Temperature evolution in the spray zones: Plant measurements and CON1D predictions
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1 ANNUAL REPORT 2006 Meeting date: June 15, 2006 Temperature evolution in the spray zones: Plant measurements and CON1D predictions Amar Kumar Behera (Ph.D. Student) & Brian G. Thomas Department of Mechanical & Industrial Engineering University of Illinois at Urbana-Champaign University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 1 Surface Temperature down strand (sec) time (s) Surface Temperature ( o C) Temperature (degree) mold spray zone (rolls) Radiation zone Distance from Meniscus (mm) Distance below Meniscus (mm) Example: thin slab caster 3.5 m/min Note: reheating below mold; and after sprays variations caused by rolls (slab caster) University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 2
2 Heat transfer between rolls natural/forced convection, hconv Slab Roll Spray nozzle radiation, hrad_spray spray impinging, hspray roll contact, hroll Distance (mm) heat transfer Surface Temperature ( 0 C) University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 3 Pyrometer Locations Pyrometer 1 Pyrometer 2 Pyrometer 3 Pyrometer 4 Pyrometer 5 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 4
3 Pyrometer Specifications Model Name and Number Length Focus spot size Location of Pyrometer 1 from meniscus Location of Pyrometer 2 from meniscus Location of Pyrometer 3 from meniscus Location of Pyrometer 4 from meniscus Location of Pyrometer 5 from meniscus Modline 5, 5R , 4M5# mm 15.5 mm mm 8380 mm mm 3875 mm mm University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 5 Zones in CON1D File Zone No. M/S (1) M/S, IA, IB (2) IB (3) IB, II (4) II, III (5) III (6) III, IV (7) IV (8) IV (9) V (10) V (11) ( ) CON1D Zone No. Zone Starts # of Rolls Roll Radius (m) End of last spray zone (mm) University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 6
4 Experiments at Nucor Steel Case Number Time 01/13/ /13/ /16/ /13/ Steady/ Transient Steady Steady Steady Transient University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 7 Case 1 13 Jan Steady State Parameter Value Time of Experiment Casting Speed Spray Pattern Number Composition (%) Caster Pouring Temperature hrs ipm (3.44 m/min) (0.057 m/s) 2 C 0.247% Mn 1.09 S Al Ca.0018 Si.175 P.014 Cu.087 N (leco).0076 North o C University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 8
5 Simulation CON1D Mold Heat Flux Mean heat flux (MW/m 2 ) Powder Viscosity at 1300 o C (Pa-s) Melting Temperature of Mold Flux ( o C) Carbon Content Casting Speed (m/min) μ = Pa-s 0 T 0 flow = 1180 C 7 Mold Heat Flux - Casting Speed 3.44 m/min, % Carbon Average Mold Heat Flux - Argentina Paper Nucor Case 1 6 Average Mold Heat Flux - Experiment Nucor Case 1 MOLD HEAT FLUX (MW/m^2) DISTANCE BELOW MENISCUS (mm) University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 9 Simulation CON1D Spray Zones h (W/m^2K) Radiation heat transfer coefficient, h_rad Spray heat transfer coefficient, h_spray Roll heat transfer coefficient, h_roll Distance below meniscus (mm) Water Flux Temperature of spray cooling water Ambient Temperature Fraction of heat extraction to rolls Nozaki - A= c=0.55 b= steel = 0.8 Tspray = Tamb = 25 C 8 σ = 5.67*10 WK ε Distance below meniscus (mm) m University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 10 h (W/m^2K) Total heat transfer coefficient, h_tot
6 Case 1 Results Close up comparision Result Outer Surface Temperature - CONID Pyrometer Temperature Pyrometer Temperature Prediction -CON1D Surface Temperature (C) h (W/m^2K) Distance below meniscus (mm) 0 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 11 Pyrometer 4 Zone 4 Zone 5 Zone 6 Φ140 Φ160 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 12
7 Pyrometer 3 Zone 6 Zone 7 Zone 8 Φ160 Φ190 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 13 Pyrometer 2 Zone 8 Zone 9 Zone 10 Φ190 Φ190 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 14
8 Pyrometer 1 Zone 10 Zone 11 Beyond zone 11 Φ190 Φ230 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 15 Pyrometer 5 Beyond zone 11 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 16
9 Case 2-13 Jan Steady State Time of Experiment Casting Speed Caster Parameter Spray Pattern Number Composition of Elements (%) Pouring Temperature hrs ipm (3.61 m/min) (0.06 m/s) 4 C.247 Mn 1.09 S Al Ca.0018 Si.175 P.014 Cu.087 N (leco).0076 South o C Value University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 17 Case 2 Results Close up comparision Result Outer Surface Temperature - CONID Pyrometer Temperature Pyrometer Temperature Prediction -CON1D Surface Temperature (C) h (W/m^2K) Distance below meniscus (mm) 0 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 18
10 Pyrometer 4 Zone 4 Zone 5 Zone 6 Φ140 Φ160 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 19 Pyrometer 3 Zone 6 Zone 7 Zone 8 Φ160 Φ190 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 20
11 Pyrometer 2 Zone 8 Zone 9 Zone 10 Φ190 Φ190 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 21 Pyrometer 1 Zone 10 Zone 11 Beyond zone 11 Φ190 Φ230 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 22
12 Case 3 16 Jan Steady State Parameter Time of Experiment Casting Speed Spray Pattern Number Composition of Elements (%) Pouring Temperature hrs ipm (3.03 m/min) (0.051 m/s) 1 C.247 Mn 1.09 S Al Ca.0018 Si.175 P.014 Cu.087 N (leco) o C Value University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 23 Case 3 Results Surface Temperature (C) Close up comparision Result Outer Surface Temperature - CONID Pyrometer Temperature Pyrometer Temperature Prediction -CON1D h (W/m^2K) Distance below meniscus (mm) 0 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 24
13 Pyrometer 2 Zone 8 Zone 9 Zone 10 Φ190 Φ190 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 25 Pyrometer 1 Zone 10 Zone 11 Beyond zone 11 Φ190 Φ230 University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 26
14 Case 4 13 Jan Transient Time of Experiment Casting Speed Caster Parameter Spray Pattern Number Composition of Elements (%) Pouring Temperature hrs ipm (3.61 m/min) (0.06 m/s) 4 to 7 C.247 Mn 1.09 S Al Ca.0018 Si.175 P.014 Cu.087 N (leco).0076 South o C Value University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 27 Spray Pattern Change University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 28
15 Spray Pattern Change University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 29 Spray Pattern Change University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 30
16 Experimental Temperature Profile University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 31 Case 4 Pyrometer mm University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 32
17 Case 4 Pyrometer mm University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 33 Case 4 Pyrometer mm University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 34
18 Case 4 Pyrometer mm University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 35 Case 4 Results Pyrometer mm University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 36
19 Sources of Error Steam surrounding the slab Scale formation Pyrometer positioning Random Noise in PDA system University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 37 Conclusions Comparison of Temperature Profile from CON1D with Pyrometer Measurements shows good results for pyrometers 5,1 and 2 Pyrometers at top of caster (3 and 4) are consistently over-predicted Transient behavior seems to be modeled reasonably University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 38
20 Future Work Further calibration of CON1D S. Vapalahti experiments in Mexico Top hat Heat transfer profile to be put in place of Flat top Transient case with casting speed variation to be studied University of Illinois at Urbana-Champaign Metals Processing Simulation Lab AK Behera 39
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