CN113011068B - Three-dimensional simulation method for walking beam type plate blank heating - Google Patents
Three-dimensional simulation method for walking beam type plate blank heating Download PDFInfo
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Abstract
The invention provides a walking beam type plate blank heating three-dimensional simulation method, which comprises the following steps: building a three-dimensional simulation model of the heating furnace and the plate blank; generating a grid for the three-dimensional simulation model, and encrypting the combustor and the slab area; acquiring a control equation and a slab motion equation according to the grids; simulating and solving the three-dimensional simulation model based on a control equation and a slab motion equation; and (4) visually solving a result, and obtaining temperature cloud pictures of the plate blank in different positions in the heating furnace. The method can be used for identifying whether the plate blank reaches the tapping temperature standard or not, carrying out fault diagnosis and optimizing the reheating process, and greatly saves the labor cost.
Description
Technical Field
The invention relates to the technical field of computer numerical simulation, in particular to a walking beam type plate blank heating three-dimensional simulation method.
Background
Hot rolling of slabs is a key process for producing high quality steel products, and a heating furnace is one of key apparatuses of a steel rolling line and is also a major energy consumption apparatus. Because the heating furnace is located at the upstream of the steel rolling mill, and the defective slab products can damage downstream equipment, unnecessary losses such as product reworking, energy resource waste, shutdown and equipment maintenance/replacement are caused, and the quality of the products output by the heating furnace is particularly important. The purpose of heating the slab using a furnace is to heat the slab to a target rolling temperature to reduce the stresses introduced during rolling. Industrial furnaces generally consist of three zones: a preheating zone, a heating zone, and a soaking zone. During the moving process of the plate blank in the furnace, the heat released by combustion is transferred to the steel plate by radiation, convection, conduction and the like. The heating quality of the slab and the temperature distribution inside the slab are important indicators for determining the heating degree of the slab. However, in the actual production process, the steel mill rolls different steel grades every day, and the optimal balance between slab reheating quality and furnace output can only be achieved if there is a good temperature prediction for the slab.
The traditional slab temperature prediction method generally detects the real-time temperature of the slab through technicians, and then predicts the slab temperature according to the real-time temperature of the slab, thereby being time-consuming, labor-consuming and high in cost.
Disclosure of Invention
Based on the above, in order to solve the problems of time and labor waste and higher cost of the traditional slab temperature prediction method, the invention provides a walking beam type slab heating three-dimensional simulation method, which has the following specific technical scheme:
a walking beam type plate blank heating three-dimensional simulation method comprises the following steps:
building a three-dimensional simulation model of the heating furnace and the plate blank;
generating a grid for the three-dimensional simulation model, and encrypting a combustor and a slab region;
acquiring a control equation and a slab motion equation according to the grids;
simulating and solving the three-dimensional simulation model based on the control equation and the slab motion equation;
and (4) visually solving a result, and obtaining temperature cloud pictures of the plate blank in different positions in the heating furnace.
According to the walking beam type three-dimensional simulation method for heating the plate blank, the heating furnace and the three-dimensional simulation model of the plate blank are constructed, the three-dimensional simulation model is subjected to grid generation processing, then a control equation and a plate blank motion equation are obtained according to the grid, finally the three-dimensional simulation model is subjected to simulation solution and visual solution results based on the control equation and the plate blank motion equation, temperature cloud pictures of the plate blank in different positions in the heating furnace are obtained, the temperature distribution of the plate blank in the heating furnace can be simulated and simulated, compared with the traditional plate blank temperature prediction method, the labor cost is greatly saved, whether the plate blank reaches the temperature standard of discharging the furnace or not can be recognized, fault diagnosis is carried out, the reheating process is optimized, and a steel mill can realize high-efficiency production while the quality of steel products is guaranteed.
Further, a three-dimensional simulation model of the heating furnace and the slab is constructed according to the space structures of the heating furnace and the slab to be simulated.
Further, the specific method for performing the mesh generation processing on the three-dimensional simulation model includes the following steps:
partitioning the three-dimensional simulation model into grids in a partitioning mode to generate unstructured tetrahedral and hexahedral grids;
and carrying out grid refinement treatment on the combustor and the slab region in the three-dimensional simulation model.
Further, the governing equation includes:
conservation of mass equation
Equation of conservation of momentum
Equation of energy of turbulence
Component transfer equation of each component
Component transfer equation for combustion average component i
Equation of gas radiation characteristics
Where p is the static pressure, p
And
gravity and external force, respectively, ρ is the fluid density,
is the fluid velocity with x, y and z directional components,
is the tensor of the stress(s),
C μ for empirical coefficients, k is the kinetic energy of the turbulence, ε is the dissipation ratio of the turbulence, σ k Is the turbulant number of k, G k Is the turbulent kinetic energy, G, caused by the mean velocity gradient b Is the kinetic energy of the turbulence, Y, caused by buoyancy M To account for the contribution of wave expansion in compressible turbulence to the overall dissipation ratio, ε is the turbulent dissipation ratio, S k Is a preset value, R i Is the net rate of chemical reaction of component i,
is the diffusion flux of component i,
is that component i is reacted at a reaction time τ * After mass fraction, Y i Is the average mass fraction, ξ, of component i * Is the mass fraction, τ, in the structure * Is the residence time of the reaction, a ε,i Emissivity weighting coefficient, k, of the ith gas i Is the absorption coefficient, P is the sum of the partial pressures of all gases, S is the path length, e is the natural constant.
Further, the slab motion equation is as follows:
where p is the density of the fluid,
is a vector of the flow velocity and,
is the moving speed of the moving grid, gamma is the diffusion coefficient, V is the control volume, phi is the general scalar,
representing the boundaries of the control volume.
Further, the specific method for simulating and solving the three-dimensional simulation model according to the control equation and the slab motion equation comprises the following steps:
determining a reaction mechanism according to the combustion reaction of the three-dimensional simulation model;
setting initial conditions, and acquiring the temperature of an initial plate blank according to the initial conditions;
calculating the furnace temperature under the problem according to the initial slab temperature and taking the furnace temperature as the initial furnace temperature;
and setting a total time step, and solving the three-dimensional simulation model according to the initial furnace temperature and the total time step to obtain the temperature change of the plate blank in the heating process.
Further, the governing equations further include a momentum equation
Wherein, delta ij Is the stress tensor due to molecular viscosity.
Further, the governing equation also comprises an energy conservation equation
Wherein k is eff Is the effective electrical conductivity of the conductive material,
is the diffusion flux of component j, S h Including the heat of chemical reaction and any other heat of volume, E from
By definition, where h is the sensible enthalpy of the incompressible stream.
Furthermore, the furnace wall of the heating furnace is an insulating wall surface, the boundary condition of the plate blank is a coupling wall, and the boundary condition of the slide block in the heating furnace is constant heat flux.
Accordingly, the present invention provides a computer-readable storage medium storing a computer program which, when executed, implements the walking beam type slab heating three-dimensional simulation method as described above.
Drawings
The invention will be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Like reference numerals designate corresponding parts throughout the different views.
Fig. 1 is a schematic overall flow chart of a walking beam type slab heating three-dimensional simulation method according to an embodiment of the present invention;
fig. 2 is a temperature cloud diagram of a slab at different positions according to a walking beam type slab heating three-dimensional simulation method in an embodiment of the invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to embodiments thereof. It should be understood that the detailed description and specific examples, while indicating the scope of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only and do not represent the only embodiments.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
The terms "first" and "second" used herein do not denote any particular order or quantity, but rather are used to distinguish one element from another.
As shown in fig. 1, a walking beam type three-dimensional simulation method for slab heating in an embodiment of the present invention includes the following steps:
building a three-dimensional simulation model of the heating furnace and the plate blank;
generating a grid for the three-dimensional simulation model, and encrypting a combustor and a slab region;
acquiring a control equation and a slab motion equation according to the grids;
simulating and solving the three-dimensional simulation model based on the control equation and the slab motion equation;
and (4) visually solving a result, and obtaining temperature cloud pictures of the plate blank in different positions in the heating furnace.
The visual solution result comprises the slab speed on any plane in the heating furnace and temperature clouds of the slabs at different positions, and is shown in fig. 2.
The walking beam type three-dimensional simulation method for heating the plate blank comprises the steps of firstly constructing a heating furnace and a three-dimensional simulation model of the plate blank, generating a grid for the three-dimensional simulation model, then obtaining a control equation and a plate blank motion equation according to the grid, finally carrying out simulation solution and visualization solution on the three-dimensional simulation model based on the control equation and the plate blank motion equation, obtaining temperature cloud charts of the plate blank in different positions in the heating furnace, simulating the temperature distribution of the plate blank in the heating furnace, and accurately predicting the temperature and the temperature distribution of the plate blank in the heating furnace. Compared with the traditional slab temperature prediction method, the walking beam type slab heating three-dimensional simulation method greatly saves labor cost, can be used for identifying whether the slab reaches the tapping temperature standard and carrying out fault diagnosis and optimizing the reheating process, and enables a steel mill to realize high-efficiency production while ensuring the quality of steel products.
In one embodiment, an actual walking beam type slab and a heating furnace drawing are obtained, and then a three-dimensional simulation model of the heating furnace and the slab is constructed according to the space structure of the heating furnace and the slab to be simulated. The heating furnace is installed with a burner, which is divided into a preheating zone, a heating zone, and a soaking zone.
In one embodiment, the specific method for performing the mesh generation processing on the three-dimensional simulation model includes the following steps:
partitioning the three-dimensional simulation model into grids in a partitioning mode to generate unstructured tetrahedral and hexahedral grids;
and carrying out grid refinement treatment on the combustor and the slab region in the three-dimensional simulation model.
Specifically, tetrahedral and hexahedral partition grid division is performed on the three-dimensional simulation model by using an ANSYS Meshing advanced grid division technology, and a three-dimensional simulation grid model with refined grids, namely unstructured tetrahedral and hexahedral grids, is generated. Therefore, the calculation accuracy of the walking beam type plate blank heating three-dimensional simulation method can be improved.
In one embodiment, the governing equation comprises:
conservation of mass equation
Equation of conservation of momentum
Equation of turbulent energy
Component transfer equation of each component
Component transfer equation for combustion average component i
Equation of gas radiation characteristics
Where p is the static pressure, p
And
gravity and external force, respectively, ρ is the fluid density,
is the fluid velocity with x, y and z directional components,
is the tensor of the stress(s),
C μ for empirical coefficients, k is the kinetic energy of the turbulence, ε is the dissipation ratio of the turbulence, σ k Is the turbulant number of k, G k Is the turbulent kinetic energy, G, caused by the mean velocity gradient b Is the kinetic energy of the turbulence, Y, caused by buoyancy M To account for the contribution of wave expansion in compressible turbulence to the overall dissipation ratio, ε is the turbulent dissipation ratio, S k Is a preset value, R i Is a chemical reaction of component iThe net rate of the flow is,
is the diffusion flux of component i,
is component i at reaction time τ * After mass fraction, Y i Is the average mass fraction, ξ, of component i * Is the mass fraction, τ, in the structure * Is the residence time of the reaction, a ε,i Emissivity weighting coefficient, k, of the ith gas i Is the absorption coefficient, P is the sum of the partial pressures of all gases, S is the path length, e is the natural constant, μ is the kinetic viscosity, u is the fluid mean velocity i Represents the average velocity in the direction of flow I, I is the total number of imaginary gray gases, a epsilon, I (t) is the emissivity weighting factor for the ith imaginary gray gas.
In one embodiment, the moving speed of a specific slab and the three-dimensional simulation grid model are controlled according to a User Definition Function (UDF) code developed under actual conditions, so as to realize the dynamic motion of the slab in the three-dimensional simulation model. The slab motion equation is as follows:
where p is the density of the fluid,
is a vector of the flow velocity of the fluid,
is the moving speed of the moving grid, gamma is the diffusion coefficient, V is the control volume, phi is the general scalar,
representing the boundary of the control volume, a being the total surface area of the fluid boundary,
is a vector of a.
In one embodiment, the moving speed of the slab is the average moving speed per minute and does not include the moving speed of the slab in the vertical direction, so that the efficiency of calculating the moving speed of the slab by the method is improved.
In one embodiment, the specific method for simulating and solving the three-dimensional simulation model according to the control equation and the slab motion equation comprises the following steps:
firstly, determining a reaction mechanism according to the combustion reaction of the three-dimensional simulation model.
To reduce the complexity of the boundary condition changes, the fuel input is averaged hourly. A two-step reaction mechanism is employed for methane-air to obtain more detailed component concentrations. A one-step reaction mechanism is employed for ethane-air due to the smaller ethane-air combustion ratio.
And secondly, setting initial conditions, and acquiring the temperature of the initial slab according to the initial conditions.
Specifically, the specific slab length, width, initial temperature, steel grade and position of all slabs in the furnace are arranged according to actual production conditions, based on the conditions at a certain point in time of a given rolling mill test as initial conditions. And setting thermal physical parameters (including thermal conductivity, specific heat capacity and the like) of the slab and the slide block according to the material property of the slab.
And thirdly, calculating the furnace temperature under the problem according to the initial slab temperature and taking the furnace temperature as the initial furnace temperature.
And fourthly, setting a total time step length, and solving the three-dimensional simulation model according to the initial furnace temperature and the total time step length to obtain the temperature change of the slab in the heating process.
Specifically, according to the thermophysical parameters of the plate blank, the three-dimensional simulation model is numerically solved by using ANSYS Fluent software.
In one embodiment, the three-dimensional simulation Model comprises a turbulence Model, a combustion Model and a radiation Model, wherein the turbulence Model is a kappa-epsilon Model, the radiation Model is a WSGGM (Weighted Sum of Gray Gases Model), and the combustion Model is an EDC turbulence combustion Model to consider the combustion reaction of natural gas.
In one embodiment, the governing equations further include a momentum equation
Wherein, delta ij Is the stress tensor caused by molecular viscosity, u' is the pulsation velocity, u i 、u j 、u l Respectively representing the average velocity in the direction of the fluid i, j, l,
in one embodiment, the governing equations further comprise an energy conservation equation
Wherein k is eff Is the effective electrical conductivity of the conductive material,
is the diffusion flux of component j, S h Including the heat of chemical reaction and any other heat of volume, E from
Where h is the sensible enthalpy of the incompressible flow,
which is indicative of a temperature gradient, is,
j is the constant pressure specific heat of component j,
v is the slab velocity, the effective stress tensor.
In one embodiment, the furnace wall of the heating furnace is an insulating wall surface, the boundary condition of the plate blank is a coupling wall, the plate blank transfers heat in a convection mode and a radiation mode, the boundary condition of a sliding block in the heating furnace is constant heat flux, and the feeding door and the discharging door are both in a closed state.
In one embodiment, the invention provides a computer-readable storage medium storing a computer program which, when executed, implements the walking beam type slab heating three-dimensional simulation method as described above.
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that various changes and modifications can be made by those skilled in the art without departing from the spirit of the invention, and these changes and modifications are all within the scope of the invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (9)
1. A walking beam type plate blank heating three-dimensional simulation method is characterized by comprising the following steps:
building a three-dimensional simulation model of the heating furnace and the plate blank;
generating a grid for the three-dimensional simulation model, and encrypting a combustor and a slab region;
acquiring a control equation and a slab motion equation according to the grids;
simulating and solving the three-dimensional simulation model based on the control equation and the slab motion equation;
visualizing a solution result to obtain temperature cloud charts of the plate blank in different positions in the heating furnace;
wherein the governing equation comprises:
conservation of mass equation
Equation of conservation of momentum
Equation of energy of turbulence
Component transfer equation of each component
Component transfer equation for combustion average component i
Equation of gas radiation characteristics
Wherein, p is a static pressure,
and
respectively gravity and outerThe force, p, is the density of the fluid,
is the fluid velocity with x, y and z directional components,
is the tensor of the stress(s),
C μ for empirical coefficients, k is the kinetic energy of the turbulence, ε is the dissipation ratio of the turbulence, σ k Is the turbulant number of k, G k Is the turbulent kinetic energy, G, caused by the mean velocity gradient b Is the kinetic energy of the turbulence, Y, caused by buoyancy M Contribution of wave expansion in compressible turbulence to the overall dissipation ratio, S k Is a preset value, R i Is the net rate of chemical reaction of component i,
is the diffusion flux of component i,
is that component i is reacted at a reaction time τ * After mass fraction, Y i Is the average mass fraction, ξ, of component i * Is the mass fraction, τ, in the structure * Is the residence time of the reaction, a ε,i Emissivity weighting coefficient, k, of the ith gas i Is the absorption coefficient, P is the sum of the partial pressures of all gases, S is the path length, e is the natural constant.
2. The method as claimed in claim 1, wherein the three-dimensional simulation model of the heating furnace and the slab is constructed according to the space structure of the heating furnace and the slab to be simulated.
3. The walking beam type slab heating three-dimensional simulation method as claimed in claim 1, wherein the specific method for generating the grid of the three-dimensional simulation model comprises the following steps:
partitioning the three-dimensional simulation model into grids in a partitioning mode to generate unstructured tetrahedral and hexahedral grids;
and carrying out grid refinement treatment on the combustor and the slab region in the three-dimensional simulation model.
4. The walking beam type slab heating three-dimensional simulation method as claimed in claim 1, wherein the slab motion equation is as follows:
where p is the density of the fluid,
is a vector of the flow velocity of the fluid,
is the moving speed of the moving grid, gamma is the diffusion coefficient, V is the control volume, phi is the general scalar,
representing the boundaries of the control volume.
5. The walking beam type slab heating three-dimensional simulation method as claimed in claim 1, wherein the specific method for simulating and solving the three-dimensional simulation model according to the control equation and the slab motion equation comprises the following steps:
determining a reaction mechanism according to the combustion reaction of the three-dimensional simulation model;
setting initial conditions, and acquiring the temperature of an initial plate blank according to the initial conditions;
calculating the furnace temperature under the problem according to the initial slab temperature, and taking the furnace temperature as the initial furnace temperature;
and setting a total time step, and solving the three-dimensional simulation model according to the initial furnace temperature and the total time step to obtain the temperature change of the plate blank in the heating process.
6. The walking beam type slab heating three-dimensional simulation method of claim 1, wherein the governing equation further comprises a momentum equation
Wherein, delta ij Is the stress tensor caused by molecular viscosity.
7. The walking beam type slab heating three-dimensional simulation method of claim 4, wherein the governing equation further comprises an energy conservation equation
Wherein k is eff Is the effective electrical conductivity of the conductive material,
is the diffusion flux of component j, S h Including the heat of chemical reaction and any other heat of volume, E from
By definition, where h is the sensible enthalpy of the incompressible stream.
8. The walking beam type slab heating three-dimensional simulation method according to claim 1, wherein the wall of the heating furnace is a heat insulation wall surface, the boundary condition of the slab is a coupling wall, and the boundary condition of the slide block in the heating furnace is a constant heat flux.
9. A computer-readable storage medium, characterized in that it stores a computer program which, when executed, implements a walking beam type slab heating three-dimensional simulation method as claimed in any one of claims 1 to 8.
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