CN116306256B - Simulation method for efficiently and stably adding molten iron in steelmaking process - Google Patents

Simulation method for efficiently and stably adding molten iron in steelmaking process Download PDF

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CN116306256B
CN116306256B CN202310148570.4A CN202310148570A CN116306256B CN 116306256 B CN116306256 B CN 116306256B CN 202310148570 A CN202310148570 A CN 202310148570A CN 116306256 B CN116306256 B CN 116306256B
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刘威
孙烨
杨树峰
黄成永
李京社
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University of Science and Technology Beijing USTB
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Abstract

The application provides a simulation method for efficiently and stably adding molten iron in a steelmaking process, and relates to the field of metallurgy. The simulation method comprises the following steps: obtaining simulation experiment parameters, and constructing a three-dimensional geometric model of the ladle according to the actual size; performing grid division on the geometric model; setting a basic assumption, a control equation, a boundary condition and an initial value of numerical simulation of the molten iron flow field; extracting and analyzing ladle rotation speed change data points; and loading the UDF program to enable the ladle to rotate so as to finish the ladle hot metal charging process. The application can simulate the molten iron charging process in the steelmaking process, and the quality flow and the molten iron charging completion time result obtained by analyzing numerical simulation are in line with the molten iron charging process in actual production, and after the ladle rotation curve is optimized, the molten iron charging time is reduced from 55s to 49s, thereby realizing efficient and stable molten iron charging and providing guidance data for actual stable production.

Description

Simulation method for efficiently and stably adding molten iron in steelmaking process
Technical Field
The application relates to the field of metallurgy, in particular to a simulation method for efficiently and stably adding molten iron in a steelmaking process.
Background
The steel industry is taken as a high-energy consumption industry, and the potential of energy conservation and emission reduction of each working procedure is deeply dug as a necessary path of the steel enterprises. Among them, most of the heat comes from the physical heat of the molten iron during the converter steelmaking process, and insufficient heat of the molten iron is an obstacle to low-consumption production. The time for adding molten iron is shortened, so that the loss of heat of the molten iron can be effectively reduced, but the phenomenon of molten iron splashing can occur when the molten iron is added too quickly, and the unsafe performance of the working environment of operators is increased. Meanwhile, as the ladle is observed and operated by a manual site, the unstable factors in the molten iron mixing process are increased.
Therefore, in the process of adding molten iron into the ladle, the change rule of the rotating speed of the ladle and the mass flux of molten iron injection is controlled, which is a key for ensuring the high efficiency, stability and smoothness of the process of adding molten iron and is also a highly intelligent bedding for the steel industry.
Regarding the improvement of the efficiency of the converter hot metal charging process, chinese patent CN 112907637A discloses an artificial intelligence based converter hot metal charging auxiliary control method in which an artificial intelligence technique is used to obtain an optimal inclination angle of the hot metal ladle according to the inclination range, the molten iron splashing region and the molten iron remaining amount. However, the patent is limited to temporary extraction and temporary judgment of field data, is a control method and a control system for assisting field manual operation, cannot predict the rotation condition of a non-occurred ladle, and has the problem of over high optimization cost for improving the molten iron mixing efficiency.
Chinese patent CN 105219911A discloses a method for adding molten iron into a simulated converter steelmaking, which adds a flowing animation of molten iron and a forming animation of a ladle into a simulation process, so that the flowing molten iron during molten iron adding and the removal of the ladle after molten iron adding can be directly observed, and people can understand the flowing state in the ladle. The method only can observe the molten iron charging process, but does not truly simulate the transient process of molten iron charging, and does not optimize the speed curve of molten iron charging.
Disclosure of Invention
The application aims to provide a simulation method for efficiently and stably adding molten iron in a steelmaking process, so as to solve the problems.
In order to achieve the above purpose, the application adopts the following technical scheme:
a simulation method for efficiently and stably adding molten iron in a steelmaking process comprises the following steps:
step S1: constructing a three-dimensional geometric model of the ladle according to the actual size, wherein the three-dimensional geometric model of the ladle comprises an air area for the ladle and the surrounding of the ladle;
step S2: dividing a calculation domain of the three-dimensional geometric model of the ladle into a molten iron calculation domain, a molten iron inner upper calculation domain and a molten iron outer calculation domain, and respectively carrying out tetrahedral meshing on the three calculation domains to obtain a fluid calculation domain mesh model;
step S3: the fluid calculation domain grid model is imported into a fluent flow field simulation calculation module, a calculation model is selected, and material properties of different calculation domains are set; setting a basic assumption model, boundary conditions and an algorithm of the numerical simulation of the molten iron flow field, and then inputting the rotation axis direction and the rotation center coordinate of the ladle under the geometric model coordinate system of the flow field calculation domain in the initial setting of the part of the rotation domain;
step S4: according to ladle motion parameters acquired at a smelting site, writing a UDF program for realizing calculation of transient flow fields inside and outside the ladle;
step S5: loading the UDF program in Fluent, and carrying out iterative computation on a flow field of the molten iron mixing process after initialization to obtain a simulation computation result of the molten iron outflow flow of each time step;
step S6: and carrying out post-processing according to the simulation calculation result, drawing a flow field distribution diagram and a molten iron mass flow diagram changing along with time, and finishing a video of the rotation process.
Preferably, in the process of performing tetrahedral meshing, a plurality of areas are subjected to common node processing.
Preferably, the selecting a calculation model includes: selecting a VOF multiphase flow model to solve and starting level-set to track a phase interface, and selecting a k-well model by using a turbulence modelAnd (5) a model.
Preferably, the setting the material properties of the different computing domains comprises: setting physical parameters of materials, wherein the density of molten iron is 7138kg/m 3 The kinematic viscosity was 0.01 kg/(m.s), and the air density was 1.12. 1.12 kg/m 3 A kinematic viscosity of 1.7892 ×10 -5 kg/(m·s)。
Preferably, the assumption conditions for setting the numerical simulation of the molten iron flow field comprise:
(1) The geometric model ignores a main hook, an auxiliary hook, a furnace lining and a furnace shell of the ladle, only the interior of the ladle is reserved as a fluid calculation domain, and only one side of the molten iron is reserved on a nozzle of the ladle;
(2) Assuming that the rotation center is the center of the cross section of the height of the main hook;
(3) Neglecting a small amount of slag on the upper layer of the molten iron ladle;
(4) Assuming that the physical and chemical parameters of the density and the kinematic viscosity of the molten iron are all constant values.
Preferably, the control equation for setting the numerical simulation of the molten iron flow field comprises:
(1) Fluid continuity equation:
；
in the method, in the process of the application,is the flow rate component; />Is a flowable area fraction;
(2) Momentum equation:
；
；
；
in the method, in the process of the application,respectively->Gravitational acceleration in direction, m/s 2 ；/>Respectively isDirectional stiction; />Is a flowable volume fraction; />Is fluid density, kg/m 3 ；/>Is the pressure acting on the fluid element;
（3）k-turbulence equation:
and (c) equation:
；
equation:
；
wherein:
；
；
；
in the method, in the process of the application,=0.09，/>=1.0，/>=1.3，/>=1.45，/>=1.92；
(4) Volume equation:
for the i-th phase, the volume fraction equation is:
；
the volume segment equation of the main phase is:
；
in the method, in the process of the application,the value of the volume number of the fluid in the ith fluid volume segment is 0-1.
Preferably, setting the boundary condition and the initial value of the numerical simulation includes:
(1) Setting boundary conditions including outlet and wall boundary conditions; the boundary of the outlet adopts a pressure outlet, and the gradient of the speed at the outlet is zero; for the N-S equation, the fluid is viscous and the wall is set to a standard slip-free wall;
(2) Setting initial values, including operating pressure and calculating domain initial speed; the initial value is determined or selected according to the actual condition of the smelting site.
Preferably, the coupling algorithm of numerical simulation is set as PISO algorithm, the volume algorithm is Geo-Reconstruction, and the pressure algorithm is PRESTO-! Other algorithms are second order windward algorithms.
Preferably, in the step S4, ladle rotation speed change data points are extracted and analyzed according to the field data to obtain ladle rotation speeds at different times, and a rotation speed curve of the geometric model is obtained according to ladle motion parameters.
Preferably, in the step S5, the UDF procedure invokes a define_zone_motion macro, and specifies a speed of the ladle region and the air region around the ladle during each time step, a rotation center, a rotation shaft direction, and a rotation angular speed during the rotation; the speed of the two areas in translation and the rotation center, the rotation shaft direction and the rotation angular speed in Euler rotation are determined according to ladle motion parameters.
Compared with the prior art, the application has the beneficial effects that:
the simulation method for efficiently and stably adding molten iron in the steelmaking process can simulate the molten iron adding process in the steelmaking process, the mass flow obtained through analysis numerical simulation and the result of the molten iron adding completion time accord with the molten iron adding process in actual production, after the ladle rotation curve is optimized, the molten iron adding time is reduced to 49s from 54-57s, the molten iron mass flow is stabilized at 6000-8000kg/s, and efficient and stable molten iron adding is realized. The stability and punctuality of the converter hot metal charging process are improved by controlling the hot metal charging rotation speed curve, a foundation is laid for improving the scrap steel ratio, reducing the steel material cost and the converter refractory material cost, the smelting efficiency is effectively improved, and guidance data is provided for actual stable production.
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In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope of the present application.
FIG. 1 is a flow chart of a numerical simulation method of a ladle molten iron charging process;
FIG. 2 is a view of the spot of a ladle in a splash situation;
FIG. 3 is a geometric view of a ladle;
FIG. 4 is a grid view of a ladle;
FIG. 5 is a grid view of a computational domain;
FIG. 6 is a graph showing the rotational speed of various ladles over time;
FIG. 7 is a diagram of ladle mass flux for a ladle with varying rotational speeds;
FIG. 8 is a geometric model of a furnace mouth profile;
fig. 9 is a cloud view of the ladle in different phases in the case of a special shape of the nozzle.
Description of the embodiments
Embodiments of the present application will be described in detail below with reference to specific examples, but it will be understood by those skilled in the art that the following examples are only for illustrating the present application and should not be construed as limiting the scope of the present application. The specific conditions are not noted in the examples and are carried out according to conventional conditions or conditions recommended by the manufacturer. The reagents or apparatus used were conventional products commercially available without the manufacturer's attention.
Example 1
As shown in FIG. 1, the application provides a simulation method for efficiently adding molten iron into a ladle, which comprises the following steps:
step S1: constructing a three-dimensional model of the ladle according to equipment drawings provided by a factory and by utilizing Soildworks software, and storing the model as a x.t file; the calculation domain of the air around the cylindrical ladle is added because of the need of simulating the condition of tapping molten iron injection and the need of good visual effect;
step S2: importing the geometric model into Workbench software, carrying out joint processing on two calculation domains by using a Design model, importing the geometric model after joint processing into Meshin, naming each surface, selecting tetrahedron and mesh size as 0.05m, and finally carrying out mesh division and storing as a msh file;
step S3, importing the msh file into a fluent, and performing model checking and setting the size of a model unit; starting gravity and transient state, and loading the file c into fluent software; the calculation model selects a VOF model, wherein the model tracks the volume ratio occupied by each phase in the whole calculation domain, but the model is too dependent on the number of grids, so a Level-set tracking phase interface is started at the same time; select k-A turbulence model; setting physical parameters of the material, wherein the main phase is air, the second phase is steel, the third phase is slag, and the density of molten iron is 7138kg/m 3 The kinematic viscosity is 0.01 kg/(m.s), and the air density is 1.12 kg/m 3 A kinematic viscosity of 1.7892 ×10 -5 kg/(m.s); the outlet type selects a pressure outlet, and the wall surface selects a standard non-slip wall surface; meanwhile, the influence of pressure and adjacent unit speed on volume flux is considered, so that a PISO algorithm is adopted in a pressure-speed coupling mode, and the obtained discrete solution is closer to a momentum equation and a continuous equation; the volume algorithm is Geo-Reconstruct, the pressure algorithm is PRESTO-! The other algorithms are second-order windward algorithms;
the assumption conditions for setting the numerical simulation of the molten iron flow field of the molten iron comprise:
(1) The geometric model ignores a main hook, an auxiliary hook, a furnace lining and a furnace shell of the ladle, only the interior of the ladle is reserved as a fluid calculation domain, and only one side of the molten iron is reserved on a nozzle of the ladle;
(2) Assuming that the rotation center is the center of the cross section of the height of the main hook;
(3) Neglecting a small amount of slag on the upper layer of the molten iron ladle;
(4) Assuming that the physical and chemical parameters of the density and the kinematic viscosity of the molten iron are all constant values.
The control equation for setting the numerical simulation of the molten iron flow field comprises the following steps:
(1) Fluid continuity equation:
；
in the method, in the process of the application,is the flow rate component; />Is a flowable area fraction;
(2) Momentum equation:
；
；
；
in the method, in the process of the application,respectively->Gravitational acceleration in direction, m/s 2 ；/>Respectively isDirectional stiction; />Is a flowable volume fraction; />Is fluid density, kg/m 3 ；/>Is the pressure acting on the fluid element;
（3）k-turbulence equation:
and (c) equation:
；
equation:
；
wherein:
；
；
；
in the method, in the process of the application,=0.09，/>=1.0，/>=1.3，/>=1.45，/>=1.92；
(4) Volume equation:
for the i-th phase, the volume fraction equation is:
；
the volume segment equation of the main phase is:
；
in the method, in the process of the application,the value of the volume number of the fluid in the ith fluid volume segment is 0 to the whole1。
Step S4: according to the data collected on site, using Visual Studio software to write UDF program, calling DEFINE_ZONE_MOTION macro, writing sentences with rotation angular speed changing along with time into the circulation to form a c file;
step S5: the method comprises the steps of starting a Mesh Zone in a region, setting a rotating shaft and a rotating center, and selecting loaded UDF at a rotating speed; calculating a residual error of 10-3, and after global initialization, patch regional phase and setting the regional phase volume fraction to be 1; setting file storage intervals and storage positions, and starting a monitor function to detect a numerical simulation process, wherein the numerical simulation process comprises mass flow, a flow field distribution diagram and the like; setting the step length to be 0.001, and performing iterative calculation;
step S6: and re-drawing the exported file by using Origin software, and processing and cartooning the molten iron pouring process by using Fluent software to post-process the functional analysis result.
FIG. 1 is a flow chart of a numerical simulation method of a ladle molten iron charging process; FIG. 2 is a view of the spot of a ladle in a splash situation; FIG. 3 is a geometric view of a ladle; FIG. 4 is a grid view of a ladle; FIG. 5 is a grid view of a computational domain; FIG. 6 is a graph showing the rotational speed of various ladles over time; fig. 7 is a diagram of the mass flow rate of molten iron for a ladle with different rotational speed variations.
Example 2
FIG. 8 is a geometric model of a furnace mouth profile; fig. 9 is a cloud view of the ladle in different phases in the case of a special shape of the nozzle. With reference to fig. 8 to 9, this embodiment provides a method for simulating abnormal furnace mouth of a ladle, in which after the ladle is used for too long, slag bonding occurs to cause deformation of the furnace mouth, and the steps are the same as those in embodiment 1. Wherein, the tetrahedral mesh is selected to well construct the mesh of the abnormal model, and the average mesh quality is maintained at 0.89.
Comparative example 1
The furnace master operation of a certain actual shift without simulation of the molten iron mixing process is used as a comparison, and the molten iron mixing time is 54-57 s.
From the above, the application can completely simulate the ladle rotation transient process, so that people can observe the complete molten iron mixing process, optimize the rotation curve, achieve stable molten iron mixing, and reduce the molten iron mixing time from 54-57s to 49s by about 11%. Compared with the method that the flowing animation of the molten iron and the forming animation of the ladle are added into the simulation process, the method provided by the application realizes the dynamic numerical simulation of the on-site known and unknown ladle rotation process, including the abnormal condition of the furnace mouth, and the numerical simulation method of the transient process of the molten iron has the advantages of low optimization cost, wide optimization range and the like. The application fills the blank of numerical simulation of the transient process of molten iron mixing, can effectively reduce the field test cost and paves the way for highly intelligent steelmaking.
To further illustrate the advantages of the shortened time for adding molten iron, practical production verification is performed, specifically as follows:
about 2.1 ten thousand tons of molten iron are produced in a steel mill daily, about 245t of molten iron is produced in a ladle, and about 85 furnaces, so that the iron charging time is reduced by about 425s in a single day. And the smelting time of a 100t converter is about 30 minutes, so that more 700t steel can be produced in one month, and the benefit is improved by about 280 ten thousand yuan.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present application, and not for limiting the same; although the application has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the application.
Furthermore, those skilled in the art will appreciate that while some embodiments herein include some features but not others included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the application and form different embodiments. For example, in the claims below, any of the claimed embodiments may be used in any combination. The information disclosed in this background section is only for enhancement of understanding of the general background of the application and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

Claims (10)

1. A simulation method for efficiently and stably adding molten iron in a steelmaking process is characterized by comprising the following steps of:
step S1: constructing a three-dimensional geometric model of the ladle according to the actual size, wherein the three-dimensional geometric model of the ladle comprises an air area for the ladle and the surrounding of the ladle;
step S2: dividing a calculation domain of the three-dimensional geometric model of the ladle into a molten iron calculation domain, a molten iron inner upper calculation domain and a molten iron outer calculation domain, and respectively carrying out tetrahedral meshing on the three calculation domains to obtain a fluid calculation domain mesh model;
step S3: the fluid calculation domain grid model is imported into a fluent flow field simulation calculation module, a calculation model is selected, and material properties of different calculation domains are set; setting a basic assumption model, boundary conditions and an algorithm of the numerical simulation of the molten iron flow field, and then inputting the rotation axis direction and the rotation center coordinate of the ladle under the geometric model coordinate system of the flow field calculation domain in the initial setting of the part of the rotation domain;
step S4: according to ladle motion parameters acquired at a smelting site, writing a UDF program for realizing calculation of transient flow fields inside and outside the ladle;
step S5: loading the UDF program in Fluent, and carrying out iterative computation on a flow field of the molten iron mixing process after initialization to obtain a simulation computation result of the molten iron outflow flow of each time step;
step S6: and carrying out post-processing according to the simulation calculation result, drawing a flow field distribution diagram and a molten iron mass flow diagram changing along with time, and finishing a video of the rotation process.
2. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to claim 1, wherein a plurality of areas are subjected to joint processing in the process of performing tetrahedral meshing.
3. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to claim 1, wherein the selecting a calculation model comprises: selecting a VOF multiphase flow model to solve and starting level-set to track a phase interface, and selecting a k-well model by using a turbulence modelAnd (5) a model.
4. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to claim 1, wherein the setting of the material properties of different calculation domains comprises: setting physical parameters of materials, wherein the density of molten iron is 7138kg/m 3 The kinematic viscosity was 0.01 kg/(m.s), and the air density was 1.12. 1.12 kg/m 3 A kinematic viscosity of 1.7892 ×10 -5 kg/(m·s)。
5. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to claim 1, wherein the assumption conditions for setting numerical simulation of a molten iron flow field comprise:
(1) The geometric model ignores a main hook, an auxiliary hook, a furnace lining and a furnace shell of the ladle, only the interior of the ladle is reserved as a fluid calculation domain, and only one side of the molten iron is reserved on a nozzle of the ladle;
(2) Assuming that the rotation center is the center of the cross section of the height of the main hook;
(3) Neglecting a small amount of slag on the upper layer of the molten iron ladle;
(4) Assuming that the physical and chemical parameters of the density and the kinematic viscosity of the molten iron are all constant values.
6. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to claim 1, wherein the control equation for setting the numerical simulation of the flow field of the molten iron comprises:
(1) Fluid continuity equation:
；
in the method, in the process of the application,is the flow rate component; />Is a flowable area fraction;
(2) Momentum equation:
；
；
；
in the method, in the process of the application,respectively->Gravitational acceleration in direction, m/s 2 ；/>Respectively->Directional stiction; />Is a flowable volume fraction; />Is fluid density, kg/m 3 ；/>Is the pressure acting on the fluid element;
（3）k-turbulence equation:
and (c) equation:
；
equation:
；
wherein:
；
；
；
in the method, in the process of the application,=0.09，/>=1.0，/>=1.3，/>=1.45，/>=1.92；
(4) Volume equation:
for the i-th phase, the volume fraction equation is:
；
the volume segment equation of the main phase is:
；
in the method, in the process of the application,the value of the volume number of the fluid in the ith fluid volume segment is 0-1.
7. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to claim 1, wherein setting boundary conditions and initial values of numerical simulation comprises:
(1) Setting boundary conditions including outlet and wall boundary conditions; the boundary of the outlet adopts a pressure outlet, and the gradient of the speed at the outlet is zero; for the N-S equation, the fluid is viscous and the wall is set to a standard slip-free wall;
(2) Setting initial values, including operating pressure and calculating domain initial speed; the initial value is determined or selected according to the actual condition of the smelting site.
8. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to claim 1, wherein a coupling algorithm of numerical simulation is set as a PISO algorithm, a volume algorithm is Geo-Reconstruct, and a pressure algorithm is PRESTO-! Other algorithms are second order windward algorithms.
9. The method according to claim 1, wherein in step S4, the ladle rotation speed variation data points are extracted and analyzed according to the field data to obtain the ladle rotation speed at different times, and the rotational speed curve of the geometric model is obtained according to the ladle motion parameters.
10. The simulation method for efficiently and stably adding molten iron in a steelmaking process according to any one of claims 1 to 9, wherein in the step S5, a define_zone_motion macro is called in the UDF program, and the speed of the ladle region and the air region around the ladle and the rotation center, the rotation shaft direction and the rotation angular speed during rotation are specified in each time step; the speed of the two areas in translation and the rotation center, the rotation shaft direction and the rotation angular speed in Euler rotation are determined according to ladle motion parameters.
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JP2019077932A (en) * 2017-10-26 2019-05-23 Ｊｆｅスチール株式会社 Methods for determining refining conditions, controlling refining facility, and refining molten iron
CN108536952A (en) * 2018-04-03 2018-09-14 东北大学 The computational methods of biphase gas and liquid flow gas holdup in a kind of determining ladle
CN115098922A (en) * 2022-06-27 2022-09-23 中冶华天工程技术有限公司 Rapid construction method of steelmaking-continuous casting logistics simulation model based on modular design
CN115270654A (en) * 2022-07-05 2022-11-01 北京科技大学 Numerical simulation method for converter steelmaking tapping process

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