Effect of the Tundish Inhibitor Design on the Flotation Efficiency of Nonmetallic Inclusions: Water Modeling and Mathematical Simulations by the Reynolds Stress Model

Abstract

Numerical fluid simulations using the Reynolds stress model and water model experiments are conducted to test different designs of tundish turbulence inhibitors (A, B, C, D, and E) for their effectiveness in removing nonmetallic inclusions from steel. The results reveal a unique flow pattern, with a mushroom‐like shape forming around the entry jet. The acceleration of small eddies within this mushroom is a significant factor in inclusion removal. This discovery has practical implications for the steel industry, leading to a longer residence time in the entry jet mushroom and improved inclusion flotation performance. Additionally, the turbulent kinematic viscosity and Reynolds stress fields in the flow mushroom influence the tracer's local dispersion rate and the interactions of the inclusions in this region. These findings are further validated using a tundish water model to track the dynamics of amine particles injected into the ladle shroud, enhancing their practical relevance.