Tapping of Blast Furnace Main Trough: Modelling and Simulation

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ABSTRACT: Recently, the use of computational fluid dynamics, CFD, is acquiring importance on metallurgical industrial sector, mainly due to the rising of demand and the hard competition of the global market. By its nature, metallurgical processes are physically complex, conjugating many physical phenomena at high temperatures. A multiphase approach of the issues related to liquid metals fluid dynamic is even uncommon nowadays. Generally, the systems are considered as composed by only one phase. A critical unit operation where this assumption is not reasonable is the blast furnace withdraw, which has at least three phases: the cast-iron, slag, and atmospheric air. The aim of the operation is to separate the cast-iron from slag, and its efficiency is affected by jet/free-surface interaction. The life campaign of blast furnace main trough is determined by its lining refractory wear rate. And the wear mechanism is quite complex and controversial, but one knows that the fluid dynamics behavior is related to the process. As a first approach, this work presents a mathematical model that describes the two-phase flow of cast-iron and air, considering its three-dimensional, transient and turbulent nature. The temperature changing is not accounted for in the present work. The model has been solved with commercial code ANSYS CFXTM Release 11. Afterwards, obtained results have shown that the multiphase approach accounting for the jet/free-surface interaction is more suitable. Many details as the oscillatory behavior and the vortical and reverse flow, that had seen only in experiments and or in the industrial facility, were captured by model. A comparison to the velocity, wall shear stress, air volume fraction and turbulent kinetics energy fields to wear profile from industrial facility has been performed, and it was found that the turbulent kinetic energy levels seem to be the main factor responsible by the erosion, followed by cast iron superficial velocity action close to the walls. These data corroborate what has been written about the process reinforcing the hypothesis that there is a probable superposition of many effects, it been one of them the turbulence generation together the impact zone and a weak but continual wall shear stress field imposed on wall by the flow, what promotes the physical-chemical erosion of refractory lining

Category:

Science & Technology

Tags:

• Blast
• Furnace
• Main
• Trough
• Modelling
• and
• Simulation

[rvprezende]

@nctuche

The physical model is not of my own. It's from IAS - Institute Argentino de Siderurgia ( Argentin Institutite of Siderurgy). It's a work made by Begnis , Topolevsky and Brandalezi.

[nctuche]

What a amazing simulation, the results and animations are very perfect.

Would you mind telling me how to build the physical model?

Thank you very much..

[rvprezende]

the animation was done in ensight and the video edition on windows movie maker.

[rvprezende]

I've used ansys CFX release 11

[ciks66ciks]

Can you tell me where to work program