新型电磁出钢系统的研发及其效果分析
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摘要
钢包出钢系统作为衔接炼钢和轧钢之间的一项特殊作业方式,在钢材生产过程中起着至关重要的作用。为了满足高效、节能、环保的要求,并生产出高洁净、高品质的钢材,本文提出了用与钢液成分相同或相近的Fe-C合金代替传统引流砂,通过电磁感应加热,使钢包底部上水口的Fe-C合金全部或部分迅速熔化,从而实现自动出钢的电磁出钢系统。电磁出钢系统与传统出钢方法相比具有以下优点：(1)可以显著提高钢水的洁净度；(2)可以有效提高钢包的自动开浇率,使其达到100%；(3)可以减少浸入式水口的絮流,增加连浇炉数；(4)避免因使用引流砂而形成有毒的6价Cr对环境造成污染；(5)降低企业用于外购引流砂的成本。
电磁出钢系统能否在工业生产中得以成功应用,不仅取决于替代传统引流砂的Fe-C合金的烧结层能否快速实现全部或部分熔化,同时还取决于在感应加热的过程中,钢包的结构安全是否能够满足要求。本研究其目的是考察电磁出钢系统应用于钢包出钢的可行性,开发可以替代传统引流砂的Fe-C合金材料,找到最优的线圈结构参数和电流参数,并在此基础上提出一种适用于实际工业生产的电磁出钢系统。
为了验证电磁出钢系统是否可以满足出钢工艺效果的要求,先采用Fe/C混合物作为传统引流砂的替代材料,利用ANSYS通用有限元分析软件对钢包上水口处进行了稳态及瞬态分析,初步考察了感应加热的冶金效果。发现在钢包上水口处会形成稳定的温度梯度,在感应加热的过程中,感应热可以熔化Fe/C混合物中的Fe粒,说明电磁出钢系统应用于钢包出钢是可能并且可行的。在此基础上,通过实验的方法验证了Fe-C合金是可以作为钢包上水口处的填充材料。
根据电磁出钢的原理,本文自行设计和制造了模拟钢包底部的实验装置。首先,为了找出电流强度、电源频率和线圈直径等参数对出钢效果的影响规律,利用有限元数值模拟方法对自行设计的模拟钢包底部的实验装置进行了数值模拟研究,通过对试验装置底部圆形阻挡片外缘任一点温度变化的研究,发现了不同工艺参数对出钢时间的影响规律,讨论了因提高加热效率能否最大化缩短出钢时间的可行性。其次,根据数值模拟结果选择了相应的出钢用感应加热电源和线圈直径,并与模拟钢包底部的实验装置相结合,组成了高温热态实验装置。在此基础上,发现出钢时间随着功率的上升而不断缩短；达到工艺要求后,继续提高功率时,出钢时间还可以进一步缩短。再次,通过电磁出钢热态实验,研究了热态实验装置中钢包上水口处Fe-C合金的液固界面位置及其形貌。发现在钢包出钢前,将会在上水口中形成液态Fe-C合金、凝固的液态Fe-C合金、液态烧结的Fe-C合金、固态烧结的Fe-C合金及原始松散的Fe-C合金等5层。由凝固层、液态烧结层和固态烧结层所组成的钢液隔离层将有利于阻止钢液流入上水口侵蚀滑板。不仅如此,液固界面还会随着Fe-C合金熔点的降低而降低,也就是说,稳定状态时液固界面位置可以通过调节Fe-C合金熔点来调节。在此基础上,通过对不同成分的Fe-C合金对出钢效果的影响规律的研究,得出Fe-C合金熔点越低,出钢时间越短的结论。最后,找到了可以通过监测上水口外一点温度在出钢过程中的变化来在线控制滑板拉开时间的一种监测方法。
为了进一步探讨不同工艺参数对出钢效果的影响规律,利用ANSYS通用有限元分析软件对可以在工业中应用的电磁出钢系统进行建模,模拟了在电磁出钢装置中用Fe-C合金替代传统引流砂时,上水口处的温度场分布,找出了最佳的工艺参数,发现钢液与线圈距离H为214mn,线圈长度L为132mm,线圈直径D为140mm为,安匝数为36kA·N,电源频率为10kHz为最优的工艺参数。并在此工艺参数下进行了实现凝钢在短时间内熔化的可行性分析,研究表明在此工艺参数下可以实现顺利出钢。在此基础上,校验了钢包外壳在电磁出钢过程中的安全性。从而,为电磁出钢方法在工业中的应用提供了理论支持,为以后的实验方案提供可靠的参考数据。
在前文研究的基础上,本文对工业应用的电磁出钢系统进行了初步设计。提出了两种钢包底部的结构改造方案,并对不同方案的优缺点进行了探讨。讨论了感应加热电源和感应线圈选择的原则和方法,进而研究了工业实验中的功率和电流频率,为进一步的工业实验提供了钢包改造模型及可行性方案,提出了钢包底部电磁功能集成的理念,分析了工业实验中应注意的问题。
As a connection of the converter process and continuous-casting process, ladle teeming system of the molten steel from the ladle to the tundish is extremely important in steelmaking. In order to improve the productivity, energy efficiency and environmental protection and to produce cleaner and high-quality steel, a new ladle teeming method (electromagnetic steel-teeming method) using electromagnetic induction heating in slide-gate was proposed. The basic idea of this new process is to melt part of or the whole of the new ladle well-packing materials (i.e. Fe-C alloy with similar composition of the molten steel), which substitute the traditional nozzle sand, and achieve smoothly molten steel-teeming.
Electromagnetic steel-teeming method is regarded as an efficient way to reduce the inclusions in the molten steel and achieve100%automatic steel teeming. This new technology is one of the electromagnetic metallurgy methods and it shows great promise. The application of electromagnetic steel-teeming system can (1) significantly improve the clean degree of the molten steel;(2) significantly improve the ladle automatically open casting rate;(3) reduce blocking of the immersion nozzle, increase the continuous casting numbers;(4) avoid the environment pollution for using the nozzle sand and (5) avoid outsourcing nozzle sand and decrease costs.
Whether the electromagnetic steel-teeming system can be successfully applied in industrial production depends not only on the melting of part of or the whole of the Fe-C alloy, but also on the safety of the ladle shell under the induction heating condition. The purpose of this research is to investigate the feasibility of the electromagnetic steel-teeming system, to find better coil structural parameters and electrical parameters and to develop a suitable electromagentic steel-teeming system, which could be used in the inductrial steelmaking process.
In order to verify whether the electromagnetic steel-teeming system can meet the requirements of the ladle steel-teeming, the mixture of Fe particles and graphite powder was used to replace the traditional nozzle sand in the upper nozzle. Using ANSYS finite element analysis software, the temperature distribution of the upper nozzle in the bottom of the ladle is analyzed in steady and transient state, to examine the effects of the induction heating. It was found that a steady gradient temperature was formed in the upper nozzle. The Fe particles could be melted under the induction heating condition, which indicates that the electromagnetic steel-teeming is feasible. Furthermore, experimental method was employed to verify that the Fe-C alloy was suitable to be the substitutable material of the traditional nozzle sand.
Electromagnetic steel-teeming hot-condition experimental facility was designed and produced. Base on the facility, the numerical simulation method was employed to investigate the effects of the induction parameters such as current intensity, frequency and diameter of the coil on teeming time, which was tested by calculating the surface temperature of the blocker which located in the bottom of the upper nozzle in the hot-condition experiment. The results showed that the teeming time was decreased with the increases of current intensity and frequency, and with the decrease of coil diameter. The suggested parameters were found under the conditions of this research. The sintering mechanism and sintering conditions were discussed with the Fe-C alloy replaced the traditional nozzle sand in the upper nozzle. It was confirmed that the Fe-C alloy in the upper nozzle could form five layers as following:liquid layer, solidified layer, liquid-sintering layer, solid-sintering layer and original layer. The solidified, liquid-sintering and solid-sintering layers could prevent the molten steel stream from corroding the sliding plate. The position of the liquid/solid interface and its morphology were investigated by means of the hot-condition experiment. It was shown that the position of the interface was decreased with the decrease of Fe-C alloy melting point, that is, the position of the liquid/solid interface could be adjusted by changing the melting point of the Fe-C alloy. Furthermore, the effects of Fe-C alloy with different composition on teeming time were investigated. The opening time of the sliding plate in the electromagnetic steel-teeming process was found according to online detecting the temperature on the external surface of the upper nozzle.
The model of the electromagnetic steel-teeming system used in the industry was established by ANSYS finite element analysis software. Numerical simulation method based on the integration of both electromagnetic and thermal analysis modules of ANSYS was employed to investigate the surface temperature of the sintered Fe-C alloy which was used to prevent the molten steel from destroying the sliding plate. In addition, the effects of the coil structure parameters (such as distance of the molten steel and the coil, length and diameter of the coil) and electric current parameters (such as ampere turns, frequency) on teeming time were investigated. The optimal parameters were found according to the simulation, and the smoothly steel-teeming using induction heating was achieved in the optimal parameters'condition. How the ladle refractory met the technological requirements in the electromagnetic steel teeming process was also discussed. Additionally, the effects of molten steel temperature and melting point of Fe-C alloy on teeming time were studied. The safety of the steel shell under the action of electromagnetic induction heating with the optimal parameters was checked via the distribution of temperature field on the shell.
On the basis of above mentioned investigation, the electromagnetic steel-teeming system which could be used in the industry was preliminarily designed. We proposed two kinds of restructuring proposals to meet the requirements of the use of electromagnetic steel-teeming system in the ladle bottom. The advantages and disadvantages of the two proposals were discussed. The selected principle and methods of power and structure of the coil in the electromagnetic steel-teeming system were discussed as well. Additionally, the concept of electromagnetic-function integration was proposed. On the basis of the above analysis, we discussed the particular problems that should be took into account in the industrial experiments.
电磁出钢系统能否在工业生产中得以成功应用,不仅取决于替代传统引流砂的Fe-C合金的烧结层能否快速实现全部或部分熔化,同时还取决于在感应加热的过程中,钢包的结构安全是否能够满足要求。本研究其目的是考察电磁出钢系统应用于钢包出钢的可行性,开发可以替代传统引流砂的Fe-C合金材料,找到最优的线圈结构参数和电流参数,并在此基础上提出一种适用于实际工业生产的电磁出钢系统。
为了验证电磁出钢系统是否可以满足出钢工艺效果的要求,先采用Fe/C混合物作为传统引流砂的替代材料,利用ANSYS通用有限元分析软件对钢包上水口处进行了稳态及瞬态分析,初步考察了感应加热的冶金效果。发现在钢包上水口处会形成稳定的温度梯度,在感应加热的过程中,感应热可以熔化Fe/C混合物中的Fe粒,说明电磁出钢系统应用于钢包出钢是可能并且可行的。在此基础上,通过实验的方法验证了Fe-C合金是可以作为钢包上水口处的填充材料。
根据电磁出钢的原理,本文自行设计和制造了模拟钢包底部的实验装置。首先,为了找出电流强度、电源频率和线圈直径等参数对出钢效果的影响规律,利用有限元数值模拟方法对自行设计的模拟钢包底部的实验装置进行了数值模拟研究,通过对试验装置底部圆形阻挡片外缘任一点温度变化的研究,发现了不同工艺参数对出钢时间的影响规律,讨论了因提高加热效率能否最大化缩短出钢时间的可行性。其次,根据数值模拟结果选择了相应的出钢用感应加热电源和线圈直径,并与模拟钢包底部的实验装置相结合,组成了高温热态实验装置。在此基础上,发现出钢时间随着功率的上升而不断缩短；达到工艺要求后,继续提高功率时,出钢时间还可以进一步缩短。再次,通过电磁出钢热态实验,研究了热态实验装置中钢包上水口处Fe-C合金的液固界面位置及其形貌。发现在钢包出钢前,将会在上水口中形成液态Fe-C合金、凝固的液态Fe-C合金、液态烧结的Fe-C合金、固态烧结的Fe-C合金及原始松散的Fe-C合金等5层。由凝固层、液态烧结层和固态烧结层所组成的钢液隔离层将有利于阻止钢液流入上水口侵蚀滑板。不仅如此,液固界面还会随着Fe-C合金熔点的降低而降低,也就是说,稳定状态时液固界面位置可以通过调节Fe-C合金熔点来调节。在此基础上,通过对不同成分的Fe-C合金对出钢效果的影响规律的研究,得出Fe-C合金熔点越低,出钢时间越短的结论。最后,找到了可以通过监测上水口外一点温度在出钢过程中的变化来在线控制滑板拉开时间的一种监测方法。
为了进一步探讨不同工艺参数对出钢效果的影响规律,利用ANSYS通用有限元分析软件对可以在工业中应用的电磁出钢系统进行建模,模拟了在电磁出钢装置中用Fe-C合金替代传统引流砂时,上水口处的温度场分布,找出了最佳的工艺参数,发现钢液与线圈距离H为214mn,线圈长度L为132mm,线圈直径D为140mm为,安匝数为36kA·N,电源频率为10kHz为最优的工艺参数。并在此工艺参数下进行了实现凝钢在短时间内熔化的可行性分析,研究表明在此工艺参数下可以实现顺利出钢。在此基础上,校验了钢包外壳在电磁出钢过程中的安全性。从而,为电磁出钢方法在工业中的应用提供了理论支持,为以后的实验方案提供可靠的参考数据。
在前文研究的基础上,本文对工业应用的电磁出钢系统进行了初步设计。提出了两种钢包底部的结构改造方案,并对不同方案的优缺点进行了探讨。讨论了感应加热电源和感应线圈选择的原则和方法,进而研究了工业实验中的功率和电流频率,为进一步的工业实验提供了钢包改造模型及可行性方案,提出了钢包底部电磁功能集成的理念,分析了工业实验中应注意的问题。
As a connection of the converter process and continuous-casting process, ladle teeming system of the molten steel from the ladle to the tundish is extremely important in steelmaking. In order to improve the productivity, energy efficiency and environmental protection and to produce cleaner and high-quality steel, a new ladle teeming method (electromagnetic steel-teeming method) using electromagnetic induction heating in slide-gate was proposed. The basic idea of this new process is to melt part of or the whole of the new ladle well-packing materials (i.e. Fe-C alloy with similar composition of the molten steel), which substitute the traditional nozzle sand, and achieve smoothly molten steel-teeming.
Electromagnetic steel-teeming method is regarded as an efficient way to reduce the inclusions in the molten steel and achieve100%automatic steel teeming. This new technology is one of the electromagnetic metallurgy methods and it shows great promise. The application of electromagnetic steel-teeming system can (1) significantly improve the clean degree of the molten steel;(2) significantly improve the ladle automatically open casting rate;(3) reduce blocking of the immersion nozzle, increase the continuous casting numbers;(4) avoid the environment pollution for using the nozzle sand and (5) avoid outsourcing nozzle sand and decrease costs.
Whether the electromagnetic steel-teeming system can be successfully applied in industrial production depends not only on the melting of part of or the whole of the Fe-C alloy, but also on the safety of the ladle shell under the induction heating condition. The purpose of this research is to investigate the feasibility of the electromagnetic steel-teeming system, to find better coil structural parameters and electrical parameters and to develop a suitable electromagentic steel-teeming system, which could be used in the inductrial steelmaking process.
In order to verify whether the electromagnetic steel-teeming system can meet the requirements of the ladle steel-teeming, the mixture of Fe particles and graphite powder was used to replace the traditional nozzle sand in the upper nozzle. Using ANSYS finite element analysis software, the temperature distribution of the upper nozzle in the bottom of the ladle is analyzed in steady and transient state, to examine the effects of the induction heating. It was found that a steady gradient temperature was formed in the upper nozzle. The Fe particles could be melted under the induction heating condition, which indicates that the electromagnetic steel-teeming is feasible. Furthermore, experimental method was employed to verify that the Fe-C alloy was suitable to be the substitutable material of the traditional nozzle sand.
Electromagnetic steel-teeming hot-condition experimental facility was designed and produced. Base on the facility, the numerical simulation method was employed to investigate the effects of the induction parameters such as current intensity, frequency and diameter of the coil on teeming time, which was tested by calculating the surface temperature of the blocker which located in the bottom of the upper nozzle in the hot-condition experiment. The results showed that the teeming time was decreased with the increases of current intensity and frequency, and with the decrease of coil diameter. The suggested parameters were found under the conditions of this research. The sintering mechanism and sintering conditions were discussed with the Fe-C alloy replaced the traditional nozzle sand in the upper nozzle. It was confirmed that the Fe-C alloy in the upper nozzle could form five layers as following:liquid layer, solidified layer, liquid-sintering layer, solid-sintering layer and original layer. The solidified, liquid-sintering and solid-sintering layers could prevent the molten steel stream from corroding the sliding plate. The position of the liquid/solid interface and its morphology were investigated by means of the hot-condition experiment. It was shown that the position of the interface was decreased with the decrease of Fe-C alloy melting point, that is, the position of the liquid/solid interface could be adjusted by changing the melting point of the Fe-C alloy. Furthermore, the effects of Fe-C alloy with different composition on teeming time were investigated. The opening time of the sliding plate in the electromagnetic steel-teeming process was found according to online detecting the temperature on the external surface of the upper nozzle.
The model of the electromagnetic steel-teeming system used in the industry was established by ANSYS finite element analysis software. Numerical simulation method based on the integration of both electromagnetic and thermal analysis modules of ANSYS was employed to investigate the surface temperature of the sintered Fe-C alloy which was used to prevent the molten steel from destroying the sliding plate. In addition, the effects of the coil structure parameters (such as distance of the molten steel and the coil, length and diameter of the coil) and electric current parameters (such as ampere turns, frequency) on teeming time were investigated. The optimal parameters were found according to the simulation, and the smoothly steel-teeming using induction heating was achieved in the optimal parameters'condition. How the ladle refractory met the technological requirements in the electromagnetic steel teeming process was also discussed. Additionally, the effects of molten steel temperature and melting point of Fe-C alloy on teeming time were studied. The safety of the steel shell under the action of electromagnetic induction heating with the optimal parameters was checked via the distribution of temperature field on the shell.
On the basis of above mentioned investigation, the electromagnetic steel-teeming system which could be used in the industry was preliminarily designed. We proposed two kinds of restructuring proposals to meet the requirements of the use of electromagnetic steel-teeming system in the ladle bottom. The advantages and disadvantages of the two proposals were discussed. The selected principle and methods of power and structure of the coil in the electromagnetic steel-teeming system were discussed as well. Additionally, the concept of electromagnetic-function integration was proposed. On the basis of the above analysis, we discussed the particular problems that should be took into account in the industrial experiments.
引文
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