phase modeling technique was employed for this purpose. The CFD findings revealed that the optimal position of the second plug is to be placed diametrically opposite the existing one at an equal mid-radius distance (R/2). An equal distribution of argon flow rates yielded the best results in terms of refractory erosion. A comparative study was conducted between single- and dual-plug-configured ladles based on flow behavior and wall shear stresses using this method. Furthermore, a transient multiphase model was developed to examine the formation of slag open eyes (SOE) for both single- and dual-plug configurations using a volume of fluid (VOF) model. The results indicated that the dual-plug configuration outperformed the current single-plug configuration. Full article

Ladle metallurgy is an important steelmaking technology in high-quality steel production. The blowing of argon at the ladle bottom has been applied in ladle metallurgy for several decades. Until now, the issue of breakage and coalescence among bubbles was still far from being solved. In order to have a deep insight into the complex process of fluid flow in the gas-stirred ladle, the Euler–Euler model and population balance model (PBM) are coupled to investigate the complex fluid flow in the gas-stirred ladle. Here, the Euler–Euler model is applied to predict the two-phase flow, and PBM is applied to predict the bubble and size distribution. The coalescence model, which considers turbulent eddy and bubble wake entrainment, is taken into account to determine the evolution of the bubble size. The numerical results show that if the mathematical model ignores the breakage of bubbles, the mathematical model gives the wrong bubble distribution. For bubble coalescence in the ladle, turbulent eddy coalescence is the main mode, and wake entrainment coalescence is the minor mode. Additionally, the number of the bubble-size group is a key parameter for describing the bubble behavior. The size group number 10 is recommended to predict the bubble-size distribution. Full article

Industrial fusion of microalloying elements in steelmaking is imperative in defining and optimizing certain steel properties due to their strengthening and significant grain refinements effects at minute quantities. Copper, vanadium, and columbium are explored in this investigation to monitor their respective dissolution processes in a ladle metallurgy furnace (LMF), with concise parametric studies on effects of number of plugs and variations in argon gas flow rates for stirring. To track particle disintegration in the molten bath inside, intricate numerical processing was carried out with the use of mathematical models and to simulate the mixing process; turbulent multiphase computational fluid dynamics (CFD) models were combined with a user-defined function. The numerical findings highlight the connection between mixing time and gas blowing since the quantity of stirring plugs employed and the gas flow rates directly affect mixing effectiveness. The amount of particles to be injected and their total injection time were validated using industrial measurement; an average difference of 9.9% was achieved. In order to establish the need for an exceptionally high flow rate and inevitably reduce resource waste, extreme charging of flow rates for gas stirring were compared to lesser gas flow rates in both dual- and single-plug ladles. The results show that a single-plug ladle with a flow rate of 0.85 m³/min and a dual-plug ladle with a total flow rate of 1.13 m³/min have the same mixing time of 5.6 min, which was the shortest among all scenarios. Full article

In this work, the fluid dynamic and thermal behavior of steel was analyzed during argon gas stirring in a 140-t refining ladle. The Eulerian multiphase mathematical model was used in conjunction with the discrete ordinates (DO) thermal radiation model in a steel-slag-argon system. The model was validated by particle image velocimetry (PIV) and the analysis of the opening of the oil layer in a physical scale model. The effect of Al₂O₃ and Mg-C as a refractory in the walls was studied, and the Ranz-Marshall and Tomiyama models were compared to determine the heat exchange coefficient. The results indicated that there were no significant differences between these heat exchange models; likewise, the radiation heat transfer model adequately simulated the thermal behavior according to plant measurements, finding a thermal homogenization time of the steel of 2.5 min for a gas flow of 0.45 Nm³·min⁻¹. Finally, both types of refractory kept the temperature of the steel within the ranges recommended in the plant; however, the use of Al₂O₃ had better heat retention, which would favor refining operations. Full article

In a steel-refining ladle, the properties of manufactured steel can be notably degraded due to the presence of excessive inclusions. Stirring via gas injection through a porous plug is often used as part of the steel-refining process to reduce these inclusions. In this paper, 3D computational fluid dynamics (CFD) modeling is used to analyze transient multiphase flow and inclusion removal in a gas-stirred ladle. The effects of gas stirring with bubble-inclusion interaction are analyzed using the Euler–Euler approach for multiphase flow modeling, while the effects of inclusions aggregation and removal are modeled via a population balance model (PBM). Full article

The paper presents new results concerning the influence of the gas density and porous plug diameter on the nature of liquid steel stirring with an inert gas in the ladle. The tests were carried out on a cold model of a 30t ladle using particle image velocimetry (PIV) with a high-speed camera to analyse the plume zone formed during the supply of argon and helium as a stirring gas. The similarity criteria for the investigation of stirring processes in cold model in the past were discussed and compared. The modified Morton number was used in this paper to relate the gas flow rate in the model with real objects. The presented results constitute complete documentation of the influence of the plug diameter and gas density on the size of formed gas bubbles and the velocity of gas bubbles rising in different zones of the plume, plume, and spout geometry, including the expansion angle, spout height, open eye area, and gas hold-up. Full article

To investigate the gas agitation characteristics of side blowing, the fluid flow and mixing phenomenon in a 1:3 scale model ladle of a 150 t industrial gas-stirred ladle with bottom and side plugs were studied by using physical and numerical modelings together. Side blowing enhanced the horizontal flow of water in the model ladle. Compared with bottom blowing, side blowing that is close to the ladle bottom with more than two plugs increases the average velocity of water, which represents the agitation power, improves the uniformity of water velocity distribution, reduces the stagnant region rate, and shortens the mixing time. The mixing time of dual bottom plugs is almost 1.5 times of that of four side plugs at 116 mm under the same flow rate. The mixing time is not only influenced by the agitation power but also by the uniformity of water velocity distribution. Although the agitation power of four side plugs at 450 mm under the flow rate of 1.8 m³/h is about 1.5 times of that at 116 mm with 0.6 m³/h. The mixing time of the 1.8 m³/h flow rate is about 1.2 times of that of the 0.6 m³/h because of the different water velocity distributions. Full article

This work aims at figuring out the influence of gas bubble size distribution on the ladle stirring process. The work is conducted through three-dimensional (3D) numerical simulation based on the finite volume method. Mesh sensitivity test and the cross-validation are performed to ensure the results are mesh independent and the numerical set-up is correct. Two distributions, uniform and Log-normal function, are investigated under different gas flow rates and number of porous plugs. The results indicate that the results, e.g., the axial velocity and the area of the slag eye, have little difference for low flow rate. The difference becomes dominant whilst the flow rate is increasing, such as 600 NL/min. The Log-normal function bubble size distribution gives a larger axial velocity and a smaller slag eye area compared to the uniform bubble size distribution. This work indicated that, at a higher flow rate, the Log-normal function is a better choice to predict the melt behavior and the slag open eye in the ladle refining process if the bubble interaction is not considered. Full article

Molten steel is alloyed during tapping from the melting furnace to the argon-bottom stirred ladle. The metallic additions thrown to the ladle during the ladle filling time are at room temperature. The melting rates or kinetics of sinking-metals, like nickel, are simulated through a multiphase Euler–Lagrangian mathematical model during this operation. The melting rate of a metallic particle depends on its trajectory within regions of the melt with high or low turbulence levels, delaying or speeding up their melting process. At low steel levels in the ladle, the melting rates are higher on the opposite side of the plume zone induced by the bottom gas stirring. This effect is due to its deviation after the impact of the impinging jet on the ladle bottom. The higher melting kinetics are located on both sides at high steel levels due to the more extensive recirculation flows formed in taller baths. Making the additions above the eye of the argon plume spout increases the melting rate of nickel particles. The increase of the superheat makes the heat flux more significant from the melt to the particle, increasing its melting rate. At higher superheats, the melting kinetics become less dependent on the fluid dynamics of the melt. Full article