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電磁攪拌條件下結晶器內鋼液多相流動和卷渣現象的大渦模擬

Large eddy simulation on the multiphase fluid flow and slag entrainment in a continuous casting mold with electromagnetic stirring

  • 摘要: 針對大方坯連鑄結晶器內的流動和卷渣行為進行了三維數值模擬仿真,應用大渦模擬模型模擬湍流、應用VOF模型模擬渣相?鋼液和空氣?渣相?鋼液的多相流。研究對比了鋼液單相流動、渣相?鋼液兩相流動和空氣?渣相?鋼液三相流動3種模型下結晶器內的流動、鋼?渣界面液位形狀和波動及卷渣行為,并通過工業用計算機斷層成像技術(工業CT)檢測了連鑄坯中大顆粒卷渣類夾雜物數量隨著電磁攪拌電流強度的變化。結果表明,在150 A、2 Hz結晶器電磁攪拌下,3種模型得到的結晶器內鋼液流場差別較小,但在鋼?渣界面處差別較大。鋼液單相模型下鋼液表面流動速度比其他兩種模型鋼?渣界面處的速度更大。渣相?鋼液兩相模型和空氣?渣相?鋼液三相模型的卷渣速率分別為0.00118和0.00040 kg?s?1。渣相?鋼液兩相模型條件下,由于上表面即渣的頂面不能彎曲,所以鋼?渣界面處的湍動能沒有得到耗散,所以比三相模型的湍動能更大,因此其預測的卷渣速率偏大。當攪拌電流強度增大到300 A,渣相?鋼液兩相模型和空氣?渣相?鋼液三相模型的卷渣速率分別為150 A條件下的5倍和15倍;當電流頻率增大到4 Hz,渣相?鋼液兩相模型的卷渣速率變化很小,空氣?渣相?鋼液三相模型的卷渣速率降低為2 Hz條件下的1/3。因此,為了正確的模擬和預測結晶器鋼?渣界面處的卷渣行為,必須使用空氣?渣相?鋼液三相瞬態模型進行模擬仿真。

     

    Abstract: Due to the closed environment with high temperature and pressure in the continuous casting (CC) process, numerical simulation technology with flexible control and low cost of phenomena in the CC mold has been a research hotspot. The multiphase flow, heat transfer, solidification of steel and slag, and other complex interaction in the mold are some of the simulation difficulties. Various physical models have been established in recent studies to obtain the reactions and effects of the different phases. However, the influence of different models on the simulation results is rarely studied. In the current study, a three-dimensional (3D) mathematical model, coupled with the large eddy simulation (LES) turbulent model and volume of fluid (VOF) multiphase model, was established to investigate the multiphase flow, slag-steel interface level fluctuation, and slag entrainment in the mold of a steel bloom CC with mold electromagnetic stirring (M-EMS). The air?slag?steel three-phase flow, slag?steel two-phase flow, and steel single-phase flow were compared. An industrial computerized tomography (CT) was used to detect the large entrainment slag inclusions in blooms with different stirring current intensities. With a 150-A current intensity and a 2-Hz frequency electromagnetic stirring at the mold, the multiphase flows are approximately identical for the three models, although different at the slag?steel interface. The speed on the top surface of the single-phase model is higher than that of the multiphase models. The level fluctuation of the two-phase model is slightly more severe than that of the three-phase model, and the net slag entrainment rates of the two-phase and three-phase models are 0.00118 and 0.00040 kg·s?1, respectively. The turbulence kinetic energy at the slag?steel interface of the two-phase model is significantly greater than that of the three-phase model because the turbulence kinetic energy can not be dissipated, unlike that in the actual process. Thus, the predicated slag entrainment obtained by the two-phase model is higher. On increasing the stirring current intensity to 300 A, the net slag entrainment rate is 5 times and 15 times higher for the two-phase and three-phase model higher than that under 150 A; when the current frequency increases to 4 Hz, the net slag entrainment rate of the two-phase model varies little, while that of the three-phase model becomes 1/3 of that under 2 Hz. To accurately simulate and predict the slag entrainment phenomena at the CC mold, the air?slag?steel three-phase multiphase model should be mandatory.

     

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