1. Your Success is Our Goal Understanding the steel solidification in tundish nozzles X International PHOENICS Users Conference Melbourne, May 2004

2. Your Success is Our Goal CST 20-08-03 Slide 2 © IT PS 2003 Steel Solidification Chemtech - A Siemens Company, Rio de Janeiro / RJ – Brazil Carlos Eduardo Fontes Flávio Martins de Queiroz Guimarães CST - Companhia Siderúrgica de Tubarão, Serra / ES – Brazil Henrique S. Furtado Sandro de Souza Santos AUTHORS

3. Your Success is Our Goal CST 20-08-03 Slide 3 © IT PS 2003 Steel Solidification Projeto de Equipamentos Sistema de Inertização

4. Your Success is Our Goal CST 20-08-03 Slide 4 © IT PS 2003 Steel Solidification Objective and Motivation To model the steel solidification phenomena that is occurring in the tundish outlet valves in the continuous casting process, in order to identify and mitigate its causes. To use the CFD technique to simulate this process, since it has already been used by Chemtech to the optimal design of the tundish inertization system. To analyze the flow of two different steels (Family 10 and 40) and three different valves (MLC1, MLC2 Single and MLC2 Twin).

5. Your Success is Our Goal CST 20-08-03 Slide 5 © IT PS 2003 Steel Solidification The Tundish

6. Your Success is Our Goal CST 20-08-03 Slide 6 © IT PS 2003 Steel Solidification The Problem

7. Your Success is Our Goal CST 20-08-03 Slide 7 © IT PS 2003 Steel Solidification Solidification Model Entalphy Velocity Porosity associated to the lost latent heat fraction

8. Your Success is Our Goal CST 20-08-03 Slide 8 © IT PS 2003 Steel Solidification Model Validation Data from Voller & Prakash Solid fraction in 250 s: PHOENICS: 34,8%Voller & Prakash: 35%

9. Your Success is Our Goal CST 20-08-03 Slide 9 © IT PS 2003 Steel Solidification CST Model Physical Properties of Solid Blocks

10. Your Success is Our Goal CST 20-08-03 Slide 10 © IT PS 2003 Steel Solidification CST Model Physical properties of Steel

11. Your Success is Our Goal CST 20-08-03 Slide 11 © IT PS 2003 Steel Solidification Model Validation: Use of Field Data Valve MLC1: start-up programmation given by CST; Steel heights during the process: 0.5, 0.8 e 1.2 m Inlet Temperature:1565ºC Initial Temperature of solid blocks: 1000ºC Steel Family: 20 External Temperature: 40ºC

12. Your Success is Our Goal CST 20-08-03 Slide 12 © IT PS 2003 Steel Solidification Comparison with Field data: Mass Flow x Valve aperture

13. Your Success is Our Goal CST 20-08-03 Slide 13 © IT PS 2003 Steel Solidification Comparison with Field data: Valve Temperature

14. Your Success is Our Goal CST 20-08-03 Slide 14 © IT PS 2003 Steel Solidification Testing the Solidification Model: Base Case Steel flow is function of the steel height inside the tundish Steel height: 0,5 m Steel Family: 10 Inlet Temperature: 1535°C (2°C Super-heat) Valve: MLC1 External Temperature: 40°C Initial Temperature of solid blocks: 1000°C

15. Your Success is Our Goal CST 20-08-03 Slide 15 © IT PS 2003 Steel Solidification Base case results: Solidification after 30 seconds

16. Your Success is Our Goal CST 20-08-03 Slide 16 © IT PS 2003 Steel Solidification Choosing the geometry for the analysis: Comparison 2D x 3D MLC1 Valve with defined steel flow; Same grid and domain; time: 100 seconds. 2D 3D

17. Your Success is Our Goal CST 20-08-03 Slide 17 © IT PS 2003 Steel Solidification Comparison 2D x 3D: Velocity Profiles 2D 3D

18. Your Success is Our Goal CST 20-08-03 Slide 18 © IT PS 2003 Steel Solidification Comparison 2D x 3D: Temperature Profiles 2D 3D

19. Your Success is Our Goal CST 20-08-03 Slide 19 © IT PS 2003 Steel Solidification Simulated Cases MLC1 Valve with Family 10 MLC1 Valve with Family 40 MLC2 Single Valve with Family 10 MLC2 Single Valve with Family 40 MLC2 Twin Valve with Family 10 MLC2 Twin Valve with Family 40

20. Your Success is Our Goal CST 20-08-03 Slide 20 © IT PS 2003 Steel Solidification Valve: MLC1 Steel: FAM 10

21. Your Success is Our Goal CST 20-08-03 Slide 21 © IT PS 2003 Steel Solidification MLC1 – Family 10 Solid Fraction t = 160 s t = 150 s

22. Your Success is Our Goal CST 20-08-03 Slide 22 © IT PS 2003 Steel Solidification MLC1 – Family 10 Temperature t = 150 s t = 160 s

23. Your Success is Our Goal CST 20-08-03 Slide 23 © IT PS 2003 Steel Solidification MLC1 – Family 10 Pressure and Velocity Pressão Velocidade

24. Your Success is Our Goal CST 20-08-03 Slide 24 © IT PS 2003 Steel Solidification Results Analysis Tendency of steel solidification in the sliding plate region [begin of the process]; Tendency of steel solidification in the end of the valve [begin of the process] – However it is not real, since the valve is ducked in liquid steel.

25. Your Success is Our Goal CST 20-08-03 Slide 25 © IT PS 2003 Steel Solidification Remarks of this Group of Simulations Tendency of steel solidification in the sliding plate region – This behavior is commented in many papers ; Tendency of steel solidification in the end of the valve [begin of the process] – However it is not real, since the valve is ducked in liquid steel. ; Results show that solidifation problem only occurs before the first 200 seconds. Process fluid dynamics is not conclusive about the causes of the solidification problem. Sensibility analysis (SH, Tini)

26. Your Success is Our Goal CST 20-08-03 Slide 26 © IT PS 2003 Steel Solidification Sensibility Analysis Simulation Conditions MLC1 Valve 12mm opened. Boundary condition for Inlet is a constant pressure of 60000 Pa (equivalent to a 0.8 m steel height in tundish). Simulation Time: 200 s.

27. Your Success is Our Goal CST 20-08-03 Slide 27 © IT PS 2003 Steel Solidification Worst case Family 10 – SH 05 – Tini 800°C Temperature Solid fraction

28. Your Success is Our Goal CST 20-08-03 Slide 28 © IT PS 2003 Steel Solidification A zoom in the problem

29. Your Success is Our Goal CST 20-08-03 Slide 29 © IT PS 2003 Steel Solidification Suggestions and Next steps: Super-heat temperature is more sensible than blocks initial temperature, although is more difficult to control. The possible solutions for the problem are: Increase pre-heating temperature; Increase super-heat; Increase the steel flow, respecting process constrains. Model improvements [next steps]: To include the valves cooling system; To use the 3D model of the whole tundish to get more information of the phenomena.

30. Your Success is Our Goal CST 20-08-03 Slide 30 © IT PS 2003 Steel Solidification Kontaktadresse: Peter Muster I&S GC Schuhstraße 60 91052 Erlangen Tel: 09131-7-24607 Mail: peter.muster@siemens.com Your Success is Our Goal www.siemens.com/itps1 www.chemtech.com.br Contact: Flávio Guimarães Senior Manager Tel: +55 (21) 3233-5100 Mail:flavio.guimaraes@chemtech.com.br THANK YOU