| 研究生: |
范志銘 Fan, Chih-Ming |
|---|---|
| 論文名稱: |
數學模式與物理模式在鋼鐵盛鋼桶精煉與連鑄製程之應用研究 Application of Mathematical Model and Physical Model in Ladle Refining and Continuous Casting Processes of Steel |
| 指導教授: |
黃文星
Hwang, W-S |
| 學位類別: |
博士 Doctor |
| 系所名稱: |
工學院 - 材料科學及工程學系 Department of Materials Science and Engineering |
| 論文出版年: | 2003 |
| 畢業學年度: | 91 |
| 語文別: | 中文 |
| 論文頁數: | 199 |
| 中文關鍵詞: | 鋼液分配器 、盛鋼桶 |
| 外文關鍵詞: | tundish, ladle |
| 相關次數: | 點閱:72 下載:3 |
| 分享至: |
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本研究的主要目的是針對鋼鐵連鑄製程中的盛鋼桶二次精煉氣體攪拌與鋼液分配器導流現象各發展一套基於SOLA計算流體力學的技術與K-ε 擾流模式技術的數學模式。第一套數學模式可以分析二次精煉時盛鋼桶內底吹攪拌的操作條件對盛鋼桶中之鋼液與氣體流動行為的影響,並藉此探討鈣線射入的最佳位置。第二套數學模式可以針對鋼液分配器內啟鑄期、穩態期與盛鋼桶交換期的流體流動現象進行模擬解析,了解不同型態鋼液分配器之擋牆設計對鋼液流動與鋼液清淨度的影響,並進一步設計出最佳的擋牆設計。本研究也建構物理模式,用以觀察、量測並驗證數學模式的準確度。研究結果顯示數學模式具有相當的可靠度可以作為一工具,解析現場連鑄製程的流體流動、熱傳與質傳現象。
針對現場盛鋼桶二次精煉氣體攪拌之模擬結果與水模實驗的結果有相同的趨勢,在盛鋼桶的正切底吹管與圓心的切面上,靠近plume zone加入添加物會造成添加物提早上浮,遠離plume zone加入添加物則有助於添加物向底部傳遞,射入點D 有最短的均混時間。現場操作模擬結果發現在盛鋼桶的正切底吹管與圓心的平面上,遠離底吹管的方向上,離圓心約為0.5~0.8 r附近是最理想的鈣矽線投入點,可產生最佳的傳遞與擴散的效果,可促進混合與化學反應。
針對現場垂直式下擋牆小鋼胚鋼液分配器啟鑄的充填流動現象與後續的開始連鑄流動現象,予以分析熱傳現象、介在物的分佈以及污穢粒子從鑄道出口離開的數目。分析結果發現出鋼前的鋼液分配器溫度分佈相當不均勻,而介在物在啟鑄充填過程中會累積聚集在第二道鑄道出口附近。現場也證實第二道澆道比第一道澆道出現頻率更高的啟鑄阻塞現象。使用斜置式下擋牆(LP-SD)的速度場中沒有明顯的渦流,不會使介在物在啟鑄充填過程中累積聚集在鑄道出口的附近,能降低澆道出現啟鑄阻塞現象的機會。此外使用斜置式下擋牆有較均勻的溫度分佈,表示使用斜置式下擋牆能使鋼液的分配更均勻。
本研究分別針對三個不同型態之鋼液分配器進行穩態流動的分析。這三個鋼液分配器包括A型四鑄道小鋼胚鋼液分配器、雙鑄道小鋼胚鋼液分配器與單鑄道扁鋼胚鋼液分配器。在A型四鑄道小鋼胚鋼液分配器中發現斜置式Baffle擋牆比正擺式的下擋牆設計有較高的均勻性。HP-SB之擋牆設計能大幅縮短第一道與第二道出口滯留時間的差距,因此A型四鑄道小鋼胚鋼液分配器是最佳的擋牆設計。在雙鑄道小鋼胚鋼液分配器中發現發現加高長槽狀流動控制元件(HLPP)引起最長的最小駐留時間,不但具有抑制入口區之紊流,而且可以引導鋼液沿著渣層移動,可促進介在物去除的能力。因此,加高長槽狀流動控制元件(HLPP)是雙鑄道小鋼胚鋼液分配器最佳的單元件式流動控制元件(SEFCD)。在單鑄道扁鋼胚鋼液分配器中,發現無擋牆之設計有明顯的短路現象以及最差的介在物去除效率,安裝擋牆後明顯消除短路現象。安裝凹型衝擊磚(PP)有最高的去除效率,對小於50 μm以下之介在物而言,也有相當高的去除效率,是單鑄道扁鋼胚鋼液分配器中最適合的擋牆設計。
本研究針對T型單鑄道扁鋼胚鋼液分配器分析盛鋼桶交換期鋼液分配器的流動現象。研究結果發現安裝上擋牆與斜置擋牆後不但可達到鋼液減速的效果,且可大幅減少渣粒子進入出口的數目,而WSLD40-F120擋牆有最少的渣粒子進入出口。因此,WSLD40-F120擋牆是T型單鑄道扁鋼胚鋼液分配器中最適合的擋牆設計。
The purpose of this study is to develop two mathematical models, which are based on a computational fluid dynamics technique, named SOLA, and the k-ε two-equation turbulence model, to analyze the fluid flow phenomena of molten steel in the ladle during the secondary refining process and the tundish operation in the continuous casting process of steel. The first mathematical model is used to analyze the fluid flow phenomena and the corresponding diffusion of the injected Ca-Si under various design and operating conditions to find the optimal Ca-Si injection position. The second mathematical model is used to analyze fluid flow phenomena and design the optimal flow control device during initial casting operation, steady state operation and ladle-interchange operation. Several physical models are also constructed in this study. Water model experiments are conducted to verify the accuracy and reliability of the mathematical models. Good agreements are observed between the simulations and measurements. As the mathematical model is verified to be a trustworthy tool, it is then applied to the actual operation to simulate the fluid flow; heat transfer and mass transfer phenomena of the secondary refining and continuous casting processes.
The flow pattern of two-phase flow in the stirred ladle for the secondary refining is simulated. The results show that the injection position of D, which has the coordinate of , has the shortest mixing time. The simulated results for the actual ladle operation show the similar trend to the water model. For the injection positions on the tuyere/circle center plane, the additives prematurely float to the top as the injection positions are near the plume zone. It helps the additives to transport to the bottom as the injection positions are away from the plume zone. The simulated results for the actual ladle operation show that the optimal positions for injection are located on the tuyere/circle-center plane, opposite side of the tuyere, and 0.5-0.8 r away from the circle center. For these injection positions, the mixing time is shorter and the flow pattern favors the transport of the additive to the bottom of the ladle.
The fluid flow and heat transfer phenomena of the molten steel in the tundish during its filling stage and subsequent initial casting operation are studied. The results show that the temperature field in LP-ND operation is not uniform Inclusion distribution and the extents of inclusion contamination among the outlets of the various strands in the tundish are also analyzed. The left half of tundish, inclusion contamination in the #2 strand is significantly more severe then that in the #1 strand. This is confirmed by the actual experience on the shop floor of that particular billet caster that the #2 strand experiences more difficulty in clogging problem during the initial casting operation than the #1 strand does. The LP-SD has no eddy near outlet strand and has more uniform temperature field. It shows that LP-SD lowers nozzle clogging and makes distribution of steel more uniform.
The fluid flow and mass transfer phenomena of the molten steel in the three different tundish caster during steady state are studied. Three tundish caster include A-shaped four strands billet tundish, twin strand billet tundish, and single strands slab tundish. In A-shaped four strands billet tundish, HP-SB reduces the difference of residence times between two strands, and makes distribution of steel more uniform. In twin strands billet tundish, the billet tundish with the HLPP design has the longest min-RT and it can inhibit turbulence as well as guide flow upward along slag/metal interface in the tundish. It is thus considered that HLPP arrangement is the optimal SEFCD design for twin strands billet tundish. In the single strand slab tundish, the result shows that the plain tundish has short circuit and the lowest inclusion removal ratio. The tundish with PP can reduce short circuit and has the highest inclusion removal ratio, even for inclusions, which is smaller than 50 μm. PP is the optimal SEFCD design for the single strand slab tundish.
The fluid flow and mass transfer phenomena of the molten steel in the tundish caster during ladle-change period are also studied. The results show that the weir and slanting dam reduce the velocity of steel and lower the chance for slag particles to flow into the outlet. WSLD40-F120 has the smallest number of slag particles to flow into the outlet and is considered the optimal flow control design in the T-shaped single strand slab tundish caster.
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