Redistribution of solid inclusions in the turbulent flow of metallurgical induction furnaces

Numerical and experimental study of liquid metal stirring by rotating permanent magnets

In this work, we study liquid gallium stirring by rotating permanent magnets. We demonstrate possibility of easily creating different flow patterns by rotating permanent magnets, which can be industrially important for controlling heat and mass transfer processes in the system. Unlike the typical approach of simulating magnet rotation as a transient problem and time-averaging the Lorentz forces, we solve the magnet rotation as a harmonic (frequency domain) problem, which leads to forces equal to time-averaged ones and decreases the simulation time considerably. Numerical results are validated using qualitative flow structure results from the neutron radiography visualization of tracer parti…

LES modelling of recirculated flows in crucible furnaces

A Model for Homogenization of Solid Alloying Admixtures in an Induction Crucible Furnace

The paper presents a methodology for identification of homogenization time of alloying inclusions in an induction crucible furnace. The methodology is based on the Large Eddy Simulation (LES) Euler-Lagrange calculation of inclusions and a regression model for size of the inclusions and their density. The presented regression model avoids the repeated LES calculations and, therefore, is suitable for an optimization task.

LES investigation of heat and mass exchange in channel induction furnaces

Particle transport in recirculated liquid metal flows

PurposeAims to present recent activities in numerical modeling of turbulent transport processes in induction crucible furnace.Design/methodology/approach3D large eddy simulation (LES) method was applied for fluid flow modeling in a cylindrical container and transport of 30,000 particles was investigated with Lagrangian approach.FindingsParticle accumulation near the side crucible boundary is determined mainly by the ρp/ρ ratio and according to the presented results. Particle settling velocity is of the same order as characteristic melt flow velocity. Particle concentration homogenization time depends on the internal flow regime. Separate particle tracks introduce very intensive mass exchang…

Thermal and Hydrodynamic Analysis of the Melting Process in the Cold Crucible Using 3D Modeling

Solid inclusions in an electromagnetically induced recirculated turbulent flow: Simulation and experiment

Abstract The paper presents the numerical and the experimental investigation of the particle-laden recirculated turbulent flow of liquid metal that is driven by electromagnetic force. Such flow is typical for induction metallurgical furnaces. The paper describes the behaviour of solid spherical particles that are mixed in the flow from a top surface of a melt and covers 3 stages of an admixing process as well as deposition of inclusions on the wall of a vessel. Experimental investigation of particles concentration at the quasi-stationary stage is fulfilled on the basis of a novel idea: ferromagnetic particles are proposed as a physical model of non-conductive inclusions in liquid metal at t…

Statistical analysis of the influence of forces on particles in EM driven recirculated turbulent flows

The present paper contains an analysis of the statistical distribution of forces affecting non-conducting particles dispersed in an EM induced recirculated flow in induction furnaces. The simulation is conducted adopting the LES-based Euler-Lagrange approach in the limit of dilute conditions (one-way coupling). It is done by means of a development of OpenFOAM software code. The used Lagrange equation for particle tracking includes drag, EM, buoyancy, lift, acceleration and added mass forces. The relevant approximations for the forces are chosen on the basis of the statistical analysis of the non-dimensional parameters (particle Reynolds number, shear stress and acceleration parameter). The …

A numerical model for coupled free surface and liquid metal flow calculation in electromagnetic field

Simulation of turbulent metal flows

Comprehensive knowledge of the heat and mass transfer processes in turbulent metal flows is required to realize efficient and reliable melting and casting processes. Experimental and numerical studies of the melt flow in induction furnaces show that the flow pattern, which comprise several vortexes of the mean flow, and the temperature distribution in the melt are significantly influenced by low-frequency large scale flow oscillations. Two- and three-dimensional hydrodynamic calculations of the melt flow, using two-equation turbulence models based on Reynolds Averaged Navier-Stokes approach, do not predict the large scale periodic flow instabilities obtained from the experimental data. That…

Gas bubbles and liquid metal flow influenced by uniform external magnetic field

Influence of the channel design on the heat and mass exchange of induction channel furnace

PurposeThe purpose of this paper is to present in‐depth numerical modelling of heat and mass exchange in industrial induction channel furnace (ICF).Design/methodology/approachThe turbulent heat and mass exchange in the melt is calculated using a three‐dimensional (3D) electromagnetic model and a 3D transient large eddy simulation method. The simulation model has been verified by flow velocity and temperature measurements, which were carried out using an industrial sized channel inductor operating with Wood's metal as a low temperature model melt.FindingsThe ICF is well‐established for melting, holding and casting in the metallurgical industry. But there are still open questions regarding th…

Large scale electromagnetic levitation melting of metals

Analysis and Design of Induction Liquid Metal Processes Using Advanced Numerical Modelling

Comprehensive knowledge of the turbulent flows, heat and mass transfer processes in the melt of induction applications is required to realize efficient metallurgical processes. Therefore, the process oriented development, design and optimization of induction furnaces for melting and casting of metals require praxis oriented simulation and analysis of the complex in-stationary turbulent melt flows and temperature distributions as well as the heat and mass transfer processes in the liquid metal. The studies, presented in this paper, demonstrate the possibilities of using advanced three-dimensional transient numerical modelling for successful simulation of the melt flow as well as heat and mas…

Experimental investigations and numerical modelling of the melting process in the cold crucible

PurposeAims to present recent activities in experimental investigations and numerical modelling of the induction cold crucible installation.Design/methodology/approachTemperature and velocity measurements using thermocouples and electromagnetic velocity probes were performed in aluminium melt which was used as a model melt. Measured temperature field and flow pattern were compared with transient 3D calculations based on large eddy simulation (LES) turbulence modelling scheme. Numerical results are in good coincidence with the experimental data.FindingsThe modelling results show that only 3D transient LES is able to model correctly these heat and mass transfer processes.Originality/valueIt i…

Experimental investigation of low-frequency pulsed Lorentz force influence on the motion of Galinstan melt

Abstract The paper presents the results of the numerical and physical experiments, aimed at assessing the influence of pulsed force of electromagnetic field on the melt motion and the fluid velocities. The experiment was performed on the eutectic alloy Galinstan in the cylindrical volume, where an ultrasonic Doppler velocimeter was employed for velocity measurements under conditions of pulsed and steady EM field application. A numerical simulation of the melt flow, forced by the steady EM force, involved a 2D axisymmetric model. The k-e turbulence model was used to obtain the information about the melt velocities. The verification of the numerical model was carried out for the steady case. …

Numerical simulation and analysis of heat and mass transfer processes in metallurgical induction applications

Comprehensive knowledge of the heat and mass transfer processes in the melt of induction applications is required to realize efficient metallurgical processes. Experimental and numerical studies of the melt flow in induction furnaces show that the flow pattern, which comprise several vortexes of the mean flow, and the temperature distribution in the melt are significantly influenced by low-frequency large scale flow oscillations. Two- and three-dimensional hydrodynamic calculations of the melt flow, using two-equation turbulence models based on Reynolds Averaged Navier-Stokes approach, do not predict the large scale periodic flow instabilities obtained from the experimental data. That's why…

Numerical Simulation of Turbulent Flows, Heat and Mass Transfer in Metallurgical Induction Processes

Numerical studies of the melting process in the induction furnace with cold crucible

PurposeAims to present recent activities in numerical modeling of cold crucible melting process.Design/methodology/approach3D numerical analysis was used for electromagnetic problem and 3D large eddy simulation (LES) method was applied for fluid flow modeling.FindingsThe comparative modeling shows, that higher H/D ratio of the melt is more efficient when total power consumption is considered, but this advantage is held back by higher heat losses through the crucible walls. Also, calculations reveal that lower frequencies, which are energetically less effective, provide better mixing of the melt.Originality/value3D electromagnetic model, which allows to take into account non‐symmetrical dist…

Influence of the Richardson number on EM force driven flow structures in square-shaped crucible

Abstract This study is devoted to the experimental investigation of the turbulent melt motion in a square crucible where the flow is created by Lorentz forces generated by an external AC magnetic field. As a strong vertical thermal gradient is present in melt during a directional solidification process, a stratification effect takes place and motion in the vertical direction is damped by buoyancy forces. Such a situation arises if density of fluid layers decreases with height. Experimental velocity and temperature measurements are conducted. Transient effects, like collapse of stratification, are observed experimentally. The significance of stratification in the directional solidification m…