Mathematical Modeling on Erosion Characteristics of Refining Ladle Lining with Application of Purging Plug
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THE wear of refractories in ladle lining is a complex physical and chemical process; it was affected by many factors which influence each other. The molten steel in the ladle was stirred by blowing gas through the purging plug in the refining process, the lining refractories were eroded more severely, and its service life was shortened significantly.[1] The wear of lining refractories in the refining ladle mainly includes chemical corrosion, mechanical damage, and erosion of molten steel.[2] The chemical corrosion of refractories was mainly studied by slag corrosion experiments and microscopic analysis.[3] In recent years, the corrosion rate of refractories, which is considered primarily to be controlled by the diffusion process, was simulated by calculating the transfer rate of the reaction products in molten steel,[4] and the thermodynamic model of chemical reaction between refractory and slag was established to simulate the slag corrosion rate of refractories.[5] The mechanical damage of refractories could be analyzed by thermal stress calculation and crack propagation.[6] With the application of carbon and zirconium refractories, the slag corrosion AO HUANG, Associate Professor, HUAZHI GU, Deputy Director, Professor, MEIJIE ZHANG, Professor, TING WANG, Postgraduate, and YANG ZOU, Postgraduate, are with the State Key Lab Breeding Base of Refractories & Ceramics, Wuhan University of Science & Technology, Hubei 430081, Wuhan, P.R. China. Contact e-mail: [email protected] NING WANG, Deputy Director, Senior Engineer, is with the Steelmaking Plant, Baosteel Co., Ltd., Shanghai 201900. Manuscript submitted March 20, 2012. Article published online February 12, 2013. 744—VOLUME 44B, JUNE 2013
resistance and thermal shock resistance of ladle lining have been enhanced. So, the erosion of molten steel has been gradually given more attention[7,8] and the effect of steel flow on refractory erosion was significant, which has been confirmed by a water model experiment.[7] But, the physical modeling for a real high temperature process was very difficult to establish and implement, and the numerical simulation of the erosion was mainly limited in the analysis of shear stress on the refractory wall[8] or simple numerical calculating by defining a fluid erosion factor according to empirical data.[9,10] The refining ladle was under the harsh conditions of high temperatures and the molten steel includes lots of inclusion particles,[11,12] which has a major impact on the materials’ erosion and sometimes plays a major role.[13] The service life of ladle lining was significantly short in refining conditions; especially the partial refractories in the ladle were severely damaged in the stirring process. Obviously, the erosion of molten steel with lots of inclusions played an important role in the accelerated wear of refractories. In this paper, based on computational fluid dynamics, the comprehensive effect of molten steel and inclusion particles on refractory erosions was considered, the erosion prediction model of refractories for ladle lining w
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