CCC Annual ReportUIUC, August 14, 2013

Mihir Chavan

Department of Mechanical Science & EngineeringUniversity of Illinois at Urbana-Champaign

Nailboard Measurements of Surface Flow at Severstal

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 2

Overview

• 16 Nail board experiments were conducted Oct. 14-15, 2012 at Severstal

• Preliminary analysis is conducted here on both rows of nails, all 16 boards, with 2 positions and 2 heights measured on each nail

• Results are presented for– Slag/steel and powder/slag interface heights

– Surface velocity, before and after tilt of nail is factored in

– Angle of flow

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 3

Date & Time Nail board Case #

Casting Speed (inch/min)

Strand Width (inch)

Argon Flow Rate(SLPM)

Argon Back Pressure (psi)

Submergence Depth (mm)

10/15, 5:23:49 pm 1 55.2 67.19 5.0 15.1 221

10/15, 5:26:56 pm 2 48.0 67.3 5.0 15.38 221

10/15, 5:27:56 pm 3 45.4 67.4 5.01 15.51 221

10/15, 5:28:28 pm 4 45.4 68.2 5.02 15.45 221

10/15, 5:28:48 pm 5 45.4 69.3 5.01 15.48 221

10/16, 12:14:40 pm 6 35.6 53.87 6.8 19.08 187

10/16, 12:17:42 pm 7 35.8 53.87 6.8 19.04 187

10/16, 12:18:00 pm 8 35.8 53.87 6.8 19.04 187

10/16, 12:22:46 pm 9 45.6 53.87 7.0 19.01 187

10/16, 12:23:13 pm 10 45.4 53.87 7.0 19.01 187

10/16, 3:28:54 pm 11 65.0 54.99 7.0 18.07 222

10/16, 3:29:20 pm 12 65.0 54.99 7.0 18.07 222

10/16, 3:29:41 pm 13 65.0 54.99 7.0 18.07 222

10/16, 3:35:50 pm 14 25.5 54.99 6.3 19.18 222

10/16, 3:36:16 pm 15 25.5 54.99 6.2 19.18 222

10/16, 3:36:36 pm 16 25.5 54.99 6.2 19.18 222

List of Cases

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 4

Calculating the Distance from SEN

• w = strand width, given (in.) convert to (mm)

• ni = Distance from NF measured for every nail(mm)

• si = Distance from SEN (mm)

• si = w/2 - ni

SEN

NF

50 mm

ni

Board 7 is pictured in image. Boards 1-5 have 13 nails a side (26 nails total) and boards 6,7,9,11-16 have 10 nails a side (20 nails total) and boards 8 and 10 have 11 nails a side (22 nails total).

w

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 5

Calculating the Distances from the Steel Interface

• Need to calculate the average steel interface (havg) to find new heights (from the steel interface) of both:• lump (steel-slag interface)• Discolored region (near slag-powder interface)

• hi,lump = height to lump (mm)• hi, discoloration = height to discoloration (mm)• havg = (∑ hi, lump of all nails) / (# of nails) (mm)• yi = new heights (mm)• yi = havg – hi

hi, lump

hi, discoloration

Picture of Board 1, Inner Radius, Nail 10

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 6

vi = 0.624*di-0.696*hi

0.567

• di = diameter measured (mm) (nail or lump)

• hi = height measured (mm) (max around perimeter)

• vi = velocity (m/s)

Calculating the Velocity

Equation From:R. Liu, J. Sengupta, D. Crosbie, S. Chung, M. Trinh and B.G. Thomas, "Measurement of Molten Steel Surface Velocity with SVC and Nail Dipping during Continuous Casting Process," in Sensors, Sampling, and Simulation for Process Control, B.G. Thomas, J.A. Yurko and L. Zhang, eds., John Wiley & Sons, Hoboken, New Jersey, (TMS Annual Meeting Symposium, San Diego, CA, Feb. 27- Mar. 3, 2011), 2011, 51-58.

hi

di

hi

di

At the nail

At the lump

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 7

θ

θ

∆h, new∆h, old

d, new

d, old

θ

θ

dnew* sin(θ)

Velocity after taking into account the Tilt of nail

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 8

Calculating the new velocity due to the tilt of the nail

• dold – diameter of the nail as first measured (mm)

• ∆hold – height difference as first measured (mm)

• θ – angle of tilt as measured (radians)

• dnew = dold/cos(θ)

– diameter of the nail due the tilt of the nail (mm)

• cos(θ)= ∆hnew /(∆hold – dnew*sin(θ))

• ∆hnew = ∆hold*cos(θ) – dnew*sin(θ)cos(θ)

= ∆hold*cos(θ) – dold*sin(θ)

– Height difference due to the tilt of the nail (mm)

• vnew – velocity due to the tilt (m/s)

• vnew =0.624*dnew-0.696*hnew

0.567

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 9

Calculating the Velocity Angle

h

w• h – height of angle

• w – distance from point where height crosses reference line to where the drawn line crosses reference line

• θ = tan-1(h/w)– Positive theta is in the

counterclockwise direction

Reference line

w

h

θ

SEN

NF

OR IR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 10

Distance from Steel/Slag Interface measured at 50 mm intervals from SEN

Surface Level

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 11

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 1

Surface Level Boards 1 – 3

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 2

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 3

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

1 55.2 67.19 5.0 15.1 221

2 48.0 67.3 5.0 15.38 221

3 45.4 67.4 5.01 15.51 221

Casting Conditions

Legend

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 12

Surface Level Boards 4 – 5

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 4

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 5

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

4 45.4 68.2 5.02 15.45 221

5 45.4 69.3 5.01 15.48 221

Casting Conditions

Legend

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 13

Surface Level Boards 6 - 8

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 6

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 8

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 8

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

6 35.6 53.87 6.8 19.08 187

7 35.8 53.87 6.8 19.04 187

8 35.8 53.87 6.8 19.04 187

Casting Conditions

Legend

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 14

Surface Level Boards 9 – 10

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

9 45.6 53.87 7.0 19.01 187

10 45.4 53.87 7.0 19.01 187

Casting Conditions

Legend

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 9

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 10

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 15

Surface Level Boards 11 – 13

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

11 65.0 54.99 7.0 18.07 222

12 65.0 54.99 7.0 18.07 222

13 65.0 54.99 7.0 18.07 222

Casting Conditions

Legend

-20

-10

0

10

20

30

40

50

-20

-10

0

10

20

30

40

50

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 11

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 12

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 13

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 16

Surface Level Boards 14 – 16

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

14 25.5 54.99 6.3 19.18 222

15 25.5 54.99 6.2 19.18 222

16 25.5 54.99 6.2 19.18 222

Casting Conditions

Legend

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 16

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 15

-20

-10

0

10

20

30

40

-20

-10

0

10

20

30

40

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Board 14

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 17

-20.00-15.00-10.00

-5.000.005.00

10.0015.0020.0025.00

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Boards 1 - 3

Summary: Surface Level Averages and Standard Deviations

11 data sets 10 data sets 10 data sets

13 data sets 13 data sets 11 data sets

-20.00-15.00-10.00

-5.000.005.00

10.0015.0020.0025.00

0 100 200 300 400 500 600 700 800 900

Su

rfac

e L

evel

s(m

m)

Distance from SEN (mm)

Boards 4 - 5

-20.00-15.00-10.00

-5.000.005.00

10.0015.0020.0025.00

0 100 200 300 400 500 600 700

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Boards 6 - 8

-20.00-15.00-10.00-5.000.005.00

10.0015.0020.0025.00

0 100 200 300 400 500 600 700

Ave

rag

e L

evel

(m

m)

Distance from SEN (mm)

Boards 9 - 10

-20.00-15.00-10.00-5.000.005.00

10.0015.0020.0025.00

0 100 200 300 400 500 600 700

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Boards 11 - 13

-20.00-15.00-10.00

-5.000.005.00

10.0015.0020.0025.00

0 100 200 300 400 500 600 700

Su

rfac

e L

evel

(m

m)

Distance from SEN (mm)

Boards 14 - 16

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 18

1) Velocity Magnitude measured at 50 mm intervals from SEN at the edge of the lump and at the nail

2) Adjusted Velocity Magnitude- taking tilt into account

3) Velocity Vectors- top view of board showing both direction

and magnitude of both rows of nails

Velocity Measurements

For each board, measure:

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 19

Velocity Boards 1 – 3

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 1

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 2

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 3

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

1 55.2 67.19 5.0 15.1 221

2 48.0 67.3 5.0 15.38 221

3 45.4 67.4 5.01 15.51 221

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 20

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 1

Adjusted Velocity Boards 1 – 3

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 2

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 3

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

1 55.2 67.19 5.0 15.1 221

2 48.0 67.3 5.0 15.38 221

3 45.4 67.4 5.01 15.51 221

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 21

Velocity Vectors Boards 1 – 3

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 22

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 5

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 4

Velocity Boards 4 – 5

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

4 45.4 68.2 5.02 15.45 221

5 45.4 69.3 5.01 15.48 221

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 23

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x(m

/s)

Distance from SEN (mm)

Board 4

Adjusted Velocity Boards 4 – 5

0.000.100.200.300.400.500.600.700.80

0.000.100.200.300.400.500.600.700.80

0 100 200 300 400 500 600 700 800 900

Velo

city

v_x

(m/s

)

Distance from SEN (mm)

Board 5

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

4 45.4 68.2 5.02 15.45 221

5 45.4 69.3 5.01 15.48 221

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 24

Velocity Vectors Boards 4 – 5

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 25

Velocity Board 6 – 8

-0.40-0.30-0.20-0.100.000.100.200.300.400.50

-0.40-0.30-0.20-0.100.000.100.200.300.400.50

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 6

-0.80

-0.60

-0.40

-0.20

0.00

0.20

0.40

0.60

-0.80

-0.60

-0.40

-0.20

0.00

0.20

0.40

0.60

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x(m

/s)

Distance from SEN (mm)

Board 7

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 8

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

6 35.6 53.87 6.8 19.08 187

7 35.8 53.87 6.8 19.04 187

8 35.8 53.87 6.8 19.04 187

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 26

Adjusted Velocity Board 6 – 8

-0.40-0.30-0.20-0.100.000.100.200.300.400.50

-0.40-0.30-0.20-0.100.000.100.200.300.400.50

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 6

-0.80

-0.60

-0.40

-0.20

0.00

0.20

0.40

0.60

-0.80

-0.60

-0.40

-0.20

0.00

0.20

0.40

0.60

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 7

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 8

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

6 35.6 53.87 6.8 19.08 187

7 35.8 53.87 6.8 19.04 187

8 35.8 53.87 6.8 19.04 187

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 27

Velocity Vectors Board 6 – 8

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 28

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

9 45.6 53.87 7.0 19.01 187

10 45.4 53.87 7.0 19.01 187

Casting Conditions

Legend

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x(m

/s)

Distance from SEN (mm)

Board 10

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 9

Velocity Boards 9 – 10

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 29

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 10

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 9

Adjusted Velocity Boards 9 – 10

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

9 45.6 53.87 7.0 19.01 187

10 45.4 53.87 7.0 19.01 187

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 30

Velocity Vectors Boards 9 – 10

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 31

-0.20-0.100.000.100.200.300.400.500.600.700.800.901.00

-0.20-0.100.000.100.200.300.400.500.600.700.800.901.00

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x(m

/s)

Distance from SEN (mm)

Board 13

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 12

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 11

Velocity Boards 11 – 13

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

11 65.0 54.99 7.0 18.07 222

12 65.0 54.99 7.0 18.07 222

13 65.0 54.99 7.0 18.07 222

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 32

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 12

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 11

-0.20-0.100.000.100.200.300.400.500.600.700.800.901.00

-0.20-0.100.000.100.200.300.400.500.600.700.800.901.00

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x(m

/s)

Distance from SEN (mm)

Board 13

Adjusted Velocity Boards 11 – 13

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

11 65.0 54.99 7.0 18.07 222

12 65.0 54.99 7.0 18.07 222

13 65.0 54.99 7.0 18.07 222

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 33

Velocity Vectors Boards 11 – 13

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 34

Velocity Boards 14 – 16

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

14 25.5 54.99 6.3 19.18 222

15 25.5 54.99 6.2 19.18 222

16 25.5 54.99 6.2 19.18 222

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0.40

0.50

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0.40

0.50

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 14

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 15

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 16

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 35

Adjusted Velocity Boards 14 – 16

Nail board Case #

Casting Speed

(inch/min)

Strand Width (inch)

Argon Flow Rate

(SLPM)

Argon Back Pressure

(psi)

Submergence Depth (mm)

14 25.5 54.99 6.3 19.18 222

15 25.5 54.99 6.2 19.18 222

16 25.5 54.99 6.2 19.18 222

Casting Conditions

Legend

Nail - IR Nail - OR Lump - IR Lump - OR

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 16

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x (

m/s

)

Distance from SEN (mm)

Board 15

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0.40

0.50

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0.40

0.50

0 100 200 300 400 500 600 700 800 900

Vel

oci

ty v

_x(m

/s)

Distance from SEN (mm)

Board 14

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 36

Velocity Vectors Boards 14 – 16

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 37

-0.35

-0.25

-0.15

-0.05

0.05

0.15

0.25

0.35

0 100 200 300 400 500 600 700

Ave

rag

e V

elo

city

(m

/min

)

Distance from SEN (mm)

Boards 14 - 16

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 100 200 300 400 500 600 700

Ave

rag

e V

elo

city

(m

/min

)

Distance from SEN (mm)

Boards 11 - 13

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0 100 200 300 400 500 600 700

Ave

rag

e V

elo

city

(m

/min

)

Distance from SEN (mm)

Boards 9 - 10

Summary: VelocityAverages and Standard Deviations

11 data sets 10 data sets 10 data sets

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

0.40

0 100 200 300 400 500 600 700

Ave

rag

e V

elo

city

(m

/min

)

Distance from SEN

Boards 6 - 8

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0 100 200 300 400 500 600 700 800 900

Ave

rag

e V

elo

city

(m

/min

)

Distance from SEN (mm)

Boards 4 - 5

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0 100 200 300 400 500 600 700 800 900

Ave

rag

e V

elo

city

(m

/min

)

Distance from SEN (mm)

Boards 1 - 3

13 data sets 13 data sets 11 data sets

University of Illinois at Urbana-Champaign • Metals Processing Simulation Lab • Mihir Chavan • 38

Conclusions

• Velocity measurements based at the nail(nail diameter) and at the lump (lump diameter) roughly agree

• Both rows of nails roughly agree• Distance from steel-slag interface to discolored region is

~25mm, with similar profiles (suggesting almost constant liquid slag-layer thickness)

• For cases 1 – 5 and 9 – 13: – Clear double-roll flow pattern with higher interface near NF, lower

interface near SEN, and surface velocity towards SEN– Standing wave height ~20mm– Surface velocity has classic profile with max near midway

between SEN and NF– Max surface velocity seems very high, ~0.7 m/s

• For cases 6 – 8 and 14 – 16:– There is a complex flow pattern near the SEN due to increased

argon gas injection