Understanding of baffle effect of inserting a filter within a tundish via a water model experiment and numerical simulation

Abstract

The baffle effect of inserting a filter within a tundish was investigated using a combination of water model experiments and numerical simulations. The filter, which is a cost-effective device used to enhance the quality of molten steel by removing inclusions, was studied for its impact on the removal rate of inclusions. In the water model experiments, a scaled-down model of the tundish system was created with a geometric ratio of 1:4. Polyethylene particles of varying sizes were used to simulate the inclusions. Additionally, a three-dimensional numerical model of the water model was developed to validate the experimental findings, provide supplementary data for analysis, and propose an optimized tundish configuration by moving the weir away from the filter by 50, 100, and 150 mm. The flow patterns were also thoroughly examined. The results revealed that the presence of the filter increased the flow resistance within the tundish, leading to changes in the residence time distribution. This resulted in the formation of a ‘dead zone’ with a significantly prolonged residence time. The higher flow resistance hindered the entry and exit of particles from the last chamber of the tundish. As a result, the distribution of particles in the last chamber became more dispersed, reducing the detrimental effects of inclusions in the steel. The removal efficiency of the seven types of particles was improved by 2–7%. Furthermore, by moving the weir away from the filter by 50 mm, the removal ratio could be further increased by approximately 2%.