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Solidifying Chamber Simulation, Solidification of Molted Steel

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In this project, the solidification process of molten steel inside a solidifying chamber is investigated.

 

This ANSYS Fluent project includes CFD simulation files and a training movie.

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Description

Introduction

Solidification, also known as freezing, is a phase change of matter that results in the production of a solid. Generally, this occurs when the temperature of a liquid is lowered below its freezing point. Solidification is nearly always an exothermic process, meaning heat is released when a liquid changes into a solid. Therefore, to accelerate the solidification process, the heat transfer rate must be increased, and this can be done using different coolants to take the heat away from the solidifying matter.

Solidifying Project Description

In this project, the solidification process of molten steel inside a solidifying chamber is investigated. Water is used to lower the molten steel’s temperature and to accelerate the solidification process. The simulation is done using the VOF model for the three phases of air, water, and steel. The standard k-epsilon model using standard wall functions is applied for solving the turbulent flow inside the canal. The energy model is also activated.

Solidifying Chamber Geometry and Mesh

The geometry for analyzing this simulation consists of a chamber in which water is injected and molten steel enters inside this canal to lose its temperature and solidification. Geometry is designed in ANSYS design modeler® and is meshed in ANSYS meshing®. The mesh type is unstructured and the total element number is 560362.

The following figure shows the geometry of the modeled solidifying chamber

solidification

The following figure shows the mesh of the modeled solidifying chamber

solidifying chamber

Solidifying CFD simulation settings

The assumptions considered in this project are:

  • Simulation is done using a pressure-based solver.
  • The present simulation is transient. 500 time-steps with a step size of 1 second are exploited for this simulation.
  • The effect of gravity has been taken into account and is equal to -9.81m/s2 in the Y direction.

The applied settings are recapitulated in the following table.

 
(solidifying) Models  
Viscous model   k-epsilon
  k-epsilon model Standard
  near-wall treatment standard wall function
Multiphase   VOF
  Phase 1 Air
  Phase 2 Water
  Phase 3 Steel
Energy   On
(solidifying) Boundary conditions  
Inlets   Mass-flow inlet
Water inlet(both inlets) Mass flow rate 16 Kg/s
Outlets   Pressure outlet
Walls    
  wall motion stationary wall
  Heat flux 0 W/m2
(solidifying) Solution Methods  
Pressure-velocity coupling   Coupled
Spatial discretization pressure PRESTO!
Volume fraction Compressive
momentum first-order upwind
turbulent kinetic energy first-order upwind
turbulent dissipation rate first-order upwind
Energy first-order upwind
(solidifying) Initialization  
Initialization method   Standard
  gauge pressure 0 Pa
  velocity (x,y,z) 0 m/s-1
  Turbulent kinetic energy 1 m2/s2
  Turbulent dissipation rate 1 m2/s3
  temperature 300 K

Results

At the end of the solution we obtain contours of temperature, velocity, pressure, and enthalpy.

 

All files, including Geometry, Mesh, Case & Data, are available in Simulation File. By the way, Training File presents how to solve the problem and extract all desired results.

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