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

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Tundish Fundamentals
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Tundish Parameters
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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
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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?
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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
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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




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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

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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
)


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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
)
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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.
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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.










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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










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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

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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


Previous work results and discussions
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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
Previous work results and discussions
17 IIT Bombay 7/5/2014
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
Previous work results and discussions
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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







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THANK YOU