Water Modelling – A tool for Effective
Designing of Turbulence-suppressing
Tundish Impact Pad, TURBOSTOP
Authors: K. G. Venkatesan, S. K. Bera, S. Khurana – Foseco India Limited
Abstract
In this era of ‘Open Economy’ the role of
tundish has been transformed from being a
just mere intermediate vessel for
transferring steel from ladle to mould to a
critical reactor in the continuous casting
process. This has resulted in the need for a
detailed analysis of effectiveness of various
tundish flow modifiers in achieving
optimum flow pattern and improving steel
quality. Kinematic viscocity similarity
between water at room temperature and
liquid steel gives a excellent scope to
understand the flow pattern of steel by
physical modelling. Water Modelling
studies of tundish have shown the need for
developing flow modifier system which
apart from enhancing surface directed flow
will effectively suppress turbulence in the
pouring area and improve laminar flow.
Such a flow pattern not only increases
residence time of steel in the tundish
,thereby facilitating inclusion floatation,
but also reduces transition zone during
mixed grade casting as well as slag
emulsification during ladle change overs.
The flow pattern of steel in the tundish
depends on a host of plant parameters
which makes the tundish of each plant
unique. This uniqueness makes it
imperative to study every plant tundish
separately in order to suggest the optimum
flow modifier system.
1. Introduction
The tundish plays an important role in the
continuous casting process. In this era of
‘Open Economy’ every steel plant is now
facing new challenges of producing quality
steel through cost effective methods. This
new demand has transformed the role of
tundish which was originally considered as
a buffer vessel used to transfer molten
steel from ladle to mould, to a critical
reactor within the continuous casting
operation. In its new role the tundish is
now designed to deliver controlled flow of
metal to mould and facilitate inclusion
floatation.
During the past two decades extensive
work has been done to understand and
improve the fluid flow pattern in the
tundish with the help of both physical and
mathematical modelling. Keeping in view
the changing needs of the steel plant
Foseco India Limited set up their first
tundish water modelling laboratory in USA
in the early nineties. The experience of
developing custom designed tundish flow
modifiers for major US steel plants was
then extended to Europe and India with
two new labs in Germany and India in the
late nineties.
2. Tundish Physical Modelling
2.1 Fluid Flow Characterisation
Prior to widespread adoption of the
continuous casting process two parameters
were considered necessary to characterise
the condition of steel during steel making
and casting. These two parameters were
temperature and composition. However,
recent innovation in post-furnace
steelmaking practice such as ladle
treatments(desulfurisation, allow addition
etc.) and particularly continuous casting
procedures have pressed for the need of
considering a third parameter" Fluid Flow"
to completely characterize steel condition
at any position in the processing sequence.
As shown in Fig.1 interaction between the
three processing parameters determine the
response in terms of both quality and
productivity.
TEMPERATURE
COMPOSITION FLUID FLOW
QUALITY PRODUCTIVITY
Fig 1. Three Processing Parameters
Temperature and composition are linked
through the physical chemistry of
steelmaking process e.g. the solubility of
non-metallic levels in steel and thus the
active oxygen levels in steel are influenced
by temperature. Again the condition of
fluid flow will affect the heat loss and
therefore the temperature.
Fluid flow and composition are strongly
linked with the condition of fluid flow
exerting significant influence on
1. The ability to remove non-metallic
inclusion form metal to slag phase.
2. The degree of re-oxidation due to
atmospheric contact while pouring
3. The success of alloying procedures.
Fluid flow can be characterized by velocity,
flow pattern and turbulence intensity. As
shown in Fig 2. the fluid flow in a tundish
is of two types namely active & passive
1
(Sahai and EMI ).
TUNDISH FLOW
ACTIVE FLOW PASSIVE FLOW
MIXED FLOW PLUG FLOW DEAD FLOW
Fig 2. Tundish Flow Characterisation
Active flow consists of the plug and mixed
flow component whereas passive flow
signifies the dead flow.
2.2 Flow Modifiers
The flow pattern in the tundish having
significant influence of the quality and
productivity of the steel produced. Several
devices are generally used in the tundish to
modify steel flow in the tundish to get
optimised performance.
Over the years several designs of flow
modifiers were used in the tundish to
achieve desired results. These were namely
dams, weirs, baffles with multiple holes
etc. The main purpose of using these was
to put barriers in the steel flow path as well
as give directional metal flow upwards
which facilitated inclusion floatation. M.M
2
Collur,D. B. Love and B.V. Patil of
Alleghany Ludlum.Pensilvania, USA did a
detailed study to analyse the effectiveness
of different existing flow modifiers systems
towards inclusion floatation. Michael L.
3
Lowry and Y. Sahai , Paul Rasmussen,
4
Dofasco Inc, Canada study and their
subsequent verification during actual
practice in the plant gives a clear idea of
the improvements possible by using these
flow modifiers vis-à-vis having none.
Recent demands of steel industry has
pushed the concept of flow modifiers from
just acting as barriers and directing flow
upwards towards actually suppressing the
energy of incoming steel in the tundish by
custom designed flow controlled pads.
These pads when properly designed for
each plant taking into account its
uniqueness, did gave improved per-
formance over dams. weirs and baffle
systems not only w.r.t. steel cleanliness but
also reducing mixed tonnage produced
when two different grades of steel of wide
chemistry variations were casted in the
same tundish (Paul Rasmussen5 for Dofasco
Inc., Canada). Studies done in steel plants
like AK Middletown, OHIO USA, Sollac,
France, Nucor Hickman, USA. US Steel
Gary, USA, Algoma, Canada has also
revealed similar trends.
Recent trends, as discussed above, do
make it imperative to study in details the
fluid flow pattern for every plant’s tundish
in order to design a custom made flow
modifier system. This will enable the steel
makers to optimise steel flow pattern in
the tundish in order to derive maximum
benefit.
2.3 Physical (Water) and Mathematical
Modelling
Fluid flow in steelmaking system has been
the subject of extensive study in recent
years. The approaches used included both
physical and mathematical modeling.
Mathematical predictions of flow pattern6-9
has gained wider popularity in recent years
with the advent of improved numerical
procedures and refined turbulence models.
When augmented by experimental work,
mathematical modelling can be useful in
explaining or verifying the observed results,
and for providing guidelines for experi-
mental design.
The flow of liquid steel in a continuous
casting system cannot be observed directly.
The application of the technique of
mathematical modelling is complicated by
the occurrence of intense turbulence and
biphasic flow in certain regions of the
system. Thus, physical modeling using
water at room temperature (due to
kinematic viscocity similarity with liquid
steel at 1600°C) as a medium is finding
widespread application for the study of
fluid flow in the tundish, especially in
designing tundish flow modifiers.
To attain similarity between two flowing
systems the flowing four conditions must
be met10-13
1. Geometric Similarity – the ratio of length
in one with the corresponding one of
the another is constant. This ratio is
termed as scale factor
2. Kinematic Similarity – the streamlines in
one system are geometrically similar to
the streamlines in the other system.
3. Dynamic Similarity – the magnitude of
forces at corresponding locations in
each system are in a fixed ratio.
4. Thermal Similarity – the dimensionless
numbers involving heat transfers are
equal in both systems. Thermal
similarity is not important when
considering flow within a tundish since
forced convection in these regions is
likely to be predominant.
n
Configuration - A Configuration - B
Steady State Liquid Metal Level Steady State Liquid Metal Level
Dam - 2 Dam - 1 Baffle Dam - 1
1200 mm 320 mm
Striker Pad Striker Pad
Configuration - C Configuration - D
Steady State Liquid Metal Level Steady State Liquid Metal Level
Dam - 1 Baffle
320 mm 1000 mm
Striker Pad TURBOSTOP at 40 mm from end wall
Configuration - E Configuration - F&G
Steady State Liquid Metal Level Steady State Liquid Metal Level
Short Dam with drain holes High Dam (1&2)
320 mm
180 mm
TURBOSTOP at 40 mm from end wall TURBOSTOP at 40 mm from end wall
Configuration - H Configuration - I
Steady State Liquid Metal Level Steady State Liquid Metal Level
Baffle Dam - 1 Baffle
320 mm 320 mm 1000
mm
TURBOSTOP at 40 mm from end wall TURBOSTOP at 40 mm from end wall
Fig 3. Schematic diagram of various flow modifier position for Plant - B
Kinematic similarity between model proto- 3. Designing of Turbulence
type and model is ensured if geometric and Suppressing Tundish Impact Pad
dynamic similarities are observed. The
principal forces to be considered in
using Tundish Water Modelling
obtaining dynamic similarity in a
Tundish Water Modelling in Foseco India
continuous casting system are inertial,
Limited’s Laboratory in Pondicherry is
gravitational, viscous, and surface tension
based on Froude Number similarity
forces. The principal dimensionless groups,
criterion which allows to scale down any
which involve these forces, are given by
linear dimension e.g. tundish dimensions,
.Froude No. = v /g.L = inertial force/
2
flow modifier dimensions, shroud
gravity force dimensions etc by a suitable scale factor (f).
.Reynolds No. = V.L/␷ = inertial force/ The volumetric flow rate to be used in the
study is calculated using Froude Similarity
.Weber No. = ␳.V .L/␴ = inertial force/
viscous force
2
Criterion15
surface tension force
Qm = f 2 . 5 Qp
Absolute dynamic similarity that each of
Qm = Volumetric flow rate in the tundish
the dimensionless groups listed above have
model in the laboratory
the same value in both model and actual
Qp = Volumetric flow rate in tundish in
system which is impossible to satisfy in a
steel plant(actual)
single model of particular scale.
f = Scale Factor
Reynold No. is satisfied for a full scale only,
which is not practible in all cases. In case of The water modeling study was carried out
Weber No. 0.6 scale14 is necessary which in with the following primary objectives
turn satisfies Froude No also. But
1. Increase in Residence Time to promote
neglecting the influence of surface tension inclusion floatation
and considering only the case of
homogeneous flow, Froude No. similarity 2. Reduction of Transition Zone during
can be used which allows any scale factor. Mixed Grade Casting
2
 4. Water Modelling Experiments Flow modifiers set-up studied for both type
Configuration - A & B Done of tundish is given in Table 2 and
schematic drawing showing positioning of
Steady State Liquid Metal Level 4.1 Set-up the flow modifiers is given in Fig 3 & 4.
Brick Dam 250 mm Dam A 1/3rd & 1⁄2 scale tundish model for Plant
A & Plant B respectively was taken up for 4.2 C-Curve - RTD Curve Study (Steady
626 mm
Water Modelling Studies. Red colour liquid State)
food dye having similar density as that of
water was used as a tracer for both C- C-Curve Study helps assess the flow
Configuration - C & D Curve and F-Curve studies. The outlet dye characteristics of steel in the tundish at
concentration was measured with the help steady state casting condition with
Steady State Liquid Metal Level
of an optical probe at an interval of 5 secs. different sets of flow modifiers. During the
Weir
The concentration data is acquired online experiment water is filled up to the
Brick Dam 250 mm Dam
by a computer through an data acquisition working level and then held at that level
1650 mm
626 mm set up while the experiment is going on. A with inlet and outlet flow remaining same
special software simultaneously plots the for a duration of 3theta (1 theta=one
respective curves (C-Curve & F-Curve) using tundish emptying time at existing flow
Configuration - E & F the online concentration values. At the end rate) to allow the bath to stabilise.
of each experiment the computer Subsequently a pulse of dye is injected as
Steady State Liquid Metal Level
computes the values of key parameters tracer. The dye concentration is monitored
(e.g. Plug Volume %, Dead Volume % etc) at the outlet at every 5sec time intervals.
Brick Dam 250 mm Dam Weir
from C-Curve. Computer directly acquires the data and
1900 mm concentration curve (C-Curve) is generated
626 mm
Table 1. Values of different parameters used for Water online.
Modelling Study

Configuration - G Plant – A Plant - B

Steady State Liquid Metal Level Parameter Plant Value Water Model Plant Value Water Model
Study Value Study Value

Casting Rate 2.64 tons/min 24.19 lt/min of 2 tons/min 50.51 lt/min of

water water

Tundish Weight at steady state 24 tons 126.98 lt of 29 tons 517.86 lt of

TURBOSTOP - 40 mm from end wall water water

Theta (time taken to empty 1

Configuration - H & I 9.09 min 314 secs 14.5 min 615 secs
tundish volume at above
mentioned casting rate)
Steady State Liquid Metal Level

Brick Dam / Medium Dam

Scale Factor (f) 1 1/3rd 1 0.5

300 mm
Table 2. Flow Modifier Set-up details
TURBOSTOP - 40 mm from end wall
Configurations Description Symbol
Configuration - J Plant - A
Steady State Liquid Metal Level A Brick Dam (Existing System) BD
High Dam -
75% of Liquid Metal Ht B 250 mm Dam D1

300 mm C Weir (1650 mm from shroud end wall) & Brick Dam W(1650)+BD

D Weir (1650 mm from shroud end wall) & 250 mm Dam W(1650)+D1
TURBOSTOP - 40 mm from end wall
E Weir (1900 mm from shroud end wall) & Brick Dam W(1900)+BD

F Weir (1900 mm from shroud end wall) & 250 mm Dam W(1900)+D1
Fig 4. Schematic diagram of various flow modifier position
for Plant - A G TURBOSTOP Only TS

H TURBOSTOP & Brick Dam TS+BD

3. Reduction of Slag Emulsification during
ladle change over I TURBOSTOP & Short Dam with holes TS+SD1/holes

4. Reduction of turbulence near the pouring J TURBOSTOP & High Dam, Dam ht - 75% steady state metal level TS+HD1
area – Minimise Red-Eye formation Plant - B

Two type of slab caster tundish was A Striker Pad & Dams (1&2) (Existing System) SP+D1+D2
studied with the above primarily objective B Striker Pad, Dam (1) & Baffle SP+D1+B1
which are
.Flat Bottom Tundish – Plant A C Striker Pad, Baffle & Dam (2) SP+B1+D2

.Well Shaped tundish – Plant B D TURBOSTOP Only TS

E TURBOSTOP & Short Dam with drain holes TS+SD1/holes

Table 1. shows the values of different F TURBOSTOP & High Dam (1), Dam ht - 75% of steady state metal level TS+HD1
parameters used for water modelling (all G TURBOSTOP & High Dam (2), Dam ht equal to steady state metal level TS+HD2
conversions are done using Froude number
H TURBOSTOP & Baffle at 320 mm from the slope TS+B1/320
similarity & Liquid Steel: Water density ratio
of 7:1) I TURBOSTOP & Baffle & Dam (1) TS+B1+D1

3
Each test was also visually observed using a
video recorded and event recorded. Table 3
gives the parameters for which a com-
parative analysis is done for different sets
of flow modifiers.
The characterization of the flow for the
experimental RTD curves is carried out
using the methods of Sahai and Emi1 as
well as the principles presented by
Levenspiel16.
Parameter Description
Minimum Residence Time This is the time when concentration of dye at the outlet is 1% of total dye injected
(This represents the time taken for a fluid element to reach the nozzle after it enters
the tundish at steady state)
Plug Flow The flow in which all fluid through the tundish travel at nearly the same velocity
(This corresponds to the volume fraction of steel which moves in a laminar fashion
with no back mixing)
Dead Flow The flow of steel in the tundish, which is nearly stagnant.
Mixed Flow Turbulent flow in which there is complete mixing.
Peak Concentration The maximum concentration point in the curve.

4.3 F-Curve – Grade change study Peak Time The time at which the peak concentration is reached.

F-Curve study gives an idea of the nature Table 3. Parameters for comparative analysis

of fluid flow with respect to casting of two

different grades in two consecutive heats Configurations Description Symbol
in the same tundish. Through this study it Plant - A
is possible to get an estimation of the
A Brick Dam (Existing System) BD
transition zone. These tests are conducted
at different draining levels with fill up rate G TURBOSTOP Only TS
upto the steady state being twice that of
H TURBOSTOP & Brick Dam TS+BD
the steady state. For Plant – A study was
carried out for drain levels of 18 Tons & 15 I TURBOSTOP & Short Dam with holes TS+SD1/holes
Tons and for Plant – B it was 20 Tons and Plant - B
15 Tons.
A Striker Pad & Dams (1&2) (Existing System) SP+D1+D2

In the F-Curve experiment water is filled to F TURBOSTOP Only TS2

tundish working level and both outlet and H TURBOSTOP & Short Dam with drain holes TS2+SD1/holes
inlet are closed. Subsequently 20cc of dye
is homogenously mixed with the entire Table 4. Configuration details for F_Curve Study
volume of water (to represent old steel).
Then the outlet is opened at steady state Configurations Dead Plug Mixed MRT-Min. Absolute Peak Peak
flow rate and the coloured liquid is drained Vol(%) Vol(%) Vol(%) Residence Value of Time Conc.
upto a specific level and then fresh water Time MRT(sec)
(new steel) from inlet is started at double Plant - A
the steady state flow rate to fill up up to
A– BD 24.59 6.42 68.99 0.0642 20 0.4493 0.9887
the working level. After the working level is
reached the inlet flow is brought back to B– D1 24.77 13.87 61.36 0.1387 44 0.5068 0.9961
original steady state flow rate and C– W(1650)+BD 28.56 11.20 60.24 0.1120 35 0.4478 0.9185
experiment is continued for duration of 40.
D– W(1650)+D1 27.89 11.22 60.89 0.1122 35 0.4380 0.9275
The concentration is measured at the
outlet at every 5sec time interval and the E– W(1900)+BD 26.54 9.65 63.81 0.0965 30 0.4504 0.8785
data is directly taken up by the computer
F– W(1900)+D1 27.89 11.22 60.89 0.1122 35 0.4540 0.9403
to give a concentration ratio vs. time curve
(F-Curve). This curve gives the time interval G–TS 19.97 23.62 56.41 0.2362 74 0.5960 1.3359
for transition mixes of H– TS+BD 20.36 22.22 57.42 0.2222 70 0.6342 1.2510
.10%-90%
.20%-80% I– TS+SD1/holes 18.06 30.19 51.75 0.3019 95 0.6307 1.2893

J– TS+HD1 17.19 30.65 52.16 0.3065 96 0.6339 1.3451

The 1st case (10%-90%) indicates the time Plant - B
elapsed between 10% & 90% of new steel
at the outlet. This results can be followed if A– SP+D1+D2 24.19 18.89 56.92 0.1889 116 0.5529 1.0478
the acceptance level of chemistry com- B– SP+D1+B1 27.19 10.95 61.86 0.1095 67 0.4845 0.9407
position in the final slab is 90% of the
C– SP+B1+D2 25.82 14.24 59.94 0.1424 88 0.5146 0.9402
ladle chemistry. It should be mentioned
that 10% of new steel implies 90% of old D– TS 16.80 23.53 59.67 0.2353 145 0.6869 1.1077
steel and vice versa. Similarly the 2nd case E– TS+SD1/holes 17.85 23.00 59.15 0.2300 141 0.6709 1.1660
results can be followed if the acceptance
F– TS+HD1 22.78 22.18 55.04 0.2218 136 0.5340 1.2144
level is 80%.
The above studies were carried out for G–TS+HD2 25.84 18.88 55.28 0.1888 116 0.5172 1.1281
configurations given in Table 4.
H– TS+B1/320 26.10 13.41 60.49 0.1341 82 0.4817 0.9340
For both cases existing system was
compared with configurations of I– TS+B1+D1 26.10 18.34 55.56 0.1834 113 0.4626 1.0613
TURBOSTOP giving best possible MRT.
Table 5. Experimental results of RTD Curve study
senting liquid steel) and the tundish is
4.4 Slag Emulsification Study at Ladle tundish slag and entrainment during ladle drained upto 15 Tons level. Subsequently,
Change Overs change over period for drain levels of inlet flow is started at double the steady
15Tons. state speed and continued till the working
This experiment was done to understand In this experiment mineral oil (representing level is reached. In this time the duration
the extent of emulsification of top layer of slag) is put on the top of water (repre- slag metal mixing is observed and video

4
ecorded. Static photo graphs are presented Configurations Drain Level 18 Tons Drain Level 15 Tons
in Fig 17. (each photograph was taken just
20/80 Time Diff. 10/90 Time Diff. 20/80 Time Diff. 10/90 Time Diff.
after the new ladle is opened). This
experiment was carried out for Existing Plant - A
System and only TURBOSTOP for both the A–BD 0.8410 1.1914 0.6685 0.9920
plants.
G–TS 0.6464 0.9211 0.6626 0.8996

5. Results H–TS+BD 0.5656 0.9697 0.5554 0.8412

I–TS+SD1/holes 0.5925 0.8833 0.5281 0.7760

5.1 Steady State Casting – C-Curve
Study Plant - B

Table 5 shows the results for C-Curve Configurations Drain Level 20 Tons Drain Level 15 Tons
Study carried out for the above mentioned 20/80 Time Diff. 10/90 Time Diff. 20/80 Time Diff. 10/90 Time Diff.
type of tundish
A–SP+D1+D2 0.7185 1.1290 0.6199 0.9524
5.2 Grade Change Study – F-Curve
D–TS 0.4297 0.9196 0.4517 0.8006
Table 6 gives the result of F-Curve Study
E–TS+SD1/holes 0.5788 0.9893 0.5174 0.9089
against flow modifier nomenclature for
both type of tundish. Table 6. Experimental results of F-Curve Test
In order to estimate the tonnage of
Transition Zone during mixed grade casting
the following equation was used for each Plant - B
case
Model Time(Sec) = Time Difference x Theta
Actual Time in the plant(min) = (Model
Time/(Scale factor)1/2)/60
Transition Zone Tonnage (Tons) = Actual
Time in plant(min) x Casting Rate(tons/min) Emulsified Slag No Emulsified Slag

5.3 Slag Emulsification Study

Fig 5 gives comparative photographs for
the existing system as well as only
TURBOSTOP for Ladle Change overs at 15
Tons . The photographs are taken just after Configuration A Configuration E
the ladle opening. Plant - B

6. Discussion
6.1 Steady State Fluid Flow Characteristics
Fig 6 gives a graphical representation of
the Absolute Minimum Residence
Time(MRT). The graph shows Minimum Slag
Emulsified Slag Emulsification

1. The effieciency of properly designed

turbulence suppressing pad
TURBOSTOP in substabtial improvement
of residence time of steel in the tundish. Configuration A Configuration G

2. Mere obstacles in the path of the steel

Fig 5. Photographs of Slag Emulsification at Ladle Change Overs
flow in the tundish by means of baffles,
weirs or dams dose not necessarily
mean result in improved residence time.
150

3. In terms of position of Weir/Baffle closer Plant - A 95 96

Ti m e ( s e c )

100 74 70
to the shroud better is the results.
44 35 35 35
50 30
20
4. Incorpoarating Baffles along with
TURBOSTOP substantially reduce 0
A B C D E F G H I J
residence time. Conf i gur a t i on
200
5. In case of Plant-A the best MRT is 145 141
Plant - B 150 116 136 116 113
obtained when TURBOSTOP is used
Ti me ( s e c )

88 82
along with a high dam where as in case 100 67
of Plant-B only TURBOSTOP was the 50
best. Infact in case of Plant-B MRT
progressively decreased with the 0
A B C D E F G H I
increase of dam height. Abs Re s T i m e (s e c )
Conf i gur a t i on

Fig 6. Minimum Redidence Time movement for different flow modifier configurations.

5
 Plant - A Plant - B
35 33
30 28 29
30 27 26
24 23 25 23
22 33 21 21
20 20 19
Tonnage

Tonnage
20 20 18
16 16 17
16 15
14 13 14 13 13 13
15
10 10

5
0 0
A G H I H H H
C o n fig u ra tio n s Configurations

18 Tons (20/80 Transition) 18 Tons (10/90 Transition) 20 Tons (20/80 Transition) 20 Tons (10/90 Transition)
15 Tons (20/80 Transition) 15 Tons (10/90 Transition) 15 Tons (20/80 Transition) 15 Tons (10/90 Transition)

Fig 7. Transition Zone tonnage during Mixed Grade Casting

6.2 Mixed Grade Casting The improvement in steel cleanliness due
to usage of TURBOSTOP was analysed
Fig 7 gives the mixed grade tonnage based on ther following parameters
calculated using formula descriped earlier.
Insoluble Alumina in the Tundish
The graph clearly shows
This was again analysed under 3 para-
1. The substantial reduction transition zone
with TURBOSTOP.
meters
1. Insoluble Alumina Levels in the Tundish
2. In case of Plant-A least transition zone is
where Ladle Insoluble Alumina was
achieved in case of configuration I i.e.
greater than 50ppm – More the
TURBOSTOP and short dam where as in
conversions of Ladle Insoluble Alumina
case of Plant-B only TURBOSTOP when
higher than 50ppm to less than 50 &
used gave the best results.
30ppm indicates better floatation of
Alumina (Graph 1)
6.3 Slag Emulsification Study
2. Insoluble Alumina Levels in the Tundish
Photographs in Fig 5 indicates
where Total Aluminium Drop from Ladle
1. Severe slag/metal mixing with the to Tundish is less than or equal to
existing systems in case of of the both 20ppm. This study is done to see the
the tundishes( because of oil getting effect of Alumina inclusion floatation
broken up into fine droplets and then independent of Aluminium addition
mixing with water) which continued time. If Aluminium in the Ladle is added
even after the shroud was immersed. at a proper time the it will have
This will obviously lead to high oxygen sufficient time to go into solution and its
pick-ups during changeover. drop will minimize (Table 7)
2. The above phenomenon was nearly
Tundish Norma
suppressed with the use of TURBOSTOP Insol Al l T/D
which is likely to result in cleaner steel Levels (%)
at change-over.
< = 0 .0 0 5 50.77
7. Actual TURBOSTOP usage in < = 0 .0 0 3 23.08
in specific Sulphur Range, which shows the
improving capacity of TURBOSTOP
tundishes to convert more of Class 2 into
Class 1, which again can be attributed to
better floatation of Oxide Inclusions
(reasons explained above).
. Reduction in Transition Tonnage during
Mixed Grade Casting
1. 53 cases of Grade change casting was
done out of which one was done
between JVCM02 (C% - 0.38-0.40) &
JVCM03 (C% 0.54-0.55) a combination
which was done earlier using normal
tundish with brick dam only. In case of
Brick Dam a total slab of length 8.5mts
was affected due to composition
variation where as in case of TURBO-
STOP it is 6.3 mts inspite the change
over taking place at higher tonnage (14
tons instead of 10 tons for the normal
brick dam tundish)
2. Out of 53 grade change done
a. 19 Cases (e.g.Low C to High Carbon).
For most of these radical Grade changes
the Transition was over in a single Slab
of 8.5 Mts around 17 Tons.
Total
TURBOSTOP b. 34 cases were like to like (i.e Low
(%) Carbon to Low Carbon etc)
c. In 10 cases out of above 53 2 times
69.75
Grade Change has been done in the
same tundish
36.13

the plant – The Benefits Table 7

60.00
Insoluble Alumina
7.1 Plant - A Graph 1 indicates that Insoluble Alumina Distribution in
50.78
Levels in the Tundish are lower with 50.18 Tundish where
Initially TURBOSTOP & Short Dam with 50.00
TURBOSTOP compared to that of Normal Ladle Insol
holes giving the best results during physical
Tundish of Brick Dam, where as Table 7 AL > 50 ppm
modeling was tried. During trial few cases
shows a consistent increase in the 40.00
of nozzle choking at the start-up was
percentages of heats cast with TURBOSTOP Normal Tundish %
observed which was primarily due to the
shows lower levels of Tundish Insoluble
Percentage

position of preheating burners in the 30.00

Total Turbostop %
Aluminium in those cases where addition
casting platform. The dam when placed at
of Aluminium was done to give it sufficient
300mm from the nozzle center caused
time to go into solution. 20.00 18.07
underheating of the side away from the 17.33

dam towards the npzzle as the burner Class 1 & 2 Distribution at specific
flame being obstructed by the dam. Due to sulphur ranges 10.00
the above problem the use of Short Dam
Table 8 shows a comparative analysis of
with holes was discontinued and
Class 1&2 at specified Sulphur ranges. It
TURBOSTOP was used along with brick 0.00
shows a consistent trend of increase of <=0.005 <=0.003
dam T insol Al

.Steel Cleanliness with TURBOSTOP

Class 1 in any specified Sulphur Range with
TURBOSTOP Tundish and decrease of Class 2 Graph 1

6
7.2 Plant – B Class 1
Sulphur Range
In Plant B TURBOSTOP was used along with Normal T/D (%) Total TURBOSTOP (%)
short dam with holes (Configuration E)
<=0.01 74.36 87.87
although only TURBOSTOP was giving the
best results in order to prevent metal >=0.011 - <=0.015 42.37 57.61
freezing at start of cast. >=0.016 3.85 24.62
. Reduction in Transition Zone During
Class 2
Mixed Grade Casting Sulphur Range
Normal T/D (%) Total TURBOSTOP (%)
Verification of Mixed Zone Tonnage as
predicted by F-Curve Study was done in <=0.01 25.21 10.93
plant duing the period of Dec’99 – Jan’00. >=0.011 - <=0.015 54.83 38.77
To assess the transition length, drillings
>=0.016 80.77 58.46
were taken from transition slabs at a
distance of 1m. A total of 7 cases were Table 8. Class 1 & 2 Distribution at specific sulphur ranges
tested with significant chemistry variations
with different combinations of tundish Flow Modifier Section Tundish Wt. Speed Grades Mixed Element Change in
weight, casting speed and slab width. The Set-up (mm) At change Analysed Element
Over
transition length obtained by drillings was
then compared with the L-2 predicted Striker Pad & 1050 22 t 1.19 Gr A & Gr A Cu Cu 0.007 - 0.25
legth for both Conventional and TURBO- 2 Dams 1200 24 t 1.00 AP15L & T55 (HF) C 0.13 - 0.20
STOP Tundishes.Table 9 gives the transition (Conventional
slabs details which was assessed. 1250 22 t 1.18 E-38 & Gr A Mn 0.87 - 1.42
System)
Based on chemistry analysis of the drilling Si 0.02 - 0.35
samples it was seen while mixing two
V 0.002 - 0.10
grades the starting although not shifting
TURBOSTOP Tundish gave a saving in Nb 0.023 - 0.002
Transition Zone of upto 10% approx which
is a definite indicator of improved plug
flow in the tundish. Proposed 950 20 t 1.30 EDD & IF Ti 0.001 - 0.058

.Reduction of Slag Emulsification during TURBOSTOP

System
1400 18 t 1.10 Gr1 & SAE 1021 C 0.06 - 0.18
Ladle Change Overs 1300 15 t 0.91 GrA Cu & Ap 15L Mn 0.3 - 0.66
Physical Modelling indications of much
Cu 0.24 - 0.02
reduced slag emulsification at Ladle
Change Overs were verified in the plant by V
measuring Oxygen ppm, result of which is Fig 9. Transition Slabs assesses by drilling
given in the graph 2 & 3 The findings of
which are
1. The total oxygen ppm measurement 80
indicates a marked improvement w.r.t. Ladle Change Over
70 22.45 Tons T/d Wt
minimization of slag emulsification
phenomenon during ladle change overs 60
with TURBOSTOP system even with
Total Oxygen ppm

change over tonnage being lower. 50

Ladle Change Over
Ladle Change Over 18.27 Tons T/d Wt
2. During Steady state marked difference 40 19.59 Tons T/d Wt
was not being observed in steel oxygen
ppm levels in the tundish with either of 30
the 2 systems.
20
Metal Level Variation
19.02
10
Total Oxygen ppm

Ladle Change Over Ladle Change Over

25 19.26 Tons T/d Wt 16.46 Tons T/d Wt
20
15 0
3.33
10 0 20 40 60 80 100 120 140 160 180 200
5
Time (Min)
0
TURBOSTOP System Striker Pad & 2 Dams
TURBOSTOP Trial 1 TURBOSTOP Trial 2 Striker Pad & 2 Dams
Flow Modifier Set-up

Graph 2. Total Oxygen ppm Variation During Ladle Graph 3. Total Oxygen ppm Movement During Casting
Change Overs

8. Conclusion
Water Modelling study and subsequent
trials in the 2 plants showed that
.The use of multible hole baffles and weir
although improve the flow characteristics
in comparison to no flow modifiers the
extent of such improvements was far from
desirable.
.Efforts of increasing the steel residence
time in the tundish further and thereby
enhancing the flow characteristics dose not .When such condition of cancellation of
always yield positive results. incoming velocity vector is achieved it not
.In order to increase the residence time only substantially increase the steel
residence time but also enhance plug flow
beyond the limits of what being achieved
with baffles and weirs suppression of
thereby resulting in reduction of trantion
zone. It also helps in minimizing the slag
incoming energy of the metal stream is
emulsification phenomenon during ladle
necessary. This can be achieved by proper
change overs thereby producing cleaner
designing of turbulence suppressing pad
steel.
.Since every plant is different modelling
which will rebound incoming velocity
vectors on to itself resulting velocity vector
cancellation. study is absolute imperative before arriving
7
at a particular design of the turbulence
suppressing tundish impact pads to yield
optimium results e.g for Plant-A a dam
with holes when used along with
TURBOSTOP gave the best results where as
in case of Plant-B it was only TURBOSTOP
which gave the best flow characteristics,
apart from the fact that both designs of
TURBOSTOP arrived are different from each
other.
.Properly designed tundish flow modifiers
working on the principle of dissipation of
incoming velocity vectors go a long way in
improving the flow characteristics of steel
in the tundish and yielding substantial
benefits both in terms on quality and
productivity.
9. Reference 8. Asai, S., and Szekely, J. : Ironmaking and
Steelmaking, Vol. 2, No. 3., (1975), pp.
1. Y. Sahai and Toshihiko EM1 : Melt Flow 205-213
Characterization in Continuous Casting 9. Salcudden, M. , and Guthrie, R.I.L. :
Tundish, ISIJ International, Vol. 36 Met. Trans. B., Vol. 10B, (1979), pp
(1996), No.6 423-428
2. M.M. Collur, D.B. Love and B.V. Patil : 10. Skoglund, V. J. : "Similitude – Theory
Use of flow modifiers to improve and Applications" , International
performance of a tundish, ISS Textbooks, New York, (1967)
Steelmaking Conference, April 1997
3. Michael L. Lowry and Y. Sahai :
11. Gukman, A. A. : "Introduction to the
Theory of Similarity ," Academic Press,
Investigation of steel flow in a New York (1965)
continuous casting tundish with
12. Parker, J. , Boggs, J., and Blick, E. :
multiple baffles using mathematical
"Introduction to Fluid Mechanics and
models and tracer studies, 1989
Heat Transfer," Addison-Wesely, New
Steelmaking Conference Proceedings,
York, (1969)
Pg 71-79
13. Szekely, J. : "Fluid Flow Phenomena in
4. Paul Rasmussen : Improvement of Steel
Metals Processing ," Academic Press,
Cleanliness at Dofasco’s #2 Melt Shop
New York, (1979)
5. Paul Ramussen : Mixed Grade casting
14. Robertson, A. D., and Sheridan, A.T. :
with Turbostop impact pads at
J. Iron Steel Inst., Vol. 208, (1970), pp.
DOFASCO, 79th Steelmaking
625-632
Conference, Pittsburg,USA, 1996
15. Advent Engg : Fluid Flow, Chapter Two
6. Mizikar, E. A.: Trans. Met. Soc. AIME,
Vol. 239, (1967), p. 1747 16. O. Levenspiel : Chemical Reaction
Engineering, John Wiley & Sons
7. Szekely, J., and Stanek, V.: Met. Trans.
B. , Vol. 10B, (1979), p. 119

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