Your Success is Our Goal INERTIZATION SYSTEM OF STEEL CASTING WITH PHOENICS IX International...
-
Upload
dwight-cobb -
Category
Documents
-
view
228 -
download
0
Transcript of Your Success is Our Goal INERTIZATION SYSTEM OF STEEL CASTING WITH PHOENICS IX International...
Your Success is Our Goalwww.siemens.com/itps1 www.chemtech.com.br
INERTIZATION SYSTEM OF STEEL CASTING WITH PHOENICS
IX International PHOENICS Users ConferenceIX International PHOENICS Users Conference
Moscow, 26Moscow, 26thth September 2002 September 2002
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 2
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Chemtech - A Siemens Company, Rio de Janeiro / RJ – BrazilChemtech - A Siemens Company, Rio de Janeiro / RJ – Brazil
Flávio Martins de Queiroz GuimarãesFlávio Martins de Queiroz Guimarães
Bruno de Almeida BarbabelaBruno de Almeida Barbabela
Luiz Eduardo Ganem Rubião Luiz Eduardo Ganem Rubião
CST - Companhia Siderúrgica de Tubarão, Serra / ES – BrazilCST - Companhia Siderúrgica de Tubarão, Serra / ES – Brazil
Henrique S. FurtadoHenrique S. Furtado
Sergio Lopes MattediSergio Lopes Mattedi
AUTHORS
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 3
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Longitudinal SectionLongitudinal Section Aluminum Oxide CrystalsAluminum Oxide Crystals
INTRODUCTION – THE PROBLEM
Oxidation of the steel surface during casting Oxidation of the steel surface during casting producing metallic oxidesproducing metallic oxides
Obstruction of all discharge pipesObstruction of all discharge pipes
Addition of impurities and reduces process yieldAddition of impurities and reduces process yield
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 4
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
INTRODUCTION – THE SOLUTION
ARGONIN
OXYGENOUT
Introduction of inert gases in the casting system to expel the existing atmosphere
This process usually makes use of noble gases as argon, which is very expensive to purchase
Simulations have been executed to predict the optimal argon inflow, time of inertization and process yield with minimum operational costs of impurities and reduces process yield
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 5
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
TUNDISH
INTRODUCTION – THE SYSTEM
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 6
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Upper ViewUpper View
OUTLETS & INLETS (IN BLUE)
THE TUNDISH – GEOMETRY STRUCTURE
Frontal ViewFrontal View
BAFFLES
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 7
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
All simulations were run on PHOENICS v3.4.All simulations were run on PHOENICS v3.4.
The follow configurations were setting:The follow configurations were setting:
Total Geometry: Total Geometry: 9494 mm x 1543 mm x 1790 mm9494 mm x 1543 mm x 1790 mm
Grid: Grid: 270 000 volume elements (cartesian grid) 270 000 volume elements (cartesian grid)
PARSOL: PARSOL: activeactive
Energy Equation: Energy Equation: activeactive
Turbulence Model: Turbulence Model: k-k- Chen-Kim model (KECHEN) Chen-Kim model (KECHEN)
Transient Solution: Transient Solution: activeactive
Total Number of Outlets: Total Number of Outlets: 3 (three) outlets3 (three) outlets
Total Number of Injectors: Total Number of Injectors: 3 (three) to 8 (eight) injectors3 (three) to 8 (eight) injectors
Argon Inlet Rate: Argon Inlet Rate: 250 to 380 Nm250 to 380 Nm33/h/h
Property models computed by INFORM.Property models computed by INFORM.
GENERAL SETTINGS
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 8
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
PROPERTIES SETTINGS – SPECIFIC HEAT
The following formulae for the pure components were used:The following formulae for the pure components were used:
Based on the above pure component specific heats, a Based on the above pure component specific heats, a formula for the mixture specific heat was developed. It was formula for the mixture specific heat was developed. It was considered in this formulation that the mixture is ideal and considered in this formulation that the mixture is ideal and that the air has a constant composition (21% Othat the air has a constant composition (21% O22).).
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 9
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
PROPERTIES SETTINGS – DENSITY
The following formula describe the evaluation of the mixture The following formula describe the evaluation of the mixture density. It was considered in this formulation that the mixture density. It was considered in this formulation that the mixture is ideal and binary (argon and air only).is ideal and binary (argon and air only).
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 10
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
PROPERTIES SETTINGS – VISCOSITY
The following formula describe the evaluation of the mixture The following formula describe the evaluation of the mixture viscosity. It was considered in this formulation that the viscosity. It was considered in this formulation that the viscosity is independent of the mixture composition. The viscosity is independent of the mixture composition. The temperature was computed, despite of the great difference of temperature was computed, despite of the great difference of temperature among the air inside the tundish and argon inlet temperature among the air inside the tundish and argon inlet by nozzles.by nozzles.
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 11
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
PROPERTIES SETTINGS – DIFFUSIVITY
The following formula describe the The following formula describe the evaluationevaluation of the mixture of the mixture diffusivity. It was considered in this formulation that the diffusivity. It was considered in this formulation that the mixture is ideal and binary (argon and air only). mixture is ideal and binary (argon and air only).
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 12
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
OUTPUT – OXYGEN CONCENTRATION
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 13
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
FIELD TEST VALIDATION
1 2 3 4 5ARGONNOZZLES
BAFFLES
OUTLETS OUTLETSOUTLETS
5 (five) sample points have been measured to 5 (five) sample points have been measured to analyze the dynamic behavior of the processanalyze the dynamic behavior of the process
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 14
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
FIELD TEST VALIDATION – TURBULENCE
Although both models fitted well this data, Although both models fitted well this data, the k-the k- Chen-Kim Chen-Kim
(KECHEN) was chosen(KECHEN) was chosen because the simulations results have because the simulations results have
shown that it had a little better mean correlation value andshown that it had a little better mean correlation value and
first step result fitted closer to the experimental curve. first step result fitted closer to the experimental curve.
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 15
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Point 1
0.00
5.00
10.00
15.00
20.00
25.00
0 50 100 150 200 250 300
Time (s)
%O
2 (v
/v)
Low High CFD
FIELD TEST VALIDATION – KECHEN MODEL
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 16
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Point 2
0.00
5.00
10.00
15.00
20.00
25.00
0 50 100 150 200 250 300
Time (s)
%O
2 (v
/v)
Low High CFD
FIELD TEST VALIDATION – KECHEN MODEL
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 17
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Point 3
0.00
5.00
10.00
15.00
20.00
25.00
0 50 100 150 200 250 300
Time (s)
%O
2 (v
/v)
Low High CFD
FIELD TEST VALIDATION – KECHEN MODEL
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 18
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Point 4
0.00
5.00
10.00
15.00
20.00
25.00
0 50 100 150 200 250 300
Time (s)
%O
2 (v
/v)
Low High CFD
FIELD TEST VALIDATION – KECHEN MODEL
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 19
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Point 5
0.00
5.00
10.00
15.00
20.00
25.00
0 50 100 150 200 250 300
Time (s)
%O
2 (v
/v)
Low High CFD
FIELD TEST VALIDATION – KECHEN MODEL
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 20
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Time = 2 minutes
Time = 3 minutes
Time = 1 minute
OXYGEN CONCENTRATION
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 21
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
Time = 4 minutes
Time = 5 minutes
OXYGEN CONCENTRATION
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 22
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
FINAL CASE
Several simulations have been performedSeveral simulations have been performed
The injections were relocated in order to avoid The injections were relocated in order to avoid stagnation zonesstagnation zones
The following figures show the results for the The following figures show the results for the final optimum injection pattern, as currently final optimum injection pattern, as currently implemented for daily operation (maximum residual implemented for daily operation (maximum residual oxygen concentration after 5 minutes of 2.08 %v/v):oxygen concentration after 5 minutes of 2.08 %v/v):
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 23
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
FINAL CASE – OXYGEN DYNAMIC PROFILE
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 25
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
FINAL CASE – OXYGEN PROFILE
OXYGEN CONCENTRATIONAFTER 5 MINUTES
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 26
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
OXYGEN CONCENTRATIONAFTER 5 MINUTES
FINAL CASE – OXYGEN ISOPLETH
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 27
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
CONCLUSION
The results showed:The results showed:
Excellent quantitative agreement with field data Excellent quantitative agreement with field data and good qualitative behaviorand good qualitative behavior
How CFD simulations are becoming even more a How CFD simulations are becoming even more a very important tool for equipment optimization in very important tool for equipment optimization in the process industriesthe process industries
Your Success is Our Goal
INE
RT
AR
GO
N_I
X_I
PU
C_M
OS
KO
W20
02.p
pt
Slid
e 28
© I
T P
S 2
002
Steel Casting
IX International PHOENICS Users Conference
FINAL
THANK YOUTHANK YOU
&&
QUESTIONSQUESTIONS