Featured Research

from universities, journals, and other organizations

Mathematical Model Could Remedy Costly Steel-Making Problem

Date:
April 13, 2000
Source:
University Of Illinois At Urbana-Champaign
Summary:
In the modern making of steel, molten metal flows from a bathtub-shaped vessel -- called a tundish -- into a water-cooled, bottomless mold in a continuous casting operation. Clogging of the tundish nozzle can lead to hidden defects in the steel or costly halts in production. Researchers at the University of Illinois have developed a mathematical model that successfully predicts when clogs are about to occur, allowing time for remedial action.

CHAMPAIGN, Ill. -- In the modern making of steel, molten metal flows from a bathtub-shaped vessel -- called a tundish -- into a water-cooled, bottomless mold in a continuous casting operation. Clogging of the tundish nozzle can lead to hidden defects in the steel or costly halts in production. Researchers at the University of Illinois have developed a mathematical model that successfully predicts when clogs are about to occur, allowing time for remedial action.

"Nozzle clogging has been an industrywide problem that seemed impossible to solve," said Brian Thomas, a professor of mechanical and industrial engineering and director of the Continuous Casting Consortium at the UI. "In the past, steel manufacturers simply had to wait for a clog to occur, and then suffer the consequences. By identifying potential clogging conditions in advance, manufacturers can improve both product quality and plant productivity."

One way manufacturers try to minimize clogging is by injecting inert argon gas through the nozzle wall. The gas reduces contact between metal and atmosphere, which otherwise could create small oxide inclusions in the steel. These bits of oxide, along with other foreign particles, can collect on the nozzle, eventually restricting the flow and causing the steel to freeze into a solid plug.

To maintain constant production, manufacturers use a slide gate to control the flow of molten steel. But moving the slide gate can reduce pressure in the nozzle and suck in air, further aggravating the problem of oxide formation. A necessary step in the model's creation was determining the pressure drop in the system as a function of both slide-gate position and argon-injection rate.

By using principles of fluid dynamics, heat transfer and stress analysis, Thomas and his colleagues simulated the relevant aspects of the steel-making process. The resulting computational model was verified in two independent ways.

First, the model's predictions were compared with experimental results obtained using particle image velocimetry on scale models of the tundish, nozzle and mold. The model predictions and PIV measurements compared very well. Second, actual plant measurements taken during normal steel production were compared with those predicted by the model. Again, the results agreed favorably over a wide range of operating conditions.

"Based upon process variables such as casting speed, tundish depth, slide-gate opening and

argon-injection rate, the model predicts the theoretical flow rate through the nozzle," Thomas said. "By comparing the actual flow rate with the predicted flow rate, plant personnel can infer the clogging status of the nozzle and take the appropriate action."

Thomas described the model at the annual meeting of The Minerals, Metals and Materials Society, held March 12-16 in Nashville, Tenn., and the application to clogging at the annual Steelmaking Conference, held March 26-29 in Pittsburgh.


Story Source:

The above story is based on materials provided by University Of Illinois At Urbana-Champaign. Note: Materials may be edited for content and length.


Cite This Page:

University Of Illinois At Urbana-Champaign. "Mathematical Model Could Remedy Costly Steel-Making Problem." ScienceDaily. ScienceDaily, 13 April 2000. <www.sciencedaily.com/releases/2000/04/000406092238.htm>.
University Of Illinois At Urbana-Champaign. (2000, April 13). Mathematical Model Could Remedy Costly Steel-Making Problem. ScienceDaily. Retrieved September 16, 2014 from www.sciencedaily.com/releases/2000/04/000406092238.htm
University Of Illinois At Urbana-Champaign. "Mathematical Model Could Remedy Costly Steel-Making Problem." ScienceDaily. www.sciencedaily.com/releases/2000/04/000406092238.htm (accessed September 16, 2014).

Share This



More Computers & Math News

Tuesday, September 16, 2014

Featured Research

from universities, journals, and other organizations


Featured Videos

from AP, Reuters, AFP, and other news services

FBI Finishes $1 Billion Facial Recognition System

FBI Finishes $1 Billion Facial Recognition System

Newsy (Sep. 15, 2014) The FBI announced it plans to make its Next Generation Identification System available to law enforcement, but some privacy advocates are worried. Video provided by Newsy
Powered by NewsLook.com
Microsoft to Buy 'Minecraft' Maker for $2.5B

Microsoft to Buy 'Minecraft' Maker for $2.5B

AP (Sep. 15, 2014) Microsoft will acquire the maker of the long-running hit game Minecraft for $2.5 billion as the company continues to invest in its Xbox gaming platform and looks to grab attention on mobile phones. (Sept. 15) Video provided by AP
Powered by NewsLook.com
Manufacturer Prints 3-D Car In Record Time

Manufacturer Prints 3-D Car In Record Time

Newsy (Sep. 15, 2014) Automobile manufacturer Local Motors created a drivable electric car using a 3-D printer. Printing the body only took 44 hours. Video provided by Newsy
Powered by NewsLook.com
What $2.5B Deal Could Mean For Microsoft, 'Minecraft'

What $2.5B Deal Could Mean For Microsoft, 'Minecraft'

Newsy (Sep. 15, 2014) While Microsoft looks to be expanding its mobile business, the creators of "Minecraft" are stepping aside. Video provided by Newsy
Powered by NewsLook.com

Search ScienceDaily

Number of stories in archives: 140,361

Find with keyword(s):
Enter a keyword or phrase to search ScienceDaily for related topics and research stories.

Save/Print:
Share:

Breaking News:
from the past week

In Other News

... from NewsDaily.com

Science News

Health News

Environment News

Technology News



Save/Print:
Share:

Free Subscriptions


Get the latest science news with ScienceDaily's free email newsletters, updated daily and weekly. Or view hourly updated newsfeeds in your RSS reader:

Get Social & Mobile


Keep up to date with the latest news from ScienceDaily via social networks and mobile apps:

Have Feedback?


Tell us what you think of ScienceDaily -- we welcome both positive and negative comments. Have any problems using the site? Questions?
Mobile: iPhone Android Web
Follow: Facebook Twitter Google+
Subscribe: RSS Feeds Email Newsletters
Latest Headlines Health & Medicine Mind & Brain Space & Time Matter & Energy Computers & Math Plants & Animals Earth & Climate Fossils & Ruins