Enhanced numerical tool to evaluate steel ladle thermal losses

Santos, M.F.; Moreira, M.H.; Campos, Maria Gabriela Garcia; Pelissari, P.I.B.G.B.; Angélico, Ricardo Afonso; Sako, Eric Y.; Sinnema, S.; Pandolfelli, V. C.

doi:10.1016/j.ceramint.2018.04.092

Cited by 30 publications

(28 citation statements)

References 16 publications

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“…Finally, the energy evaluation was carried out by integrating the heat flux, with respect to the surface of interest and time ( t ), according to Santos et al 17 Thus, the energy quantity, E(t), is given by:

E (T) = {false\int}_{0}^{t} \underset{S}{false\int} q ()(, r, z, t) d S d t

…”

Section: Methodsmentioning

confidence: 99%

“…The importance of evaluating the thermal behavior of steel ladles is required for the precise control of the steel temperature and the operational conditions of the refractory lining 17 . It also helps to find saving energy solutions, reduce materials consumption, improve productivity, and scale down environmental impacts.…”

Section: Introductionmentioning

confidence: 99%

“…on the steel ladle thermal state. Therefore, the present work proposes using a computational tool to estimate the energy and thermal profile of several lining configurations, which are compared to elucidate all relevant effects, as reported in 17 . The temperature gradient and energy consumption are calculated by modeling the ladle process via the finite element method (FEM).…”

Section: Introductionmentioning

confidence: 99%

“…All heat transfer mechanisms (conduction, convection, and radiation) are considered to represent the ladle cycle. In this study, the ladle lining was represented as an axisymmetric geometry and its cycle was illustrated into four main steps 17 . The analyzed cases considered several lining configurations related to position, thickness, and type of thermal insulator.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Holistic view of the insulating layer on the thermal efficiency of a steel ladle lining

Campos

Santos

Moreira

et al. 2020

Int J Ceramic Engine & Sci

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The lining design of steel ladles has a major impact on the performance of these metallurgical vessels. For instance, their better thermal performance is mainly related to the refractory materials applied in the lining, which requires continuous quality and cost optimizations. In this study, different refractory linings were investigated in order to understand their effect on the thermal performance of the steel ladle, that is, on the control of the average steel and shell temperatures, effect on the amount of stored energy in the refractory lining and on the cycling energy consumption. The influence of distinct configurations of insulating materials (position, thickness, and types) on those parameters was investigated by heat transfer simulations using numerical tools. The results pointed out the insulating materials efficiency on reducing the shell temperatures and increasing the average steel temperature. However, the benefits of applying the insulator with thicknesses over 21 mm or applying it at the bottom are less significant. The application of the foam insulator at unusual positions showed promising results, such as between the safety and working layer and at the hot face.The former position enhanced the performance during pre-heating whereas the latter significantly increased the steel temperature (34°C). Consequently, the study pointed out new designs for the project of steel ladle linings, improving their efficiency, targeting solutions for saving energy, and reducing the environmental impacts. K E Y W O R D S saving energy, steel ladle, refractory lining design, insulating layer, heat transfer modeling 114 | CAMPOS et Al. How to cite this article: Campos MGG, Dos Santos MF, Moreira MH, Angélico RA, Sako EY, Pandolfelli VC. Holistic view of the insulating layer on the thermal efficiency of a steel ladle lining. Int J Ceramic Eng Sci.

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E (T) = {false\int}_{0}^{t} \underset{S}{false\int} q ()(, r, z, t) d S d t

…”

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Holistic view of the insulating layer on the thermal efficiency of a steel ladle lining

Campos

Santos

Moreira

et al. 2020

Int J Ceramic Engine & Sci

View full text Add to dashboard Cite

show abstract

“…Similarly, Glaser et al [7] developed a 2D axisymmetric numerical model to investigate heat transfer behavior and heat losses during the liquid steel teeming step. Recently, Santos et al [8] presented a 2D axisymmetric transient thermal numerical model to investigate the impact of lining design on the transient thermal behavior and energy consumption of a steel ladle during preheating, holding liquid steel, and being empty.…”

Section: Introductionmentioning

confidence: 99%

Transient Thermo-Mechanical Analysis of Steel Ladle Refractory Linings Using Mechanical Homogenization Approach

et al. 2020

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Mortarless refractory masonry structures are widely used in the steel industry for the linings of many high-temperature industrial applications including steel ladles. The design and optimization of these components require accurate numerical models that consider the presence of joints, as well as joint closure and opening due to cyclic heating and cooling. The present work reports on the formulation, numerical implementation, validation, and application of homogenized numerical models for the simulation of refractory masonry structures with dry joints. The validated constitutive model has been used to simulate a steel ladle and analyze its transient thermomechanical behavior during a typical thermal cycle of a steel ladle. A 3D solution domain and enhanced thermal and mechanical boundary conditions have been used. Parametric studies to investigate the impact of joint thickness on the thermomechanical response of the ladle have been carried out. The results clearly demonstrate that the thermomechanical behavior of mortarless masonry is orthotropic and nonlinear due to the gradual closure and reopening of the joints with the increase and decrease in temperature. In addition, resulting thermal stresses increase with the increase in temperature and decrease with the increase in joint thickness.

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Multi‐Response Optimization of the Thermal and Thermomechanical Behavior of a Steel Ladle Lining using Grey Relational Analysis and Technique for Order Preference by Similarity to Ideal Solution

Hou

Gruber

Jin

2022

steel research int.

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The present research attempts to simultaneously optimize the thermal and thermomechanical behavior of a steel ladle lining. The lining configurations are designed with an L32 orthogonal array considering the input parameters of various material properties and lining thicknesses. From the finite‐element (FE) simulations, three responses are evaluated: the end temperature and maximum tensile stress at the steel shell and the maximum compressive stress at the hot face of the working lining. Multi‐response optimization is performed through grey relational analysis (GRA) and the technique for order preference by similarity to ideal solution (TOPSIS) by applying a distinguishing coefficient of 0.5 in GRA and the signal‐to‐noise (S/N) ratio‐based weight in both techniques. Both GRA and TOPSIS results yield the same best solution (the fourth lining configuration) and the same optimal levels for significant factors. Analysis of variance (ANOVA) is used to identify the significance of the factors and their contributions to the overall performance characteristic. The results demonstrate that the top five factors with the analyses of GRA and TOPSIS are the same and their total contribution is similar.

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Enhanced numerical tool to evaluate steel ladle thermal losses

Cited by 30 publications

References 16 publications

Holistic view of the insulating layer on the thermal efficiency of a steel ladle lining

Holistic view of the insulating layer on the thermal efficiency of a steel ladle lining

Transient Thermo-Mechanical Analysis of Steel Ladle Refractory Linings Using Mechanical Homogenization Approach

Multi‐Response Optimization of the Thermal and Thermomechanical Behavior of a Steel Ladle Lining using Grey Relational Analysis and Technique for Order Preference by Similarity to Ideal Solution

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