8/2/2019 Sail Tundish

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We rely on simulation software from ANSYS to improve ow in our tundishes to

maintain our very high product quality standards. Rajeev Kumar Singh Senior Manager

Process Simulation & Modeling Lab, RDCIS

 SAIL

+ Steel Authority of India Limited

Case Study

8/2/2019 Sail Tundish

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Steel Authority of India Limited (SAIL) Tundish

Fluid ow visualization helps to maintainproduct quality by optimizing tundish design

• Inclusionoatationinsidethetundishwas analyzedusingthediscretephasemodel(DPM).Thishelpedtovisualizetheowofthesesmallinclusionparticlesandseewhethertheywere

trappedbythetopsurfacelayer.

Benefts• TheinteractiveuserinterfaceinANSYSFluent helpedspeedtheanalysissetupandsubsequent post-processing.• Adaptivemeshinghelpedtorenethemesh whereneededtokeeptheoverallmeshcount manageable.• TheaccuracyofthesimulationhelpedSAILto understandprecisevariationsinowparameters includingturbulentkineticenergyandturbulent energydissipation.Thisledtomeaningful insightintheprocesstomakedesign  improvements.• UseofANSYSFluentreducesthecostof  plant-scaleexperimentsandtesting.

Company DescriptionSteelAuthorityofIndiaLimited(SAIL)istheleadingsteel-makingcompanyinIndia.The companyisafullyintegratedironandsteelmaker,producingbothbasicandspecialsteelsfordomesticconstruction,engineering,power,railway,automotiveanddefenceindustriesand

forsaleinexportmarkets.ThecompanyhasthedistinctionofbeingIndia’ssecondlargestproducerofironoreandofhavingthecountry’ssecondlargestminesnetwork.ThisgivesSAILacompetitiveedgeintermsofcaptiveavailabilityofironore,limestone,anddolomitewhicharerequiredforsteelmaking.

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Introduction/OverviewDuringcontinuouscastingofsteel,thetundishisanimportantlinkbetweentheladle(abatch)andthecontinuouscastingmold.Thetundishactsas

areservoiranddistributorofmoltensteel.Whenmakingqualitysteels,thetundishhastheaddedresponsibilityofimprovinginclusionoatationanditsseparation.Italsoplaysanimportantroleincompositionadjustmentduringcastingofsteel.Theeciencyandoptimizationoftheseprocessesrequireclosecontrolofthemoltensteelowbehaviorinthetundish.Iftheowofmetalinthetundishisnotproperlycontrolled,itmayreducethequalityofsteelproduced.

ChallengesDeterminethebestshapeanduseofowcontroldevicesforatundish,suchasturbo-stoppers,inordertoprovideoptimumowcharacteristicsthatimproveproductquality.

Technology UsedANSYS®Fluent®

Engineering Solution• ANSYSFluentsoftwarewiththestandardk-e 

turbulencemodelwasusedtomodeluidowinthetundish.

• Adaptivemeshingbasedonvelocitygradient 

wasemployedtogenerateanermeshinregionsofhighvelocitygradient.Aquarterofamillioncellsisneededtoaccuratelycapturetheow.

• Theunsteady-statespeciestransportmodelwasusedtogeneratetheresidenttime distributionofthevessel.

Stream traces represent the movement of liquid steel

in a tundish where a turbulence stopper is used directly

below the inlet.