Title

COMPUTATIONAL MODELING TO PREDICT SOLIDIFICATION OF HOT METAL IN TORPEDO CARS

COMPUTATIONAL MODELING TO PREDICT SOLIDIFICATION OF HOT METAL IN TORPEDO CARS

Authorship

REIS, LEONARDO CAMILO DOS; MARTINEZ, WALTER HERNAN; OLIVEIRA, ARTHUR FELIPE LINO

REIS, LEONARDO CAMILO DOS

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MARTINEZ, WALTER HERNAN

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OLIVEIRA, ARTHUR FELIPE LINO

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DOI

10.5151/2594-357X-41851

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Abstract

The solidification of hot metal inside the torpedo cars is a key factor influencing operational efficiency, safety and continuity of transport and unloading processes in steelmaking plants. Excessive solidification during waiting periods can hinder the flow of molten material, leading to production delays, thermal losses and potential equipment damage. This study proposes an advanced computational model based on fluid dynamics simulations aimed at predicting the amount of solidified hot metal prior to unloading in the steelmaking unit. If the hot metal solidifies more than 60% inside the torpedo car, it may tip over during unloading. The developed methodology enables the estimation of the time required to reach critical levels of solidification as a function of the initial temperature of hot metal when loaded into the torpedo car. Simulation results indicated that for initial temperatures of 1300°C, 1400°C and 1500°C, the time required to solidify 60% of the hot metal was 15.5, 20.5 and 25.5 hours, respectively. These findings demonstrate the direct influence of the initial temperature on solidification dynamics. The proposed model provides an effective tool for improving operational management, enhancing safety, efficiency and predictability of hot metal transportation processes in steelmaking operations.

THE SOLIDIFICATION OF HOT METAL INSIDE THE TORPEDO CARS IS A KEY FACTOR INFLUENCING OPERATIONAL EFFICIENCY, SAFETY AND CONTINUITY OF TRANSPORT AND UNLOADING PROCESSES IN STEELMAKING PLANTS. EXCESSIVE SOLIDIFICATION DURING WAITING PERIODS CAN HINDER THE FLOW OF MOLTEN MATERIAL, LEADING TO PRODUCTION DELAYS, THERMAL LOSSES AND POTENTIAL EQUIPMENT DAMAGE. THIS STUDY PROPOSES AN ADVANCED COMPUTATIONAL MODEL BASED ON FLUID DYNAMICS SIMULATIONS AIMED AT PREDICTING THE AMOUNT OF SOLIDIFIED HOT METAL PRIOR TO UNLOADING IN THE STEELMAKING UNIT. IF THE HOT METAL SOLIDIFIES MORE THAN 60% INSIDE THE TORPEDO CAR, IT MAY TIP OVER DURING UNLOADING. THE DEVELOPED METHODOLOGY ENABLES THE ESTIMATION OF THE TIME REQUIRED TO REACH CRITICAL LEVELS OF SOLIDIFICATION AS A FUNCTION OF THE INITIAL TEMPERATURE OF HOT METAL WHEN LOADED INTO THE TORPEDO CAR. SIMULATION RESULTS INDICATED THAT FOR INITIAL TEMPERATURES OF 1300°C, 1400°C AND 1500°C, THE TIME REQUIRED TO SOLIDIFY 60% OF THE HOT METAL WAS 15.5, 20.5 AND 25.5 HOURS, RESPECTIVELY. THESE FINDINGS DEMONSTRATE THE DIRECT INFLUENCE OF THE INITIAL TEMPERATURE ON SOLIDIFICATION DYNAMICS. THE PROPOSED MODEL PROVIDES AN EFFECTIVE TOOL FOR IMPROVING OPERATIONAL MANAGEMENT, ENHANCING SAFETY, EFFICIENCY AND PREDICTABILITY OF HOT METAL TRANSPORTATION PROCESSES IN STEELMAKING OPERATIONS.

Keywords

Computational model, Solidification of hot metal, Torpedo Car, Fluid-Dynamics Simulation.

Computational model, Solidification of hot metal, Torpedo Car, Fluid-Dynamics Simulation