Modeling of Coil Cooling using 2D and 3D Computational Fluid Dynamics (CFD)

IRAWAN, DODDY and Gutiérrez, A.J. and Álvarez, E. and Blanco, E. (2018) Modeling of Coil Cooling using 2D and 3D Computational Fluid Dynamics (CFD). In: -, SPAIN.

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Abstract

In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. The concept is similar to the rolling of dough. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is known as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is known as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes. Considerable researches have been devoted to research the thermal and microstructural behaviors of steels in controlled cooling process. For instance, Nobari and Serajzadeh [1] developed a mathematical model to predict temperature variations and austenite phase transformation in steel during controlled cooling. Shivpuri and co-workers [2] presented a computational approach to grain size evolution and mechanical properties of hot rolled rod. Yu et al. [3] developed an online Stelmor controlled cooling system for the stabilization of process operation. These numerical models have been successfully applied to controlled cooling process for realizing stable operation and improving product quality. Thus, in industrial practice, with more and more manipulated variables under control, the fact that the product quality varies with season and climate is more and more outstanding. But up to now, it is no available in the literature to describe the quantitative analysis on the impacts of ambient temperature and humidity upon the cooling process of hot rolled steel. Fortunately, some investigations in the similar treatment were reported, Brenn. [4] Discussed the effects of ambient conditions on the drying process of liquid coatings on round metal wires. Page et al. [5] reported a model to analyze the effects of ambient conditions during air treatment operations of food. These research results provide base for the study of the effects of ambient conditions on the controlled cooling of hot-rolled wire rod of steel. Steel Mills Lamination Coils Cooling, an integrated model for describing the effects of ambient conditions on the cooling performance of hot-rolled steel wire after rolling is presented. The effects of moist air on heat transfer have been derived from the theoretical and empirical models with the involved ambient conditions, and the results are used to calculate the temperature evolution and phase transformation of highcarbon steel, SWRH82B, by numerical approach. Then the predicted values of ultimate tensile strength are compared with the industrial trials to validate the model. Additionally, the inverse solution of wind speed is also discussed for realizing stable production process under different ambient conditions. In hot-rolled steel production processes, controlled cooling after finishing rolling plays an important role on the final microstructure and mechanical properties of product. Steel coil produced at a steel mill after the laminate must be cooled from a temperature of 673.15 K to ambient temperature to be transported and sold. In this article a model to simulate and measure the rate of cooling coil is developed. The coil geometry employed is a cylinder with height between 1.6 m and 1.8 m and an outer diameter of 1.8 m. They have a few diameter co-axial hollow centre. The coils cooling take between 4 and 6 days depending on weather conditions. Usually the cold coil will be stored in a warehouse. It produces unwanted stocks and thus represents a "bottleneck" in the marketing process. In this study, the process of coils cooling is studied using CFD techniques. To do so, 2D (two-dimensional) axisymmetric and 3D (three dimensional) transient models were used. The objective is to obtain the optimal rate of temperature decrease depending on the geometry and the orientation (horizontal or vertical arrangement) of the coils.

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