钢包电磁搅拌磁流耦合模拟研究
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摘要
钢包电磁搅拌是钢包精炼过程中的一种重要的搅拌方式。钢包电磁搅拌是利用搅拌器在钢液中产生的电磁力驱动钢包中钢液流动,这种流动能够很好改善钢包精炼过程中的流动、传热和传质条件,满足钢包精炼过程中的热力学和动力学要求。钢包电磁搅拌方法结合钢包精炼的其它手段如电弧加热等,可以产生良好的冶金效果;同时,钢包电磁搅拌具有高的可靠性、安全性和经济性,能够显著提高钢铁企业的产品质量和生产效率。
本文利用大型通用有限元软件ANSYS,以电磁场和流场基本理论为基础,建立了电磁搅拌作用下,钢包内部电磁场和流场的三维有限元模型,模拟了钢包电磁搅拌下钢包内部磁场的分布形态和钢液在电磁力作用下的速度分布。模拟结果表明:在线圈加载电流的作用下,搅拌器周围产生交变的电磁场;钢液中的磁感应强度沿钢包半径方向上显现剧烈的衰减;电磁力的总体方向是向上的,从而推动钢液沿钢包壁向上运动,进而使钢液形成一个大的单一循环流动;钢包内的速度和湍流动能分布均匀。这种钢包流动状态具有良好的冶金热力学和动力学条件,能够满足钢包冶金的要求。
本文比较了一个90t钢包电磁搅拌器,在搅拌器线圈缠绕方式和电流供电方式不同的情况下,钢包内磁场和流场的分布情况。结果表明它们在钢包内产生的磁场和流场分布趋势相同,数值不同,对于90t钢包电磁搅拌器优先选择集中式绕组,加载两相低频电流的电磁搅拌器。
本文进一步探讨了电磁搅拌器与钢液不同的距离参数和电磁搅拌器不同工艺参数下,钢包内磁场和流场分布。在实际工作条件允许的情况下,应尽量减小钢包和搅拌器之间的距离,从而增加钢液所受到的电磁力,使钢液的速度进一步提高,因此可以起到很好的搅拌效果。搅拌器频率和电流强度的增加有利于提高钢液的搅拌强度和增加搅拌区域,但太高的钢液流速并不有利于钢液的精炼,选择频率范围在1.1Hz-1.8Hz,电流强度在800A-1200A的工艺条件能够满足钢包精炼成分和温度均匀的要求。
Electromagnetic stirring in ladle furnace (LF-EMS) is an important stirring means of ladle furnace refining process. Electromagnetic stirring (EMS) utilizes the electromagnetic force that intensifies flow of molten steel. The flow improves the conditions of heat transfer and mass transfer and meets the requirement of thermodynamics and dynamics in ladle refining. Combined the other ladle refining means, for example electric arc heating, electromagnetic stirring can bring good metallurgy efficiency. Electromagnetic stirring has highly reliability, safety and economic. It can significantly improve the quality of steel products and production efficiency.
The ANSYS is a large popular finite element analytic ware. Based on the electromagnetic theory and flowing theory, the three dimensional finite element model of magnetic field and flow field of molten steel was built by ANSYS. The electromagnetic fields and the liquid metal velocity in the coupling fields were studied by the method of numerical simulation. The simulation results show that, under the coil loading, alternating electromagnetic fields are generated around stirrer, along the ladle radius direction the magnetic field intensity in the liquid steel shows acute attenuation; the electromagnetic force is generally upward direction, thus promotes the molten steel along the ladle wall upward movement, and forms a single large circulation, while, the speed and turbulent kinetic energy distributes evenly. The flow meets the need of ladle metallurgy.
In the different of coil winding and current forming of power supplying, the distribution of magnetic field and flow field in ladle furnace is basically the same, different in numerical. For the 90t ladle, electromagnetic stirrer preferentially selects the forms of centralized winding, loading two-phase low-frequency current electromagnetic stirrer.
The distribution of magnetic field and flow field in different distance between ladle and stirring were researched. With the decreasing distance between ladle and stirring, induction density and magnetic force in ladle furnace can be further enhanced, so it could play a very good mixing effect. In actual working conditions permitting, it should minimize the distance between ladle and stirring as far as possible. The influence of technological process parameters, including current intensity and current frequency are investigated. The results show that, while the increasing of the current intensity and current frequency, the stirrer can increase the stirring intensity and expand the stirring area,but too much of steel flow velocity makes against the refining of steel. Electing frequency range from 1.1Hz to 1.8Hz, current intensity in a range from 800A to 1200A, process conditions can meet ladle refining requirements.
本文利用大型通用有限元软件ANSYS,以电磁场和流场基本理论为基础,建立了电磁搅拌作用下,钢包内部电磁场和流场的三维有限元模型,模拟了钢包电磁搅拌下钢包内部磁场的分布形态和钢液在电磁力作用下的速度分布。模拟结果表明:在线圈加载电流的作用下,搅拌器周围产生交变的电磁场;钢液中的磁感应强度沿钢包半径方向上显现剧烈的衰减;电磁力的总体方向是向上的,从而推动钢液沿钢包壁向上运动,进而使钢液形成一个大的单一循环流动;钢包内的速度和湍流动能分布均匀。这种钢包流动状态具有良好的冶金热力学和动力学条件,能够满足钢包冶金的要求。
本文比较了一个90t钢包电磁搅拌器,在搅拌器线圈缠绕方式和电流供电方式不同的情况下,钢包内磁场和流场的分布情况。结果表明它们在钢包内产生的磁场和流场分布趋势相同,数值不同,对于90t钢包电磁搅拌器优先选择集中式绕组,加载两相低频电流的电磁搅拌器。
本文进一步探讨了电磁搅拌器与钢液不同的距离参数和电磁搅拌器不同工艺参数下,钢包内磁场和流场分布。在实际工作条件允许的情况下,应尽量减小钢包和搅拌器之间的距离,从而增加钢液所受到的电磁力,使钢液的速度进一步提高,因此可以起到很好的搅拌效果。搅拌器频率和电流强度的增加有利于提高钢液的搅拌强度和增加搅拌区域,但太高的钢液流速并不有利于钢液的精炼,选择频率范围在1.1Hz-1.8Hz,电流强度在800A-1200A的工艺条件能够满足钢包精炼成分和温度均匀的要求。
Electromagnetic stirring in ladle furnace (LF-EMS) is an important stirring means of ladle furnace refining process. Electromagnetic stirring (EMS) utilizes the electromagnetic force that intensifies flow of molten steel. The flow improves the conditions of heat transfer and mass transfer and meets the requirement of thermodynamics and dynamics in ladle refining. Combined the other ladle refining means, for example electric arc heating, electromagnetic stirring can bring good metallurgy efficiency. Electromagnetic stirring has highly reliability, safety and economic. It can significantly improve the quality of steel products and production efficiency.
The ANSYS is a large popular finite element analytic ware. Based on the electromagnetic theory and flowing theory, the three dimensional finite element model of magnetic field and flow field of molten steel was built by ANSYS. The electromagnetic fields and the liquid metal velocity in the coupling fields were studied by the method of numerical simulation. The simulation results show that, under the coil loading, alternating electromagnetic fields are generated around stirrer, along the ladle radius direction the magnetic field intensity in the liquid steel shows acute attenuation; the electromagnetic force is generally upward direction, thus promotes the molten steel along the ladle wall upward movement, and forms a single large circulation, while, the speed and turbulent kinetic energy distributes evenly. The flow meets the need of ladle metallurgy.
In the different of coil winding and current forming of power supplying, the distribution of magnetic field and flow field in ladle furnace is basically the same, different in numerical. For the 90t ladle, electromagnetic stirrer preferentially selects the forms of centralized winding, loading two-phase low-frequency current electromagnetic stirrer.
The distribution of magnetic field and flow field in different distance between ladle and stirring were researched. With the decreasing distance between ladle and stirring, induction density and magnetic force in ladle furnace can be further enhanced, so it could play a very good mixing effect. In actual working conditions permitting, it should minimize the distance between ladle and stirring as far as possible. The influence of technological process parameters, including current intensity and current frequency are investigated. The results show that, while the increasing of the current intensity and current frequency, the stirrer can increase the stirring intensity and expand the stirring area,but too much of steel flow velocity makes against the refining of steel. Electing frequency range from 1.1Hz to 1.8Hz, current intensity in a range from 800A to 1200A, process conditions can meet ladle refining requirements.
引文
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[2] [日]捤冈博幸.炉外精炼[M].北京:冶金工业出版社,2002:105-235.
[3]刘浏,何平.二次精炼技术的发展与配置[J].特殊钢,1999,20(2) :1-6.
[4]刘敬龙,金恒阁,刘世坚,等.谈炉外精炼技术[J].河南冶金,2004,12(2) :7-9.
[5]张鉴.炉外精炼的理论与实践[M].北京:冶金工业出版社,1999:233-518.
[6]张志杰.国际先进LF钢水精炼工程控制技术的搭建与优化[D].山东大学硕士学位论文,2004.
[7]刘川汉.我国钢包炉(LF)的发展现状[J].特殊钢,2001,(4):31-33.
[8] Marcel Garnier. Electromagnetic Processing of liquid materials in Europe [J].ISIJ International, 1990, 30(1): 1-7.
[9]匡世波.钢包炉(LF)内流动与混合过程的数值模拟[D].东北大学硕士学位论文,2003.
[10]李依依,李殿中,朱苗勇.金属材料制备工艺的计算机模拟[M].北京:科学出版社,2006.1-43.
[11] A. Jauhiainen, L. Jonsson, D.Y.Sheng. Modeling of Alloy Mixing into Steel [J]. Scandinavian Journal of Metallurgy, 2001, 30(4): 242-253.
[12] Mazumdar D, Guthrie, R.I.L .On mathematical models and numerical solutions of gas stirred ladle systems [J].Applied Mathematical Modelling, 1993, 17(5):255-262.
[13]西安电炉研究所行业室情报组.钢包精炼法[J].工业加热,1975,(2):24-42.
[14]杨洪良.钢包精炼过程中电磁搅拌技术使用效果研究[C].中国特殊钢年会2005论文集.北京:中国金属学会特殊钢分会,2005:125-129.
[15] A Lehman, O Sjoden, A Kuchaev. Electromagnetic equipment for non-contraction treatment of liquid metal in metallurgical processes[R]. Joint 15th riga and 6th PAMIR international conference on fundamental and applied MHD. Rigas Jurmala,2005:27-30.
[16] Anders J Thrum. Induction versus gas stirring in ladle furnaces [J]. AISE Steel Technology, 2003, 80(3):35-39.
[17]西安电炉研究所行业室情报组.钢包精炼法[J].工业加热,1975,(2) :24-42.
[18]范鼎东,刘国平.ASEA-SKF钢包精炼炉脱氧工艺探讨[J].炼钢,2000,16(2) :43-46.
[19]范鼎东,张建平,唐希伦等ASEA-SKF钢包精炼炉洁净钢冶炼工艺研究[J].钢铁, 2000, 35(12) :23-25.
[20] Berg Bertil, Carlsson Goran, Bramming Mats. Ladle metallurgy– influence of different stirring methods [J]. Scandinavian Journal of Metallurgy, 1982, 14(6):299-305.
[21] Anders Thrum,孔祥茂.钢水加热合金化工艺-钢包感应搅拌[J].特殊钢,1996,17(4):46-48.
[22]西安电炉研究所二室.钢包精炼炉[J].工艺加热,1975,(2):1-23.
[23] Mathias Dubke ,Karl-Hermann Tacke.Flow field in electromagnetic stirring of rectangular strands with linear inductors:Part1.theory and experiments with cold models[J].Metallurgical transaction B,1988,19b(8):581-593.
[24] Natarajan T.T., El-kaddah N. Three dimensional Finite Element Simulation of Electromagnetically Driven Flow in Sub-Mold Stirring of Steel Slabs[J]. Steelmaking Conference Proceedings, 1999, 8:437- 444.
[25]张洪丽,王恩刚,贾光霖,等.搅拌器的结构参数对钢液内电磁场和流场分布的影响[J].钢铁研究学报,2002,14(4):10-15.
[26]张洪丽,王恩刚,贾光霖,等.影响线性电磁搅拌流场分布的电参数分析[J].东北大学学报,2002,23(8):773-775.
[27] Lehman, Anders, Sjoden Olof. Improved steel quality and reduced production cost using induction stirring [J]. SEAISI Quarterly, 2003, 32(3):33-42.
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