Saul Garcia-Hernandez

Mathematical Analysis of Inclusion Removal from Liquid Steel by Gas Bubbling in a Casting Tundish

The mechanism of inclusion removal from liquid steel by gas bubbling and bubble attachment in the tundish is complex due to the great number of variables involved, and it is even more difficult to study because of the turbulent flow conditions. The main objective of this work is to analyze and improve the understanding of the alumina inclusion removal rate by bubble attachment and by gas bubbling fluid dynamics effects. The results show that the inclusion collection probability mainly depends on the attachment mechanism by collision. This parameter was determined by calculating the induction time, which is shorter when the rupture time and the formation time of a stable three phases contact (particle/liquid/gas) are ignored than when it is fully considered, affecting the attachment probability. In addition, to achieve acceptable inclusion removal, a smaller bubble diameter is required, such as 1 mm. This consideration is almost impossible to achieve during tundish operation; a more realistic bubble diameter around 10 mm is employed, resulting in a very inefficient inclusion removal process by bubble attachment. Nevertheless, in a real casting tundish the inclusion removal rate employing argon bubbling is efficient; is mainly due to the fluid flow pattern changes rather than bubble attachment. Consequently, it is imperative to consider the summation of both removal mechanisms to compute a better approximation of this important operation.

Multiphase Flow Modeling of Slag Entrainment During Ladle Change-Over Operation

Steel transfer from the ladle to a single-strand tundish using a conventional ladle shroud (CLS), and a dissipative ladle shroud (DLS) is studied during the transient period of ladle change-over operation. Fluid velocities and fluid flow turbulence statistics during this unsteady operation were recorded by an ultrasound velocimetry probe in a 1/3 scale water–oil–air analog model (to emulate steel-slag-air system). Reynolds stress model and volume of fluid model allow the tracking of water–oil, water–air, and oil-air interfaces during this operation. Velocity measurements indicate a very high turbulence with the formation of a water–air bubbles-oil emulsion. Flow turbulence and the intensity of the emulsification decrease considerably due to an efficient dissipation of the turbulent kinetic energy employing the DLS instead of the CLS. The modeling results indicate that DLS is widely recommended to substitute flow control devices to improve the fluid dynamics of liquid steel during this transient operation.

Control of Slag-Dragging Effects at the Metal–Slag Interface through Electromagnetic Brake in a Slab Mold

Abstract Turbulent flow when steel is delivered through a nozzle in a slab mold induces dragging forces at the metal–slag interface that entrain slag droplets into the metal bulk. These dragging effects are discontinuous and correspond to the velocity fluctuations of turbulence at that interface which themselves, are dependent on nozzle immersion, nozzle design, mold width and casting speed. Slag viscosity and density, metal viscosity and slag layer thickness are employed to estimate that critical velocity which is embodied in a critical capillary number for some established mold operating conditions. This approach permits the link between all operating variables including flux chemistry and nozzle design with the interface instability. A relationship between the capillary number and the magnetic field strength used to brake the liquid steel is established which is used to assure the interface stability for any operating condition and flux chemistry.