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ISIJ International Vol. 64 (2024), No. 14

ISIJ International
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Grid List Abstracts
ONLINE ISSN: 1347-5460
PRINT ISSN: 0915-1559
Publisher: The Iron and Steel Institute of Japan

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  1. Vol. 64 (2024)

    1. No.14
    2. No.13
    3. No.12
    4. No.11
    5. No.10
    6. No.9
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    14. No.1

  2. Vol. 63 (2023)

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  3. Vol. 62 (2022)

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  4. Vol. 61 (2021)

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  5. Vol. 60 (2020)

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  6. Vol. 59 (2019)

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  7. Vol. 58 (2018)

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  8. Vol. 57 (2017)

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  9. Vol. 56 (2016)

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  10. Vol. 55 (2015)

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  11. Vol. 54 (2014)

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  12. Vol. 53 (2013)

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  14. Vol. 51 (2011)

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  16. Vol. 49 (2009)

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  17. Vol. 48 (2008)

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  18. Vol. 47 (2007)

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  19. Vol. 46 (2006)

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ISIJ International Vol. 64 (2024), No. 14

Injection of Hydrogenous Gases into the Blast Furnace Tuyeres for Reducing CO2 Emissions: A Review

Volodymyr Shatokha

pp. 1945-1955

DOI:

10.2355/isijinternational.ISIJINT-2024-145

Abstract

Transitioning to alternative fuels like natural gas (NG), coke oven gas (COG), or hydrogen presents a viable path to reduce carbon emissions in blast furnace ironmaking. A review of industrial practices and simulations reveals significant variabilities in estimating the impacts of hydrogenous gases’ tuyere injection on the blast furnace operation due to a lack of representative industrial-scale experiments and diverse modeling approaches. NG is effective yet regionally constrained, while COG, although beneficial for improving efficiency and reducing emissions, has limited availability for injection. High coke replacement efficiency ranks NG superior for emission reduction. Meanwhile, COG and cold hydrogen offer similar CO2 reduction potentials, with carbonaceous gases offsetting COG’s higher coke replacement ratio. Preheating hydrogen can further improve its coke replacement efficacy, achieving the greatest reduction in CO2 emissions. Hydrogen injection has yet to reach economic viability, but technological progress, scaling up, and evolving carbon legislation could alter this, prompting steel producers worldwide to advance hydrogen injection techniques in blast furnaces.

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Injection of Hydrogenous Gases into the Blast Furnace Tuyeres for Reducing CO2 Emissions: A Review

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Chemical and Mechanical Factors on Phosphorus Dissolution Behavior from P-concentrated Slag

Takayuki Iwama, Ryo Inoue, Kenji Nakase, Shigeru Ueda

pp. 1956-1966

DOI:

10.2355/isijinternational.ISIJINT-2024-234

Abstract

Since it has been urgently demanded to secure the secondary phosphorus resources domestically in addition to the establishment of a stable supplying path of phosphate ore from overseas, the recovery of phosphorus from steelmaking slags is attracting attention. The phosphorus-enriched slag obtained by dephosphorizing the high phosphorus hot metal, which was prepared by the reduction of conventional steelmaking slag, is thought to be useful as a raw phosphorus resource. It was reported in our previous paper that phosphorus can be effectively separated from P-enriched slag by the citric acid leaching method. In this study, the effects of citric acid concentration in solution, solution temperature, slag/solution mass ratio, and P-enriched slag composition on phosphorus dissolution behavior were additively investigated. A phosphorus dissolution from the P-enriched slag was significantly promoted by increasing the citric acid concentration in solution. However, even if the solution temperature was increased during leaching, the speed and ratio of phosphorus dissolution from the P-enriched slag did not change. With increasing the slag/solution mass ratio, the concentration of each element in solution increased, while their dissolution ratios decreased. Furthermore, the phosphorus dissolution ratio was suppressed in the case of the P-enriched slag with low CaO and high P2O5 concentrations. Appropriate conditions for various factors affecting phosphorus dissolution behavior from P-enriched slag were discussed.

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Chemical and Mechanical Factors on Phosphorus Dissolution Behavior from P-concentrated Slag

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Initial Oxidation of Fe–Cr Alloys at Different Temperatures and Atmospheric Conditions: A ReaxFF Molecular Dynamics Approach

Qin Hu, Zi-yu Lyu, Li-dong Xing, Chao Gu, Yan-ping Bao

pp. 1967-1975

DOI:

10.2355/isijinternational.ISIJINT-2024-235

Abstract

Oxidation behavior during the continuous casting process significantly impacts steel quality. This study investigated the oxidation process of iron–chromium (Fe–Cr) alloys at different temperatures and atmospheric conditions using the molecular dynamics method. Results indicated that during oxidation, Fe and Cr atoms lost electrons while O atoms gained electrons. The ratio of consumed O positively correlated with temperature and O concentration. Oxidation severity was higher at increased O concentrations and 1373 K, with the most severe oxidation occurring at lower temperatures with higher O concentrations. The oxidation rate constant in wet O concentrations was lower compared with pure O, with a higher oxidation kinetic index, indicating that continuous casting billets in water-cooled conditions should have a limited duration. The initial oxidation kinetics of the Fe–Cr alloy surfaces are all manifested as the initial rapid oxidation, followed by the slow oxidation growth process Additionally, Mean-Squared Displacement (MSD) of Fe atoms is larger than that of Cr atoms and Cr oxidizes in the inner layer to form a dense oxide, it prevents Cr from continuing to oxidize and diffuse outward, thus generating Fe-rich products on the surface of Fe–Cr alloys.

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Initial Oxidation of Fe–Cr Alloys at Different Temperatures and Atmospheric Conditions: A ReaxFF Molecular Dynamics Approach

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BO-Catboost Model-based Prediction of Blast Furnace Coal Injection Rate

Lili Meng, Jinlong Wen, Ran Liu, Hongyang Li, Zhi Zheng, Jinxiang Liu, Mingliang Zhi

pp. 1976-1987

DOI:

10.2355/isijinternational.ISIJINT-2024-150

Abstract

As a critical parameter in blast furnace production, the coal injection rate is not only related to the stability of furnace condition, but also a vital index for evaluating production economy. In most of the blast furnaces, this parameter is often determined by the operator’s experience. This paper establishes a coal injection rate prediction model based on the Catboost (category gradient boosting algorithm), which can provide a better basis for operators to control the parameter. At first, the collected steel production data were processed, the last time operational parameters that had greater impact on the coal injection rate were selected out as the input of the model, and the current time coal injection rate was used as the single output of the model. Next, the Catboost model was quoted, and the Optuna optimization algorithm based on the Bayesian principle was used to optimize the Catboost model (BO-Catboost), enhancing the model’s capabilities and avoiding over-fitting phenomenon. Then, the effects of the Catboost model under different optimization algorithms were compared, and the prediction results of the BO-Catboost model were compared with the predictions of the ordinary Catboost, BO-Random Forest and BO-XGboost (Extreme Gradient Boosting) model. The results show that the BO-Catboost model is better than other models. Finally, a blast furnace coal injection monitoring system based on Web technology was established, which can display the coal injection prediction information on the board, the test shows that it has a certain guidance for the control of the coal injection rate.

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BO-Catboost Model-based Prediction of Blast Furnace Coal Injection Rate

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Application of Pellet Sintering in Manganese Ore Fines and Its Consolidation Behavior

Wei Liu, Deqing Zhu, Jian Pan, Zhenning Wei, Zhengqi Guo, Congcong Yang, Siwei Li

pp. 1988-1998

DOI:

10.2355/isijinternational.ISIJINT-2024-187

Abstract

The high solid fuel consumption has been a persistent problem for Steel production mills during the sintering process of manganese ore fines. This manuscript adopts the method of pellet-sintering to process manganese ore fines, and investigates the optimization of the sintering parameters for manganese ore fines, as well as its agglomeration mechanism. The sintering pot tests shown that the pellet-sintering required about 3.5% coke breeze dosage significantly lower than the traditional sintering (about 5%–10%), while the sintering indices can be achieved a yield of 71.12%, a tumble index of 62.48%, a solid fuel consumption of 55.87 kg/t, and a productivity of 1.29 t·h−1·m−2 under the condition of pellet size is 8–12 mm. XRD and SEM-EDS analyses indicated that the major mineral phases of sinter products included hausmannite (Mn3O4), ferrotephroite [(Fe,Mn)2SiO4], Fe–Mn oxides (FexMn3-xO4), bustamite [(Mn,Fe,Ca)·5(Si5O15)], rich-Mn bearing silicate melts and a small quantity of free quartz (SiO2). Optical microstructure and SEM images showed that hausmannite and Fe–Mn oxides are in blocky, with crystal-to-crystal bridging connections. ferrotephroite is rodlike, with a small amount appearing skeletal. The well-developed crystals are intertwined and closely interconnected, greatly enhancing the quality of the sinter product.

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Application of Pellet Sintering in Manganese Ore Fines and Its Consolidation Behavior

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Compressive Strength and Thermal Properties of Ferro Coke Prepared by Cold Pressing Method

Yanhui Li, Fei Liao, Rui Guo, Huan Cheng, Zhang Sun, Zhennan Gao, Liangyuan Hao

pp. 1999-2007

DOI:

10.2355/isijinternational.ISIJINT-2024-295

Abstract

This research aimed to investigate the production of ferro coke with high strength by cold pressing without adding binder, to meet the requirements of the metallurgical industry and avoid the environmental pollution problems caused by the hot pressing process. The effects of pressure and proportion of iron ore powder on the preparation of ferro coke from a weakly caking coal and a strongly caking coal were studied. The results show that when no binder is added, the ferro coke made from weakly caking coal has the highest compressive strength of 5.13 KN, while the ferro coke made from strongly caking coal has the highest compressive strength of 4.93 KN.

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Compressive Strength and Thermal Properties of Ferro Coke Prepared by Cold Pressing Method

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Artificial Neural Network Model for Estimating Mold Flux Melting Temperature

Carlo Mapelli, Davide Mombelli, Gianluca Dall’osto, Jung-Wook Cho, Nathalie Gruber, Irmtraud Marschall, Maïté Cornille, Marco Alloni, Riccardo Carli

pp. 2008-2019

DOI:

10.2355/isijinternational.ISIJINT-2024-151

Abstract

The accuracy of the current models for the calculation of the melting temperature of the mold flux shows that there is still room for improvement, given that their accuracy could not be satisfactory enough to keep up with the current industrial needs. In this work the use of artificial neural networks for data prediction is explored. The network acts as a “black box” capable to predict the melting temperature determined by complex physical interaction among the involved chemical species composing the flux. The network is trained by learning from real experimental data provided by different research groups through hot stage microscopy. The data was tested first within its respective batches and then tested as a single aggregate data batch. After testing and optimization of the networks’ parameters, an acceptable level of accuracy was reached because the estimated melting temperatures point out an average error lower than 30 K if compared to measured data. This opens the possibility for the development of a standalone application that can be used for reference. In order to open the possibility for further improvements of this study the paper shares and makes public the values contained in the matrixes connecting the nodes of neural networks.

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Artificial Neural Network Model for Estimating Mold Flux Melting Temperature

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In-situ Observation of Precipitation and Growth of MnS Inclusions during Solidification of a High Sulfur Steel

Haixin Yang, Ying Ren, Jinshu Wang, Lifeng Zhang

pp. 2020-2030

DOI:

10.2355/isijinternational.ISIJINT-2024-195

Abstract

The effect of the cooling rate on the morphology, number density, and size distribution of MnS inclusions in a high sulfur steel was investigated. With the increase of the cooling rate from 15 K/min to 300 K/min, the number density of MnS inclusions ranged from 91 #/mm2 to 192 #/mm2, and the average size of MnS inclusions decreased from 7.4 µm to 5.3 µm. A coupled model was developed to predict the precipitation and growth of MnS inclusions. The precipitation temperature of MnS at different cooling rates was approximately 1823 K, which agreed well with experimental results. Through the high-temperature confocal scanning laser microscope, the precipitation process of MnS in a high sulfur steel during the solidification was observed. Inclusions of MnS primarily precipitated at grain boundaries, while the morphology of MnS before and after solidification was influenced by the cooling rate. A higher cooling rate promoted elongated MnS inclusions precipitated, and smaller MnS inclusions were precipitated after solidification. Conversely, a slower cooling rate led to the massive MnS inclusions precipitated during solidification, leading to the formation of elongated MnS particles.

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In-situ Observation of Precipitation and Growth of MnS Inclusions during Solidification of a High Sulfur Steel

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Sampling Strategy of Bubble Characteristics in a 1:2 Scale Curved Continuous Casting Mold: Parametric and Prediction Study

Soumitra Kumar Dinda, Donghui Li, Fernando Guerra, Chad Cathcart, Mansoor Barati

pp. 2031-2041

DOI:

10.2355/isijinternational.ISIJINT-2024-081

Abstract

Argon gas injection in slab continuous casting is common practice to counter SEN clogging phenomena. Bubble characteristics determine the probability of bubble-driven defects such as steel cleanliness, liquid steel reoxidation, and sliver and blister defects. 1:2 scaled water model studies were performed with the help of an advanced high-speed-high-resolution camera shadowgraph imaging technique. Bubble Sauter mean diameter and count were calculated using Trainable Weka segmentation, a machine learning image-based segmentation in the ImageJ platform for different processing conditions such as gas flow rate, liquid flow rate, mold width, and submerged entry nozzle (SEN) depth. A predictive model was developed on the experimental data using an artificial neural network (ANN) algorithm to optimize the bubble mean diameter and count sampling strategy. The model performance is optimized based on the cross-validated adjusted R2. The model shows significant promise with bootstrapping aggregation, five-fold cross-validation, and improved accuracy.

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Sampling Strategy of Bubble Characteristics in a 1:2 Scale Curved Continuous Casting Mold: Parametric and Prediction Study

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Ductility Loss of a Metastable Austenitic Stainless Steel and Its TIG Weldment Due to Hydrogen Embrittlement at Low Temperatures Considering the Effect of Pre-strain at 4 K

Rafael Magalhaes De Melo Freire, Shohei Uranaka, Eita Tochigi, Mitsuo Kimura, Tomoya Kawabata

pp. 2042-2050

DOI:

10.2355/isijinternational.ISIJINT-2024-182

Abstract

The amount of martensite in austenitic stainless steels produced during plastic deformation at low temperatures is related to the reduction in hydrogen embrittlement resistance. A pre-strain at 4 K was employed in this work to produce strain-induced martensite (SIM) in the microstructure of SUS316L and its weldment to verify the changes in hydrogen embrittlement susceptibility through slow strain tensile (SSRT) tests in a high-pressure hydrogen environment. As the base metal specimens, the weld metal specimens, manufactured by gas tungsten arc welding (GTAW or TIG) were pre-strained at different levels (5%, 10%, and 15%) for comparison with the non-pre-strained condition. Analysis of the most degraded samples tested from −150°C to 0°C is conducted through fracture surface observations, lateral crack length measurement, and crack density. It was possible to indicate that the pre-strain effect induced earlier crack nucleation in comparison to the situation observed in the non-pre-strained material. The pre-existing martensite produced by the pre-strain at 4 K is responsible for earlier crack nucleation, leading to a loss in the hydrogen embrittlement resistance for the SSRT pre-strained base metal specimens.

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Ductility Loss of a Metastable Austenitic Stainless Steel and Its TIG Weldment Due to Hydrogen Embrittlement at Low Temperatures Considering the Effect of Pre-strain at 4 K

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Role of Retained Austenite and Deformation-induced Martensite in 0.15C-5Mn Steel Monitored by In-situ Neutron Diffraction Measurement during Tensile Deformation

Takayuki Yamashita, Satoshi Morooka, Wu Gong, Takuro Kawasaki, Stefanus Harjo, Tomohiko Hojo, Yoshitaka Okitsu, Hidetoshi Fujii

pp. 2051-2060

DOI:

10.2355/isijinternational.ISIJINT-2024-196

Abstract

An Fe-0.15C-5Mn-0.5Si-0.05Nb medium-Mn steel annealed at 660°C and 685°C both exhibited inhomogeneous deformation with Lüders deformation and followed by an extremely high work hardening stage, but with different Lüders strain and work hardening behavior. In-situ neutron diffraction measurements during tensile tests were performed to investigate changes in the phase stresses, the stress contribution to the strength of the constituent phases, and the crystal orientation of austenite. The role of each constituent phase on the deformation behavior and the crystallographic orientation dependence of austenite stability were examined. Deformation-induced martensite showed excellent phase stress and contributed to the strength of approximately 1000 MPa at around tensile strength, which is close to macroscopic tensile strength. Although austenite contributed less to the strength, during Lüders deformation and work hardening stages, it continuously transformed to martensite as the deformation progressed, suggesting that it mainly contributed to the ductility of the steels through a transformation-induced plasticity effect. Austenite transformed to martensite during Lüders deformation almost regardless of its crystallographic orientations. However, there was a tendency for more 311 oriented austenite grains to remain parallel to the tensile direction.

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Role of Retained Austenite and Deformation-induced Martensite in 0.15C-5Mn Steel Monitored by In-situ Neutron Diffraction Measurement during Tensile Deformation

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Effect of Inhomogeneous Microstructure on Strength and Fracture Resistance in Sharp Edge of Japanese Swords

Kwangsik Kwak, Takateru Yamamuro, Yoji Mine, Shigekazu Morito, Kazuki Takashima

pp. 2061-2070

DOI:

10.2355/isijinternational.ISIJINT-2024-224

Abstract

Microtensile and microfracture tests were performed on the sharp-edge regions of Japanese swords fabricated in the Muromachi and Showa periods, which are called old sword (OS) and modern sword (MS), respectively, to correlate the mechanical properties with the inhomogeneous microstructures. The hardness of the sharp-edge regions was characterised by the distribution of fine pearlite mixed in martensite microstructures. The OS containing a large fraction of fine pearlite exhibited a low hardness compared to the MS. Microtensile tests using sharp-edge specimens revealed a positive correlation between their tensile strength and strain-to-failure, as opposed to the common tendency in conventional carbon steels made by modern iron-making technology. The fracture surfaces of the sharp-edge specimens consisted of intergranular fracture and dimples. The tensile strength and dimple fracture area fraction were higher in the OS than in the MS. These findings suggest that the fine pearlite microstructure contributes to increased strength in the sharp-edge region through inhibiting the linkage of intergranular cracking owing to local plastic deformation. Microfracture tests using the sharp-edge specimens revealed that the intrinsic fracture resistance of both OS and MS was determined by the intergranular fracture, whereas the fine pearlite microstructure increased the resistance to crack propagation. The micromechanical testing study indicates that in the sharp-edge regions, their strength and fracture toughness are simultaneously enhanced by the presence of fine pearlite although depending on its distribution.

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Effect of Inhomogeneous Microstructure on Strength and Fracture Resistance in Sharp Edge of Japanese Swords

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Creep Rupture Strength and Phase Stability of the Austenite Phase for KA-SUS304J1HTB

Yoshiki Shioda, Noriko Saito, Kyohei Nomura, Keiji Kubushiro

pp. 2071-2078

DOI:

10.2355/isijinternational.ISIJINT-2024-264

Abstract

Metallurgical factor causing the heat-to-heat variation in creep rupture strength have been investigated for KA-SUS304J1HTB. In the long-term, there was a maximum difference of 3.5 times in creep rupture time between the heat with low creep strength and the heat with high creep strength. In the heat with low creep rupture strength, most of the creep voids occurred at the matrix/σ phase interface. Moreover, in the heat with low creep rupture strength, the area fraction of σ phase was larger than in the heat with high creep rupture strength. Considering that the difference in the area fraction of σ phase in each heat is related to the difference in phase stability of the austenite phase, the Md value in each heat was evaluated. The Md value is the parameter correlated with phase stability. The creep rupture time of each heat was correlated with the Md value. The smaller the Md value, the longer the creep rupture time. Therefore, the heat-to-heat variation in creep rupture strength is caused by the difference in the phase stability of each heat. In other words, in the heats with low phase stability, creep rupture strength is low because a large amount of σ phase precipitates during the creep test.

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Creep Rupture Strength and Phase Stability of the Austenite Phase for KA-SUS304J1HTB

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Effect of the Injection Position on Mixing Time in a Centric Gas-stirred Ladle Water Model Assisted by a Systematic CFD Study

Rodrigo Villarreal-Medina, Luis Enrique Jardón-Pérez, Adrián Manuel Amaro-Villeda, Gerardo Trápaga-Martínez, Marco Aurelio Ramírez-Argáez

pp. 2079-2083

DOI:

10.2355/isijinternational.ISIJINT-2024-201

Abstract

Mixing time is a parameter that describes the degree of agitation in a gas-stirred ladle. The literature is not conclusive on the effect of the tracer injection position on the mixing time under equal stirring conditions. This work conducted a systematic and comprehensive study on the effect of the tracer position on the mixing time for centric injection. Results in the form of a mixing time map indicate that the diagonal formed between the inlet and the upper wall region gets the fastest mixing, and specifically in the eye of the toroid of the circulation loop is the best position to mix solute rapidly. In contrast, the dead zones at the lower near-wall part of the ladle have the poorest mixing behavior for the tracer addition. The study also tested the ladle’s axisymmetric assumption since two points were at different angular positions, but the same axial and radial points presented similar mixing time.

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Effect of the Injection Position on Mixing Time in a Centric Gas-stirred Ladle Water Model Assisted by a Systematic CFD Study

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Editorial Board, Copyright Page and Announcements

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Editorial Board, Copyright Page and Announcements

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