Stirring Optimization of Consteel EAF Based on Multi-Phase Flow Water-Model Simulation

Optimizing stirring methods is crucial for enhancing the efficiency of the Electric Arc Furnace (EAF) production process. This study explores the mixing characteristics of a 150-ton Consteel EAF. The similarity ratio between the water model and the prototype is 1:8. The average mixing time (AMT) was employed as the criterion to evaluate various stirring methods, including the horizontal deflection angle of side-blowing, non-uniform bottom-blowing layouts, and their combinations. A new ice whose composition was a 35 wt% sugar solution was used to simulate the movement and bonding of scrap steel. The melting and temperature difference were compared in this way. The conclusions are as follows: (1) The side blowing lances with a certain angle of horizontal deflection are more conducive to the mixing of the molten pool. The preferred side-blowing lances’ horizontal deflection angle is 10°. (2) The preferred bottom blowing layout is EKO. The bottom blowing layout needs to pay attention to the offset between the bottom blowing nozzles. Bottom blowing nozzles cannot be too far or too close. Rational non-uniform layout of bottom blowing is better than uniform. (3) The preferred combined stirring layout is the EKN, combined with side blowing, with counterclockwise deflection of 10° in the horizontal direction. Gas injection of side blowing and bottom blowing exhibits complementary action zones, thereby achieving enhanced stirring uniformity in the molten bath. But it is necessary to consider the bottom-blowing and side-blowing positions to avoid the local kinetic energy loss caused by airflow offset. At the same time, the deflection angle of the side-blowing lances should be consistent with the direction of the circulation formed by the non-uniform bottom blowing. (4) Under the rational combined stirring method, the scrap steel moved faster, and the bonding phenomenon was significantly reduced. And the temperature difference decreased the fastest. In summary, the rational combined stirring method is the most preferred method for mixing.