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SIMULATING THE BLISTER TAP HOLE CONCEPT DESIGNUSING CHT CAPABILITIES IN STAR-CCM+ V5.02.009 

Bateman Engineering Projects, Pyro Technologies, SA

2011 STAR European Conference: 22 & 23 March, Netherlands

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CONTENTS

•  Current Blister Tap Hole:

•  Numerical CFD Models (x4).

•  Conclusions.

•  Bull Nose Blister Tap Hole:

•  Numerical CFD Models (x3).

• 

Conclusions.

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Current SiC insert blister tap hole configuration

(oxygen fuel burner effect included).

1.  Steady state simulation – clay in tap hole with the Oxygen Fuel

Burner (OFB) off. Results not shown. Aim: Establish the initial

conditions for the subsequent transient runs.

2.  Transient simulation – clay in tap hole with the OFB on (duration =

37 minutes). Determine the OFB heat flux required to incite the 6thermocouple positions to correspond with the measured thermo-

couple values (benchmark).

3.  Transient simulation – blister flowing in tap hole with the OFB on

(duration = 62 minutes). Simulate the transient tapping process to

correspond with measured thermocouple values / trends.

4.  Transient simulation – clay in tap hole with the OFB off (duration =

62 minutes). Simulate the cool-down cycle after transient tapping

to correspond with measured thermocouple values / trends.

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Current Blister Tap Hole – Thermocouple Positions

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Clay in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)

T1T2

T3T4

T5T6

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Clay in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)

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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)

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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)

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Clay in Tap Hole – Temperature (OFB off)

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Clay in Tap Hole – Temperature (OFB off)

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BTH7 – Summary of OFB on / OFB off conditions

•  Measured- & predicted CFD temperaturevalues at the end of each transient cycle:

Measured vs.

Predicted

T1

[° C]

T2

[° C]

T3

[° C]

T4

[° C]

T5

[° C]

T6

[° C]

T/C (clay & OFB on) 242.3 91.3 50.5 43.4 47.7 64.7

CFD (clay & OFB on) 242.5 142.0 98.9 81.2 78.4 89.8

T/C (blister & OFB on) 990.3 882.2 825.3 801.4 745.0 798.8

CFD (blister & OFB on) 961.7 911.3 963.9 971.1 906.3 923.8

T/C (clay & OFB off) 399.4 431.8 438.9 478.8 460.9 529.6

CFD (clay & OFB off) 355.7 389.8 426.5 446.0 451.8 463.9

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Current Blister Tap Hole – Conclusions

•  Differences in measured vs. predicted values attributed to:

•  Thermocouple positions & measurements maybe not exactly thesame in the SiC insert (on-site vs. models).

•  Temperature CFD results are higher due to constant thermal materialproperties in all directions (isotropic).

•  Thermal resistances between region interfaces not incorporated inthe numerical models (conjugate heat transfer).

•  However: Trends of graphs predicted more or less correctly for eachtransient stage.

•  Next step: Apply oxygen fuel burner boundary condition to the newbull nose blister tap hole concept. Predict thermal behaviour beforeactual installation earlier this year (March 2011).

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Bull Nose High Alumina insert blister tap hole configuration

(oxygen fuel burner effect included).

1.  Steady state simulation – clay in tap hole with the OFB off (results

not shown). Establish the initial conditions for the subsequent

transient runs.

2.  Transient simulation – blister flowing in tap hole with the OFB on

(duration = 62 minutes). Simulate the transient tapping process to

determine the increase in the maximum monitored SG Iron bull

nose- & steel can temperatures.

3.  Transient simulation – clay in tap hole with the OFB off (duration =

62 minutes). Simulate the cool-down cycle after transient tapping

to determine the decrease in the maximum monitored SG Iron bull

nose- & steel can temperatures.

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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)

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Blister in Tap Hole – Temperature (OFB on @ 34.8 kW/m²)

SG Iron Bull Nose

Steel Frame & Can

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Clay in the Tap Hole – Temperature (OFB off)

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Clay in the Tap Hole – Temperature (OFB off)

SG Iron Bull Nose

Steel Frame & Can

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BTH8 – Summary of OFB on / OFB off conditions

•  Predicted CFD temperature values at the endof each transient cycle:

Maximum Temperatures for: SG Iron

[° C]

Steel Can

[° C]

High

 Alumina

[° C]

CFD (blister & OFB on) 483.5 386.1 1394.2

CFD (clay & OFB off) 242.2 362.4 502.8

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Bull Nose Blister Tap Hole – Conclusions

•  Maximum monitored temperature value in the SG Iron bull nose withthe OFB on just short of 500 °C after an hour of blister tapping withconstant heat flux = 34.8 kW/m² on the front face.

•  Maximum monitored temperature value in the steel can hot facetapered tip just short of 390 °C after an hour of blister tapping(Thermal cycling / induced stresses not investigated).

•  Front of the High Alumina insert much hotter with the OFB on, albeitonly locally around the tap hole exit.

•  All the regions monitored (SG Iron, Steel & High Alumina) heat-upduring the tapping cycle within acceptable operating limits.

•  Cool-down cycle with the clay plug; after an hour the SG Iron cooleddown to halve the maximum value when the OFB was on. The SteelCan cooled down by 24 °C, which is less sensitive to either tappingor plugged conditions.

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QUESTIONS?

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