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Uphill Teeming Utilizing TurboSwirl to Control Flow Pattern in Mold
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Applied Process Metallurgy.
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Applied Process Metallurgy.
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Applied Process Metallurgy.
2013 (English)In: Steel Research International, ISSN 1611-3683, E-ISSN 1869-344X, Vol. 84, no 9, 837-844 p.Article in journal (Refereed) Published
Abstract [en]

The flow pattern has widely been recognized to have an impact on the exogenous non-metallic inclusion generation in the gating system and mold flux entrapment in the mold in the uphill teeming process. The possible solutions of the flow pattern control are required to be reliable and practical in order to improve the yield and the ingot quality in the steel production. In this work, a mathematical model of a new novel swirling flow generation component, TurboSwirl, was studied to investigate the flow pattern of steel in the gating system and molds based on the authors' previous study. The same calculation method and boundary conditions were adopted. The results show that a much calmer initial filling condition with less fluctuations is achieved in the mold with a swirling flow by using the TurboSwirl compared to previous studies. In addition, the initial position of the mold powder bags can further be lowered in the mold due to a decreased hump height. Moreover, the difference between the hump height and the surface height in the present model has a maximum value of 83 mm, which gives a lower risk of mold flux entrapment. Furthermore, the maximum wall shear stress value can generally be lowered with less fluctuations after the first hump formation in the mold at 2.5 s from the teeming start. In conclusion, the initial filling conditions can be substantially improved by the use of TurboSwirl flow pattern control. In this work, a new novel swirling flow generation component, TurboSwirl, is presented for the next generation of ingot casting. Due to its great potential in enhancing the steel cleanliness, it is highly recommended to apply this component in the steel producing industry so as to further improve the yield and quality of ingots.

Place, publisher, year, edition, pages
2013. Vol. 84, no 9, 837-844 p.
Keyword [en]
flow pattern, ingot casting, mathematical modeling, realizable k-ε model, TurboSwirl
National Category
Metallurgy and Metallic Materials
Identifiers
URN: urn:nbn:se:kth:diva-117722DOI: 10.1002/srin.201200263ISI: 000327745700002Scopus ID: 2-s2.0-84883542473OAI: oai:DiVA.org:kth-117722DiVA: diva2:602780
Funder
Vinnova
Note

QC 20131204. Updated from submitted to published.

Available from: 2013-02-04 Created: 2013-02-04 Last updated: 2017-12-06Bibliographically approved
In thesis
1. Some Aspects of Improving Initial Filling Conditions and Steel Cleanliness by Flow Pattern Control Using a Swirling Flow in the Uphill Teeming Process
Open this publication in new window or tab >>Some Aspects of Improving Initial Filling Conditions and Steel Cleanliness by Flow Pattern Control Using a Swirling Flow in the Uphill Teeming Process
2013 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The flow pattern has widely been recognized to have an impact on the exogenous non-metallic inclusion generation in the gating system and mold flux entrapment in the uphill teeming process. Thus, a well-controlled flow pattern during the teeming process can improve the quality of ingots and further increase the yield during steel production. The current study focused on investigating and optimizing the flow pattern of steel in the gating system and molds to improve steel cleanliness during the initial filling moment. A mathematical model considering a trumpet was initially compared to a reduced model only considering part of the runner channel. Thereafter, the influence of swirl blades implemented at the bottom of the vertical runner on the improvement of initial filling conditions in the molds was investigated in a model considering the entire mold system including a trumpet. The effects of a swirl blade orientation on a swirling flow were further discussed. The simulation results, when utilizing swirl blades, were also verified by plant trials performed at Scana Steel. In addition, a new novel swirling flow generation component, TurboSwirl, was studied in a model considering the entire mold system including a trumpet. The model was based on modifications of the refractory geometry at the elbow of the runners near the mold without the usage of an inserted flow control device in the gating system. Owing to its great potential for improving the flow pattern of steel during the initial filling moment, the effect of TurboSwirl on steel cleanliness was also studied. The results showed that the initial filling conditions during the uphill teeming process can be improved by using a swirl blade or a TurboSwirl in the gating system. This makes it possible to further decrease the initial position of mold powder bags. In addition, it reduces the possibilities of exogenous non-metallic inclusion generation in the gating system as well as mold flux entrapment in the mold during the uphill teeming process. However, the utilization of swirl blades created a considerable amount of droplets when steel entered the molds during the first couple of seconds, which also was verified by the plant trials. The introduction of TurboSwirl showed a greater potential than a swirl blade due to a more evenly distributed swirling flow. The DPM model adopted in the simulations revealed that the TurboSwirl can improve steel cleanliness by increasing the non-metallic inclusion collision rate both with respect to Stokes and turbulent collisions.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2013. xii,, 61 p.
Keyword
uphill teeming, ingot casting, flow pattern, swirl blade, TurboSwirl, realizable k-ε model, CFD.
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:kth:diva-117718 (URN)978-91-7501-596-5 (ISBN)
Public defence
2013-02-22, B1, Brinellvägen 23, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20130204

Available from: 2013-02-04 Created: 2013-02-03 Last updated: 2013-02-04Bibliographically approved

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