Tundish Diffusion Component with Flow Disruptors
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Solution Overview
Problem
In the continuous casting of steel, re-oxidation in the tundish leads to non-metallic inclusions that cause clogging and flaws, and existing gas purging methods fail to effectively expose all liquid steel to the gas due to blind spots and disruption by flowing steel.
Innovation Solution
A diffusion component with a porous element spanning the entire width of the tundish bottom and geometrical flow disruptors to create non-laminar flow, ensuring all molten steel is exposed to gas bubbles, which attach to inclusions and float them to the surface for removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If purging bars are located at the bottom of the tundish, then gas bubbles can be introduced into the liquid steel, but blind spots are formed on the side of the tundish where the bubble curtain does not penetrate
Solution Approach 1:
The single bottom-mounted purging bar is segmented into multiple gas introduction points distributed along the width of the tundish bottom. This segmentation ensures that gas bubbles are introduced at multiple locations, creating overlapping bubble curtains that eliminate blind spots and achieve uniform coverage across the entire liquid steel column.
Solution Approach 2:
The gas introduction system transitions from a single-point bottom injection to a distributed multi-dimensional array of injection points. By adding the horizontal dimension of distribution along the tundish width, the system achieves comprehensive three-dimensional coverage of the liquid steel, eliminating the blind spots that occur with single-point injection.
2Quantity of substance
If purging bars are used to introduce gas, then gas bubbles are formed, but the steel flow disrupts the bubble curtain and heterogenizes the effective presence of gas
Solution Approach 1:
Different regions of the tundish bottom are equipped with gas introduction points tailored to local flow conditions. The distribution and configuration of gas injection points are optimized for each specific location to counteract local flow patterns and maintain stable bubble curtains despite variations in steel flow across the tundish width.
Solution Approach 2:
The gas introduction system is designed to dynamically adapt to varying steel flow conditions. By distributing multiple gas injection points throughout the tundish width, the system can maintain effective bubble curtains under varying flow conditions, as each local injection point responds to its specific flow environment rather than relying on a single static injection point.
3Quantity of substance
If the porous element spans the entire width of the tundish bottom, then all liquid steel is exposed to gas, but the device complexity increases
Solution Approach 1:
The diffusion component with the porous element serves multiple functions simultaneously: it distributes gas uniformly across the entire tundish width, creates stable bubble curtains, and eliminates blind spots. This multi-functionality justifies the increased structural complexity, as a single integrated component achieves what would otherwise require multiple separate systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures that substantially all liquid steel is exposed to gas, promoting effective attachment and flotation of inclusions, reducing clogging and inclusion flaws, and potentially eliminating the need for a separate gas supply conduit.
Implementation Method 1
a diffusion component with a porous element spanning the entire width of the tundish bottom... ensures all molten steel is exposed to gas bubbles
Implementation Method 2
The inclusions in the steel attach to a gas bubble and float up to a slag layer
Implementation Method 3
a series of geometrical flow disruptors may be arranged in the diffusion component that promote non-laminar flow, which ensures good intermixing and homogenization
Data Source
AI summary
A diffusion component for impregnating molten steel with a gas includes a barrier having a first side and a second side, a through-hole formed within the barrier, the through-hole connecting the first side to the second side, and a porous element arranged within the through-hole such that the flow of molten steel passes over the porous element. At least one flow disrupter is arranged relative to the porous element and configured to promote non-laminar flow of molten steel passing through the through-hole.