Optimization of flow control device on twin channel induction heating tundish by simulation
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摘要: 为解决双通道感应加热中间包原型死区体积比大，平均停留时间短，各铸流差异性大的问题，设计了不同导流孔方案的挡墙和加热通道，并通过数值模拟中间包的流场和温度场。结果表明，在中间包内设挡墙可以很好地改善钢液流动状况。A2方案（八字型挡墙上开两个导流孔，孔径130 mm，与挡墙水平倾角5°，下孔仰角25°，上孔仰角15°）平均停留时间延长了207.2 s，死区体积降低了23.89个百分点，边部水口与中间水口的最大温差为3 ℃。椭圆跑道型加热通道（E2方案）对中间包加热效果更好。通过生产实践证明边部水口与中间水口的最大温差约为3～4 ℃，优化的控流装置改善了中间包的流动性和差异性。Abstract: In order to solve the problems of low volume utilization, short average residence time and poor consistency of each flow of the twin channel induction heating tundish without flow control devices, weirs with different diversion holes and heating twin channels were designed. The flow field and temperature field of tundish are simulated by numerical simulation and water simulation. Simulation results show that the flow of molten steel can be improved by setting a wall in the tundish. For Scheme A2 (two diversion holes are opened on the splayed wall, with diameter of 130 mm and a horizontal inclination of 5° to the retaining wall, an elevation of 25° for the lower hole and 15° for the upper hole), the average residence time is extended by 207.2 s, the dead zone volume is reduced by 23.89%, and the maximum temperature difference between the edge nozzle and the middle nozzle is 3 ℃. Scheme E2 (Runway type heating twin channel) can achieve better heating effect on tundish. The production practice has proved that the maximum temperature difference between the edge water outlet and the middle water outlet is about 3～4 ℃.The optimized flow control device improves the fluidity inside the tundish.
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Key words:
- tundish /
- induction heating /
- flow control device /
- temperature field /
- flow field
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图 2 通道式感应加热模拟方案（原型）示意（单位：mm）
Figure 2. Schematic diagram of twin channel type induction heating simulation scheme
图 3 原型包与采用A1方案的中间包三维流线
Figure 3. 3D streamline diagram of tundish without wall and with A1 scheme
图 4 不同类型挡墙的中间包流体RTD曲线
Figure 4. RTD curves of flow liquid in tundish with different type walls
图 5 原型包与A2方案整体温度等值分布
Figure 5. Temperature equivalent distribution of tundish without wall and scheme A2
图 6 不同加热通道方案中间包整体温度等值分布
Figure 6. Equivalent distribution diagram of overall temperature in tundish under different heating twin channel schemes
图 7 方案A2数模与水模的 RTD 曲线比较
Figure 7. Comparison of RTD curves between numerical and water simulation in scheme A2
图 8 方案A2中间包的水模与数模的流体流动状态对比
Figure 8. Comparison of fluid flow state between numerical and water simulation in scheme A2
表 1 感应加热中间包工艺参数与钢液物性参数
Table 1. Process parameters of tundish with induction heating and physical parameters of molten steel
中间包
容量/t钢包长水口
直径/mm感应加热通道
长度/mm生产铸坯断
面/(mm×mm)设计拉速/
(m·min−1)密度/
(kg·m−3)粘度/
(Pa·s)热容量/
[J·(kg·K)−1]传热系数/
[W·(m·K)−1]54 75 ～1560 390×480 0.43～0.49 7000 0.0065 750 41 
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表 2 挡墙导流孔结构方案
Table 2. Structural scheme of different wall diversion holes and heating twin channels
方案 设计差异 原型 无挡墙 A1 八字形挡墙，导流孔与挡墙水平倾角5°，下孔仰角25°，
上孔仰角20°A2 八字形挡墙，导流孔与挡墙水平倾角5°，下孔仰角25°，
上孔仰角15°B1 八字形挡墙，导流孔与挡墙垂直，下孔仰角25°，
上孔仰角20°B2 八字形挡墙，导流孔与挡墙垂直，下孔仰角25°，
上孔仰角15°
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表 3 不同类型挡墙的RTD曲线的分析结果
Table 3. Analysis results of RTD curves under different type walls
方案 出水口 响应时间/s 峰值时间/s 每流平均停留
时间/s中间包总体平均
停留时间/s活塞区体积比/% 死区体积比/% 全混流体积比/% 各流示踪剂浓度
总体平均标准差原型 1流 222 598 1354.9 1041.4 37.23 34.64 28.12 0.0097 2流 82.5 365 995.8 3流 82.5 360 989.3 4流 219 612 1364.3 A1 1流 227 925.5 1170.9 1214.1 37 13.21 44.39 0.0047 2流 207 1039 1280.8 3流 208 1067.5 1249.5 4流 220 852 1161 A2 1流 232 903 1215.8 1248.6 38.14 10.75 51.11 0.0048 2流 221.5 1102 1317.3 3流 255.5 1074.5 1315.2 4流 211.5 812.5 1148.3 B1 1流 244.5 928.5 1181 1216.6 34.62 13.04 52.34 0.0037 2流 210.5 1054.5 1261.5 3流 219.5 1019 1246.4 4流 222.5 885 1179.3 B2 1流 225.5 911.5 1172.5 1212.9 33.43 13.3 53.27 0.0039 2流 226 1104 1266.6 3流 234 1067 1244.1 4流 226 878 1169.6
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表 4 中间包内边流与中间流的钢水温度
Table 4. Temperature difference between different strands in tundish
大包重量/t 中间包重量/t 边流温度/℃ 中间流温度/℃ 温差/℃ 115 52 1523 1519 4 91 51 1524 1520 4 42 54 1519 1516 3
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