Advanced Study on Comprehensive CFD Simulation of the Ladle Cycle toward Lining Service Life Optimization

Refractory-lined ladles are used in steel mill for the sake of transporting molten steel from steelmaking
furnace to a continuous casting machine. The objective of this study is to optimize ladle cycle to
enhance the lining service life. This optimization would be achieved by a better understanding of the
lining thermal conditions during the varies stages of the ladle cycle by a mathematical simulation of
the process. A 2D axisymmetric mathematical model was developed to predict the ladle lining and
steel shell temperature during the full ladle cycle. The estimated steel shell temperature during drying
and preheating process of a newly lined ladle was in good agreement with the literature and the plant
expectation. In this present work the capability of the model to predict the lining temperature history
during the ladle cycle was demonstrated. This strength would be utilized to enhance the ladle lining
service life and improve the cycle procedure. This study recommend to make some changes in the
current ladle cycle practice to reduce the abnormal lining temperature variation. Also recommend to
enhance the preheating burners for sufficient lining drying/preheating. This then would improve the
lining service life and reduce the refractory consumptions rate.