Case study

2:
Discussion of the paper An improved
model of cored wire injection in steel
melts highlighting the use of
numerical method in it

Submitted bySarbari Ganguly

Roll-143110007
MEMS

Cored wire injection

method

Uses: Ladle treatments e.g,

Developed for the
microalloying,
addition of low density
desulfurisation
alloys like Ca-alloys into
the steel bath
Higher Ca recovery
Minimum interaction with
slag, reduced liquid steel
movement, possibility of
suppressing premature
evaporation improves
utilization
Possibility of preheating
filling material
Filling material released
at such a depth in the

In this paper:
Understanding of the
dissolution mechanism
developed through a
numerical approach
Suggested modifications in
operating and design
parameters to increase the
depth of penetration
before the release of
powder
Formation of thermal
contact resistance and the
freezing of the slag on the
wire surface considered for
the first time in the study
of cored wire injection

Formulation of mathematical model

Temperature distribution inside cylinder shaped cored wired
by considering the following expressions for transient heat
conduction in :
(1) Powder

(2) Casing

(3) Slag
shell

(4) Steel
shell

The tTOT is the total time up to the

point of release of the powder and
consists of different time intervals as:

In absence of slag shell:

Where,

Equations (1) to (4)

from last slide have
been used for the
present study and
solved with the
relevant initial and
boundary conditions
to determine:
1. The temperature
distribution inside
the cored wire
and the solidified
shell
2. The total time
taken for the
melting of the
casing and the
shell and the

Initial conditions:
The temperature of the cored wire can be taken to be uniform at
To . Temperature of the slag layer and the steel bath is assumed
to be constant during the period of the computation. Using
these the following initial conditions are formulated:

While formulating a temperature distribution for this cored

wire using finite difference method for this transient
problem we see that the spatial dimensions rc, rsl and rs
are unknowns. So unlike the conventional method, our
choice of initial and boundary conditions here will be
based on the continuously changing temperature profile.
That is we start with initial condition 1 and then as soon as
the temperature reaches TSLAG from To we proceed to initial

Boundary Conditions (all do not apply simultaneously)

1) At centre
2) At powder/casing
interface
3) At casing/ shell
interface
Imperfect contact
between casing and slag
shell leads to thermal
contact resistance
between two.
a) Slag shell interface
starts melting internally
after time tm(sl) . interface
temperatures at slag shell
and casing are Tsl* and Tc*
slag shell/steel
b)4)RAt
T vanishes after
shell interface
complete
melting of both

Above boundary conditions

for solidification/melting
front.
is latent of fusion of
respective melt.
h is heat transfer coefficient
from bath to shell/casing
surface
a) Travel of wire through slag
layer
b) Through the steel bath
c) When steel shell melts,
melting of slag shell

Partial differential equations 1 to 4 converted into finite

S
O
L
U
T
I
O
N

M
E
T
H
O
D
O
L
O
G
Y

Routes for cored wire melting

Mainly presence or absence of slag at the ladle top and the bath

Temperature Above the Bath Liquidus (TABL) aka superheat dictate the
melting behaviors.
No Slag
With slag

MODEL VALIDATION
With published work

With Plant result

Unavailability of much previous

work compelled the authors to
compare the model results
with the published work on
dissolution of static metallic
cylinders in
quiescent/inductively stirred
steel melt.

Samples collected from

tundish at definite
intervals during casting
Steel in tundish assumed to
represent a particular zone
of ladle depending on flow
rate and time of sample
collection
Samples analyzed for Ca
and Si content and results
have matched well with
predictions
Evidence is supportive if not
conclusive

References
An improved Model of Cored Wire

Injection in Steel Melts, Sarbendu

Sanyal, Sanjay Chandra, Suresh Kumar,
G.G.Roy
Efficacy and recovery of calcium

during CaSi cored wire injection in

steel melts, S. Basak, R. Kumar Dhal, G.
G. Roy
Wikipedia and nptel notes for concepts of

heat transfer

Thank you