Numerical simulation and modeling of flow behavior during hot metal ladle pouring process

A new three-dimensional multiphase numerical model was built. The volume of fluid and k-ε turbulence models were used to investigate the hot metal ladle pouring process. During the pouring process, issues such as iron splashing, overflow, and significant heat loss are prevalent. To realize efficient and stable pouring, the effects of ladle tilting velocity, flow rate, and converter tilting angle on the pouring process were examined. The model was verified by comparing the actual pouring time with the numerical results. It is shown that there is a nonlinear relationship between pouring velocity and hot metal flow rate at the ladle mouth. As the mass flow increased and the converter tilting angle decreased, the impact point of the hot metal into the converter pool shifted from the side wall to the bottom, and the impact force increased accordingly. The pouring velocity curve was optimized by the volume difference of the ladle at different angles, and an empirical formula was derived. After the optimization of pouring speed, the flow rate was stabilized between 4000 and 6000 kg/s, and the pouring time was reduced by approximately 30 s. After applying this model in actual production, the hot metal temperature inside the converter increased by approximately 5 °C statistically. This model is potential to enhance the production efficiency, stability, and safety of the pouring process between open containers.