Plate-Shaped Vortex Breaker for Slag-Free Ladle Discharge
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Solution Overview
Problem
During steel production, the removal of liquid steel from tundishes or ladles often results in significant slag entrainment, leading to substantial losses of high-quality steel due to vortex formation, which existing solutions attempt to mitigate but often cause temperature loss, oxidation, and clogging issues.
Innovation Solution
A plate-shaped vortex breaker made of refractory material is positioned above the bottom outlet to disrupt and prevent vortex formation by creating a sharp edge that counters the whirlpool's rotation, ensuring the liquid steel flows without entraining slag, and is designed for easy installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a blunt concrete slab is pushed into the forming vortex during pouring, then vortex formation is disrupted, but steel loss increases due to oxidation and temperature loss
Solution Approach 1:
The harmful vortex formation is extracted and disrupted by the plate-shaped vortex breaker, which is strategically positioned to intercept and break the vortex before it can entrain slag. This separates the vortex disruption function from the steel discharge path, preventing both slag entrainment and oxidation/temperature loss in the steel stream.
Solution Approach 2:
The plate-shaped vortex breaker acts as an intermediary element between the bottom outlet and the slag layer. It mediates the flow dynamics by breaking the vortex without directly contacting the discharged steel stream, thus preventing both slag entrainment and harmful thermal/oxidative effects on the steel.
2Loss of substance
If the residual steel quantity is reduced to 15-20% of total distributor contents, then slag entrainment is minimized, but steel loss increases due to large residual steel volumes
Solution Approach 1:
The plate-shaped vortex breaker is installed in advance near the bottom outlet to preemptively disrupt vortex formation during steel discharge. This preliminary action prevents slag entrainment throughout the entire discharge process, enabling safe reduction of residual steel to below 10% without the risk of slag carryover that would otherwise require maintaining 15-20% residual steel.
Solution Approach 2:
The vortex breaker performs preliminary anti-action by counteracting the vortex formation tendency at its source near the bottom outlet. This preemptive disruption of the vortex prevents the harmful entrainment effect before it can occur, allowing aggressive reduction of residual steel volumes.
3Loss of substance
If a slag-free spot is produced on the surface by rinsing process, then slag entrainment is prevented, but temperature loss and oxidation occur
Solution Approach 1:
The harmful vortex is extracted and disrupted by the plate-shaped vortex breaker positioned near the bottom outlet. By removing the vortex formation mechanism at its source, the system prevents slag entrainment without creating a slag-free spot on the surface, thereby avoiding the temperature loss and oxidation associated with surface exposure.
Solution Approach 2:
The plate-shaped vortex breaker serves as an intermediary that disrupts the vortex flow pattern without directly exposing the molten steel surface to air. This mediation achieves slag-free discharge while maintaining surface coverage, preventing both slag entrainment and thermal/oxidative losses.
4Stability of the object's composition
If dams and weirs are installed to calm and direct steel flow, then flow direction is improved, but vortex disruption capability is insufficient
Solution Approach 1:
The plate-shaped vortex breaker provides localized vortex disruption capability at the critical region near the bottom outlet, where vortex formation most strongly affects slag entrainment. This local intervention complements the overall flow direction control provided by dams and weirs, achieving both flow stability and vortex prevention.
Solution Approach 2:
The plate-shaped vortex breaker merges with the existing flow control structures (dams and weirs) to provide comprehensive flow management. The combination achieves both macro-level flow direction control and micro-level vortex disruption, solving both flow stability and slag entrainment problems simultaneously.
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 significantly reduces steel loss by minimizing residual steel to less than 10% per melt, preventing slag entrainment, and maintaining the discharge process integrity without causing temperature loss or oxidation, thereby reducing the overall loss of high-quality steel.
Implementation Method 1
when the liquid phase is removed through the bottom outlet, a more or less strong axial laminar flow occurs, i.e. a whirlpool
Implementation Method 2
a more or less strong axial laminar flow occurs, i.e. a whirlpool
Data Source
Figure 1~2
Figure 3~7
Figure 8~9
AI summary
The invention relates to a method for the slag-free removal of molten steel from distributors and ladles that are used in an aftertreatment process. During said method, the base outlets (10, 15, 16) are opened and the slag cover (8, 14) is prevented from being carried along with the metal by means of baffles (21, 22) that interrupt or significantly retard the vortices that occur in the vicinity of the base outlets (10, 15, 16). The baffles (21, 22) that are allocated to the base outlets (10, 15, 16) thus act as vortex breakers (20), so that slag cannot be carried off with the metal. The pins (41) that are provided to fix the vortex breakers (20) on or in the distributor base (24) or ladle base (25) preferably take the form of a cylinder (56).