Pragmatical physics-based model for ladle lifetime prediction

TL;DR

This paper presents a physics-based model for predicting the erosion and temperature evolution in steel ladles, integrating CFD simulations and wall functions, enabling fast and accurate industrial predictions.

Contribution

The paper introduces a novel, fast physics-based model for ladle lining erosion that combines CFD-derived wall shear velocities with heat and mass transfer modeling.

Findings

Model accurately predicts thermal and erosion evolution.

Deviations from industrial data are analyzed.

Model is suitable for semi-online industrial use.

Abstract

In this paper we develop a physics-based model for the erosion of lining in steel ladles. The model predicts the temperature evolution in the liquid slag, steel, refractory bricks and outer steel casing. The flows of slag and steel is due to forced convection by inert gas injection, vacuum treatment (extreme bubble expansion), natural convection and waves caused by the gas stirring. The lining erosion is due to dissolution of refractory elements into the steel or slag. The mass and heat transfer coefficients inside the ladle, during gas stirring, is modeled based on wall functions which take the distribution of wall shear velocities as a critical input. The wall shear velocities are obtained from CFD (Computational Fluid Dynamics) simulations for sample of scenarios, spanning out the operational space, and using curve fitting a model could be built. The model is capable of reproducing both thermal evolution and erosion evolution well. Deviations between model predictions and industrial data are discussed. The model is fast and has been tested successfully in a "semi-online" application. The model source code is made available to the public on https://github.com/SINTEF/refractorywear.