Abstract
Thermal stratification of liquid steel in a ladle during the holding period and the teeming operation has a direct bearing on the superheat available at the caster and hence on the caster set points such as casting speed and cooling rates. The changes in the caster set points are typically carried out based on temperature measurements at the end of tundish outlet. Thermal prediction models provide advance knowledge of the influence of process and design parameters on the steel temperature at various stages. Therefore, they can be used in making accurate decisions about the caster set points in real time. However, this requires both fast and accurate thermal prediction models. In this work, we develop a surrogate model for the prediction of thermal stratification using data extracted from a set of computational fluid dynamics (CFD) simulations, pre-determined using design of experiments technique. Regression method is used for training the predictor. The model predicts the stratified temperature profile instantaneously, for a given set of process parameters such as initial steel temperature, refractory heat content, slag thickness, and holding time. More than 96 pct of the predicted values are within an error range of ±5 K (±5 °C), when compared against corresponding CFD results. Considering its accuracy and computational efficiency, the model can be extended for thermal control of casting operations. This work also sets a benchmark for developing similar thermal models for downstream processes such as tundish and caster.
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Abbreviations
- ρ :
-
Density (kg m−3)
- κ :
-
Turbulent kinetic energy (m2 s−2)
- ϵ :
-
Turbulent kinetic energy dissipation rate (m2 s−3)
- μ :
-
Dynamic viscosity (kg m−1 s−1)
- μ t :
-
Turbulent viscosity (kg m−1 s−1)
- β :
-
Coefficient of thermal expansion (K−1)
- C p :
-
Specific heat capacity (J kg−1 K−1)
- G k :
-
Generation of turbulent kinetic energy due to mean velocity gradient
- G b :
-
Generation of turbulent kinetic energy due to buoyancy
- g :
-
Acceleration due to gravity (ms−2)
- h :
-
Convective heat transfer coefficient (Wm−2 K−1)
- k :
-
Thermal conductivity (Wm−1 K−1)
- p :
-
Pressure (Pa)
- Prt :
-
Turbulent Prandtl number
- T :
-
Temperature (K)
- t :
-
Time instance (s)
- U i ,U j :
-
Velocity component of the fluid (ms−1)
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Acknowledgments
Authors would like to thank Mr. Rohan Pandya, TRDDC for his help. Authors are thankful to Professor K A Padmanabhan for his guidance and suggestions. Authors also appreciate the continuous support from Dr. Pradip, TRDDC, TCS Research, and Mr. K Ananth Krishnan, CTO, TCS.
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Manuscript submitted March 21, 2016.
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Deodhar, A., Singh, U., Shukla, R. et al. Fast and Accurate Prediction of Stratified Steel Temperature During Holding Period of Ladle. Metall Mater Trans B 48, 1217–1229 (2017). https://doi.org/10.1007/s11663-016-0874-8
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DOI: https://doi.org/10.1007/s11663-016-0874-8