高炉出铁沟流场与壁面剪切应力的数值模拟及结构优化

Numerical Simulation of Flow Field and Wall Shear Stress in a Blast Furnace Trough and Its Structural Optimization

摘要

针对高炉出铁沟耐火材料局部侵蚀严重的问题，基于流体体积 (VOF) 多相流模型和标准 k−ε 湍流模型，建立出铁沟三维数值模型，研究出铁口倾角 (0°~15°)、直径 (60~80 mm)、质量流量 (7~10 t/min) 及沟体结构对流场和壁面剪切应力分布的影响，并提出一种“宽底深池”优化结构。结果表明：侵蚀主要受射流对沟底的直接冲击和回旋涡对侧壁的贴壁剪切共同控制；倾角为 10°时，动量分配相对最优。增大出铁口直径对沟底冲刷最为不利，直径由 60 mm 增至 80 mm 时，沟底剪切应力峰值由 32 Pa 升至 352 Pa，而侧壁冲刷反而减弱；质量流量由 7 t/min 增至 10 t/min 时，射流落点后移至更深铁水区，沟底剪切应力峰值由 41 Pa 降至 17 Pa，侧壁应力稳定在 12~15 Pa。所提出的“宽底深池”结构通过降低斜坡高度和加宽沟底，使高湍动能区上移至自由液面，有效削弱了回旋涡强度。在 7 t/min 工况下，优化后沟底和侧壁剪切应力峰值分别降低 39.0% 和 39.3%，且在其他质量流量下表现出一致下降趋势。研究结果为高炉出铁沟长寿化设计提供了理论依据。

Abstract

To address the problem of severe local erosion of refractory materials in a blast furnace trough, a three-dimensional numerical model of the trough was established based on the volume of fluid (VOF) multiphase flow model and the standard k−ε turbulence model. The effects of different taphole inclination angles (0°–15°), diameters (60–80 mm), mass flow rates (7–10 t/min), and trough structures on the flow field and wall shear stress distribution were investigated, and a “wide-bottom deep-pool” optimized structure was proposed. The results show that erosion is jointly governed by the direct impingement of the jet on the trough bottom and the wall-attached shear of recirculating vortices on the side walls. The momentum distribution is relatively optimal when the inclination angle is 10°. Increasing the taphole diameter is most unfavorable for bottom erosion, when the diameter increases from 60 mm to 80 mm, the peak shear stress on the trough bottom increases from 32 Pa to 352 Pa, while sidewall erosion is weakened. When the mass flow rate increases from 7 t/min to 10 t/min, the jet impingement point shifts backward into the deeper molten iron zone, and the peak shear stress on the trough bottom decreases from 41 Pa to 17 Pa, while the sidewall shear stress remains stable at 12–15 Pa. The proposed “wide-bottom deep-pool” structure reduces the slope height and widens the trough bottom, shifting the high turbulent kinetic energy zone upward to the free surface and effectively weakening the intensity of the recirculating vortices. Under the condition of 7 t/min, the peak shear stresses on the bottom and sidewalls after optimization are reduced by 39.0% and 39.3%, respectively, and a consistent downward trend is also observed under other mass flow rates. The research results provide a theoretical basis for the long-life design of blast furnace troughs.

关键词

高炉出铁沟 / 数值模拟 / VOF 多相流 / 壁面剪切应力 / 结构优化 / 耐火材料侵蚀

Key words

blast furnace main trough / numerical simulation / VOF multiphase flow / wall shear stress / structure optimization / refractory erosion

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基金资助

安徽省高校自然科学基金项目(2022AH050293)