Tundish CFD

Prepared by:- Manas V. More.
(133374006)
CFD modelling of liquid metal flow in
tundish and validation with an
experimental model
Guide:- Prof. Sandip Kumar Saha
Prof. Rajneesh Bhardwaj

7/5/2014 1 IIT Bombay
Contents
Tundish Fundamentals
Why CFD in tundish metallurgy?
Mathematical modelling
Previous work results and discussions

2 IIT Bombay 7/5/2014
Tundish Fundamentals
Tundish Parameters
Tundish geometry
Capacity
Refractory
Flow modifiers
Metering devices
Tundish slag

Source: Tundish metallurgy and clean steel,
Department of material science and engineering,
IIT-Kanpur, 21-22 September 2012.
Physio-Chemical Phenomena
Ladle changeover and grade intermixing
Temperature drop and heat loss
Re-oxidation, inclusion generation
Slag emulsification
Slag vortexing
Inclusion removal
Strand freezing

Why CFD in tundish metallurgy?
Design of tundish
Optimization of fluid flow
Turbulence or velocity distribution
Residence time
Inclusion floatation and removal
Appropriate location of flow control device

Mathematical modelling
Boundary
conditions
Turbulence
model K-

Phase I (Melt)
Model

Phase II (Slag)
Model

Model outputs
Flow distribution,
Temperature
distribution,
Velocity
distribution,
turbulence field etc
Two phase, unsteady three dimensional flow
Incompressible Newtonian fluid
Isothermal

Thermal energy transport in multiphase tundish:-
1. Liquid or primary phase thermal energy
conservation equation
=

2. Gas or secondary phase energy conservation
=

= Gas compressibility effect, = HTC/unit Vol.

h
c
= Heat transfer coefficient,
g
=

Hydrodynamic model

Fluid flow mathematical modelling:-
Continuity and RANS equations

= Liquid density, (kg.m
3
)
u
i
= Velocity component in x
i
direction, (m.s
1
)

eff
= Effective viscosity, (kg.m
1
.s
1
)

eff
=
o
+
t
;
o
= Laminar viscosity &
t
= Turbulence viscosity.
= Thermal expansion coefficient of the molten steel, (K
1
)

The - model gives the turbulent viscosity as-

C
= 0.09, = Turbulent kinetic energy (m

2
.s
2
),
= Turbulent energy dissipation rate, (m
2
.s
3
)

Fluid flow mathematical modelling:-

Turbulent K.E

Dissipation rate

=1.0, =1.3, =1.44, =1.92.

h = Enthalpy in (J.kg
1
) Pr
t
= 0.85,
C
P
= Specific heat (J.kg
1
.K
1
)
K
o
= Laminar thermal conductivity

k
eff
= Effective thermal
conductivity (Wm
1
K
1
)
Transport and removal of inclusions:-
Langrangian particle tracking method-
= Inclusion location at any time, (m)

The inclusion velocity equation can be derived from the
force balance:

Total force acting on the inclusion F : F
D
+ F
G

m
p
= Particle mass,
a
p
= Particle acceleration rate,
u = Known liquid velocity, (m/s)
= Inclusion and liquid densities, (kg.m
3
)

Source: Tundish
metallurgy and clean steel,
Department of material
science and engineering,
IIT-Kanpur, 21-22
September 2012.
Transport and removal of inclusions:-
C
D
= Drag coefficient as a function of inclusion Reynolds number

Turbulent fluctuation on the motion of inclusions are modeled using
- flow field by adding a random velocity fluctuation at each step.

Non-Stochastic model: Time averaged fluid flow velocity
Stochastic model:
u = Instantaneous fluid velocity, (m/s)
= Random velocity fluctuation, m/s.

Volume of fluid method:-
Free surface or interface tracking method.
Phase Fraction whose values define the two phases
creating the interface.
Uses Eulerian approach - Interface movement is
calculated on a fixed grid.

Phase fraction:

Advection equation:

Source :International Journal of
Heat and Mass Transfer 49 (2006) 740754

Volume of fluid method:-
Interface reconstruction-
Maintains accurate interface
shape in two-phase cells.

Reconstruction done using
Optimization Techniques : e.g.
Least squares Volume-of fluid
Interface Reconstruction
algorithm (LVIRA).

Continuous iterations calculating
interface normal and distance
for a given volume fraction in
two-phase cell.

Source :International Journal of
Heat and Mass Transfer 49
(2006) 740754

Boundary conditions:-
Geometrical parameter
Molten metal properties
Process parameters

Source :
Lifeng Zhang, Fluid flow, heat transfer
and inclusion motion in molten steel
continuous casting tundishes, Fifth
International Conference on CFD,
Australia 13-15 December 2006

Fluid flow: Isothermal & Non-isothermal Simulation

Source :
Lifeng Zhang, Fluid flow, heat
transfer and inclusion motion in
molten steel continuous casting
tundishes, Fifth International
Conference on CFD, Australia
13-15 December 2006
Temperature distribution at longitudinal center face

Temperature distribution on walls and bottom of tundish

Source :
Lifeng Zhang, Fluid flow, heat
transfer and inclusion motion in
molten steel continuous casting
tundishes, Fifth International
Conference on CFD, Australia
13-15 December 2006
Inclusion motion
Effect of random walk on
trajectory of inclusion
with different size.
Minimum and maximum
time required for
inclusion to travel to
outlet and top surface of
tundish

THANK YOU

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Prepared by:- Manas V. More.

= 0.09, = Turbulent kinetic energy (m

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