I.
INTRODUCTION
P R I O R to continuous casting a heat of steel, it is standard practice to inject an inert gas into the bath through
a bottom-mounted porous element or through a lance.
The purpose of this operation is to control the steel temperature by mixing the cold metal at the bottom of the
ladle with the hotter metal at the top. Temperature control is vital both for product quality and the smoothness
of the operation. The superheat profoundly influences
cast structure (columnar v s equiaxed) and, thereby,
macrosegregation, centerline porosity, and crack formation in the as-cast, semifinished shape. Excessive
superheat also exacerbates breakouts, although inadequate superheat may cause nozzle freeze-off and large
skulls remaining in the tundish. Temperature control obviously depends as well on other practices from tapping
to casting, e . g . , tapping stream characteristics, ladle preheat, ladle additions, use of ladle lids, slag thickness,
ladle refractories, hold time prior to casting, and use of
ladle furnace, t~-Sl
Ladle stirring with an inert gas has the additional beneficial effect of facilitating inclusion removal and thereby
improving steel cleanness. However, excessive gas flow
rates or long stirring times can lead to dirtier steel due
to the reoxidation of the metal exposed to air by the discharging gas. [~,2,31
This paper addresses the question of the minimum stirring time necessary at typical gas flow rates to achieve
temperature homogenization in a ladle equipped with a
porous element mounted at the bottom centerline. The
approach combines a turbulent recirculating fluid f l o w
model and recently determined gas-fraction correlations
for a submerged jet.
II.
PREVIOUS W O R K
Recently, mathematical treatments of the destratification due to mixing induced by electromagnetic and gas
stirring have been published. The mathematical analysis
involves solution of the fluid flow and temperature field,
including modeling of the turbulence and the two-phase
zone with the appropriate boundary conditions, t6,71
The effects o f different algebraic and differential turbulence models on the calculated flow field have been
discussed in the literature, t7'81 The effective viscosities
predicted close to the symmetry axis and the top surface
are considerably larger when applying differential models
compared to algebraic models. This results in a comparatively higher entrainment of the liquid in the plume and,
consequently, higher velocities in the.low-velocity region of the ladle (outer bottom region). Algebraic models
are simpler and entail lower computational costs; however, due to the recirculatory nature of the flow, transport of the turbulence properties occurs so that the use
of differential models is desirable.
The characterization of the two-phase zone (size, phase
distribution, bubble size, and liquid and gas velocities)
has been approached in an increasingly sophisticated way.
In earlier studies, the two-phase region was treated as a
solid body moving with a defined velocity, which then
induced the fluid motion through friction on the surrounding liquid.t9] In later treatments, it was recognized
that fluid motion was induced mainly by density differences between the two-phase plume and the surrounding
liquid. [7,8,1~ Subsequently, the two-phase region has
been treated as a single phase with a variable density.
The gas concentration within the plume has been calculated theoretically with nonslip models tx~] and drift-flux
models, tT,s,~~ The gas concentration variation with radius
has been prescribed as uniform or as an arbitrary function. Other authors have considered a simple assumption
of uniform gas fraction over the entire plume, t~3] The
size of the plume has been defined based on visual observation of the breakthrough eye, and its geometry has
been generally considered cylindrical or at an imposed
angle.
In general, the investigations have reported good
agreement between the computed and experimental
VOLUME 20B, OCTOBER 1989--603
III.
The governing differential equations are written, respectively, for mass, momentum, and energy in the following manner:
0
0
Oz (rpu) + ~r (rpv) = 0
O(pu)
--+
Ot
O(puu)
Oz
OZ
R (m)
do (m)
3.57
1.79
0.013
Qo (m3/S)
7 . 9 6 x 10 -3
T stratification (~
Pgo (kg/m 3)
Pt (kg/m 3)
/z (kg/m s)
fit (~ -t)
kt (W/m ~
Cp~ (J/kg ~
Cpg (J/kg ~
trr
Fr
40 (1540 to 1580)
0.933
7500
6.2 >( 10 -3
4.4 10 -6
41
755
520
0.11
17,379
h b (m)
O(pruv)
+ - r Or
"-[- - -
~['~eff
rOr
o(
--
Oz
[1]
r/-Leff
) o(
/'/~eff
"l'- - -
r Or
rlff.eff
Oz
+ Pl g a + plg[3t(T -- Tref)
O(pv)
[21
O(puv) O(prvv)
Ot
Oz
r Or
o(~
ql_
~Zeff
OZ
-~- ~
Oz
l,~e ff
- -
r Or
rl.t.eff
Or
o ( O;r) -
+ --r Or rtzoee
2 m . -j
[3]
METALLURGICAL TRANSACTIONS B
O(pT)
- - +
Ot
O(puT)
- - +
Oz
O(prvT)
-
r Or
0 Far
Oz
o( O_?r
)
rFaf
L \ Qo/
[41
\pgo/ \do/
N < 1.35
[111
r Or
[(gdo5)~
2. Turbulence modeling
In the present work, the k-e model proposed by Jones
and Launder t22) was employed. The transport equations
for turbulence kinetic energy and turbulence energy dissipation in transient form are given as follows:
O(pk)
--+
Ot
O(puk)
Oz
O(prvk)
+ - r Or
O(pue)
Oz
O(prve)
+ - r Or
0 ~eff
Oz \ ~
+
Oz/
r
r Or
[61
where G, the generation term, is given by
2
G = ix, 2 \ O z /
(on
\Or/
[7]
+ Cdok2
[8]
Foff = /x + fi__L
Ofmax
[
= exp
OfT,t
METALLURGICALTRANSACTIONSB
(~oZ)
(~go)
(i)
-rotraax/2
[10]
[14]
C. Boundary Conditions
1. Axis of symmetry
Zero flux conditions are imposed as a result of
axisymmetry:
=
[91
( r ) 24 ]
-0.7
[12]
0;
Or
(9/
=0.275
--
The values of the constants recommended in the literature have been used for the turbulence equation t23~
(Table II). One should note, however, that these constants have not been tested adequately for liquid metals
having a low Prandtl number. The model is not corrected
for buoyancy effects and does not account for the presence of two phases.
--
N -> 1.35
Ou
O"T
~go
p = (1 - a)pt + ap e
+ ~r+oz/J
[131
pe
[5]
O(pe)
--+
Ot
am~x = 106.90
r.... 2
Ok
--=0;
Or
OT
--=
Or
v = 0;
Oe
--=0
Or
[15]
2. Bath f r e e surface
Zero stresses are assumed. Axial velocities and heat
flux are zero.
Ov
--
Ok
=
0;
Oz
--
Oe
=
0;
Oz
u = 0;
--
Oz
qs = 0
[16]
VOLUME20B, OCTOBER1989--605
1=o
.
. . . . .
; - - .
. . . . . . .
,. . . . . . .
"
;
.........
: ......
. ....
"__.'..u .............
" .........
9 . . . . . . . .
'
~.-~
.................. ;
. ......
!_LI
_,.
....
.i,,-!' ".~
',
'1
,,
o i
:
!
i " : !
II
,,,. . . . . .
',
r, . . ~ ,, . - .
,,
,,
......
~, . . . . . . . . . . . . .
'
:
,
....... .....
:....... i-!
'
i
$
'
.~...L
',
',
. . . . . .
i
~. . . . . ~. . . .
'
......
',
'
~ .....
'
. . . . .
i
, ,,',
r _ . . ~ . . ,
.~.L
'l',
,
--r
V.
"
-,-"
g - ;---i---: ............................
~
OI
,:
:::
J . . . . . . . . . . .
E:
"
,>,
,, . . . . ,: . . . ~ -. - ~ ,, . . . . .
ld-!
',
"
~-:~ ....
. . . . . .
:
',
o
; Ii
II
RESULTS
AND
DISCUSSION
........ :...,...-_.
! ......
~ ............
,,
:. . . . .
',. . . . . . . . .
,._., . . . . . . . . . . . . .
',
~---~ ...................
: : i
~.....
~--..a-.q---r.~-.-t
'
,
,
~
,
,
,
.
,
,,,
,. . . . . . . . . .
,. . . . . . . ',. . . . .
~ .......................
~ ...... ,
;
, ,
',
',
:
:,:;
,
' ', ,
,
,
,
,
:
~
,: ,~
',. . . . . . - - . , . . .
.........................
9. . . . - , - ~ - , ~ .
'i
,...'._1...'
". . ~. . . - .
.........
" : _.
. _.
. ] .,
<
.- .
-'~ i-
"
1.79m
k,'
>
Fig, lSchematic
diagram
of axisymmetric
gas
illustrating the 21 26 grid, the gas isoconcentration
two-phase
region,
and the boundary
conditions.
injection
system,
contours
in the
assumes that the production of the turbulence kinetic energy, k, is equal to the dissipation rate, e.
IV.
SOLUTION PROCEDURE
Table
II.
Constants
in the
k-e
Model
Cl
Cz
Ca
tr~
trr.t
1.44
1.92
0.09
1.0
1.3
1.0
606--VOLUME
20B, OCTOBER
1989
A . Predicted Fluid F l o w
The transient velocity patterns corresponding to different time-steps are shown in Figures 2(a) through
(c). The numbers in the figures indicate the ratio of the
velocity at the given time and the corresponding velocity
at 240 seconds. It is seen that the steady-state motion is
established after approximately 180 seconds o f injection
time. As expected, the central and near top surface are
the first to reach steady state. At steady state, the largest
velocities can be found in the central region (1.20 m / s ) ,
the top surface (0.4 m / s ) , and outer regions near the
surface of the bath (0.25 m / s ) . The vortex is located in
the upper half of the melt, and it moves gradually from
the center toward the wall.
Figures 3(a) through (c) show the turbulent kinetic energy distribution within the melt at different times after
the start of injection. It can be seen that high levels of
turbulence are rapidly established in the center and upper
regions of the bath. Turbulence at the inner and lower
regions develops later. The highest zones of turbulence
are located in the center and upper parts of the vessel.
A comparison between the velocity fields at 180 seconds
computed with and without thermal buoyancy showed
no significant differences. This confirms that thermal
buoyancy is appreciably smaller than the buoyancy due
to the gas density differences. No difference was found
between the calculations at 180 and 240 seconds; therefore, the results at 240 seconds are not presented.
Figures 4(a) through (c) show the predicted ratios of
the effective viscosity to the molecular viscosity at different times after the start of the injection. It can be seen
that the highest levels of the turbulent viscosity are found
in the plume at the breakthrough eye. Comparison with
the results of Sahai and Guthrie t~3j reveals that they have
reported slightly higher effective viscosities. This is
probably due to the assumption of a cylindrical plume
METALLURGICAL
TRANSACTIONS
0.75
0.93
UO
1,12
--.%\
I
9...
o~z8
,I
0.34
.,
0.94
0.85
E
o
o
1.0
1.0
LO
1.0
LO
~.
0.18
I.~
[ r
.I
0,16
I,O4
1.03
1.0
,,t
Lo,
,ot
t_o.
t1
/
!
o.ao
.
0.04
o.,gs
0.22
0.86 9s
0.94
i.?
9
0..84
(a)
o,91
/~
L,o ,
o.69
Os
(b)
Lp
1.0
LO
180s
(c~
Fig. 2 - - P r e d i c t e d mean velocity fields in a 250-ton steel-containing radle for different times after the start of injection (velocity (m/s)). Numbers
appearing in figures are the ratio of the velocity for the given time to the corresponding velocity at 240 s at (a) 9 s, (b) 60 s, and (c) 180 s.
Figures 5(a) through (e) show the temperature distribution at different times from the start of injection. It
can be seen that the isotherms are rapidly displaced upward in the central region of the bath. The outer regions
at the bottom of the bath remain stratified for a longer
time interval. The convective transport of energy is dominant at the early stages of injection. The temperature
differences are reduced to 9 ~ at 30 seconds, 3 ~ at
60 seconds, and 2 ~ at 90 seconds after the injection
starts. After 90 seconds, the homogenization becomes
slower, and the diffusive mechanism becomes more significant. For all practical purposes, the homogenization
is completed 180 seconds after the injection starts.
2. Fully transient treatment
Figures 6(a) through (e) show the temperature distribution at 9, 30, 60, 90, and 180 seconds from the start
of injection. Comparison of Figure 6 to Figure 5 shows
the large delay in mixing after the start of injection. Fast
METALLURGICAL TRANSACTIONS B
CONCLUSIONS
ce
(a)
(b)
(c)
Fig. 3 - - P r e d i c t e d turbulent kinetic energy distributions (m2/s 2) in a 250-ton steel-containing ladle for different times after the start of injection
at (a) 9 s, (b) 60 s, and (c) 180 s.
(a)
(b)
(c)
Fig. 4 - - P r e d i c t e d distributions of the ratio of effective-to-molecular viscosity in a 250-ton steel-containing ladle for different times after the start
of injection at (a) 9 s, (b) 60 s, and (c) 180 s.
608--VOLUME 20B, OCTOBER 1989
METALLURGICAL TRANSACTIONS B
30s
(a)
(b)
(c)
f
tO
j/
(d)
180s
90s
(e)
Fig. 5 - - P r e d i c t e d temperature distributions (~ in a 250-ton steel-containing ladle for different times after the "start" of mixing. Calculations
from the partially transient model at (a) 9 s, (b) 30 s, (c) 60 s, (d) 90 s, and (e) 180 s.
METALLURGICAL TRANSACTIONS B
j/
I
1541
1541
95
(a)
30s
(b)
(c)
1805
(d)
(e)
Fig_ 6 - - P r e d i c t e d temperature distributions (~ in a 250-ton steel-containing ladle for different times after the start of injection. Calculations
from the fully transient model at (a) 9 s, (b) 30 s, (c) 60 s, (d) 90 s, and (e) 180 s.
610-- VOLUME 20B, OCTOBER 1989
METALLURGICAL TRANSACTIONS B
that the convective effects are dominant in the temperature destratification. The fully transient calculations,
however, reveal much slower destratification at the early
stages of injection than in the case of the steady-state
velocity assumption. In both cases, complete homogenization occurs approximately 180 seconds after injection. This value compares well with experimentally
reported results. It is likely that the difference in mixing
dynamics predicted can have a significant influence on
the chemical mixing of species located in the lower regions of the vessel where low velocities prevail.
NOMENCLATURE
C1, C2,
Cd
hb
k
kl
heat capacity, J / k g ~
diameter of nozzle, m
Froude number = Qo/gdo
2
5
acceleration due to gravity, m / s 2
generation of turbulent energy, k g / m s 3
depth of liquid, m
turbulence kinetic e n e r g y , m2/s 2
thermal conductivity of liquid, W / ( m ~
parameter defined as
[(gdSo/ Q~)~176
P
~, Owb
ao
R
R6
t
T
Trof
U
V
2'
O/, O/max
3,
(z /do) ~
METALLURGICAL TRANSACTIONS B
ACKNOWLEDGMENT
The authors are grateful to the Natural Sciences and
Engineering Research Council of Canada for support of
this work.
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