IMF Research Project Proposals

1. IMF Research Project Proposals IMF Meeting, Spring 2018

2. Nozzle Sand Sintering Study • Background • Nozzle sand is a consumable that is used to protect the slidegate plates from the liquid steel in the ladle during the steelmaking process. It is deposited in the well block area on top of plates prior to tapping into the ladle, and then flushed out during the start of the teeming process (preferably outside of the bottom pour setup). In this way it is important that the sand sinter to form a complete barrier to keep steel from getting into the well block area where it could freeze off or damage the slidegate system. It is also important, however, that the sand is able to be dislodged by the ferrostatic pressure of the liquid steel when the slidegate is opened to avoid having to lance the heat open which adds time, safety risk, and can potentially damage the ladle refractory.

3. Nozzle Sand Sintering Study • The proposed study is to identify various properties that can affect the nozzle sand’s ability to sinter. These include the following: • Percentage of fines (sorted by mesh) • Moisture content • Sintering time • The project would involve varying these (or other) parameters and simulate the experience of the sand in the ladle during the steelmaking process. The effect of these factors could then be quantified by measuring the percentage of sintered sand in each of the batches. Ideally this study would be performed with multiple sands used by IMF member companies.

4. Exothermic Hot Top Board Study • Background • Hot top boards are commonly used in the production of ingots in order to maintain a liquid feeder into the ingot during solidification, improving both quality and yield. The hot top boards may be insulating or exothermic type. The exothermic boards contain some amount of combustible material (i.e. aluminum) that ignites and generates additional heat when the liquid metal reaches the hot top.

5. Exothermic Hot Top Board Study • The proposed study is to analyze the heat generated during this exothermic reaction and its effect on the heat transfer through the hot top. A quantitative theoretical analysis of the heat transfer through a 1D (or 2D, 3D) hot top should be performed for various levels of exothermic material contained, all assuming that the exothermic reaction produces no change in the insulating properties of the material. This analysis would include the following: • Amount of generated heat transferred to liquid metal • Amount of generated heat self-absorbed into the hot top board • Amount of generated heat transferred to mold wall / casting • Amount of generated heat lost to atmosphere, if applicable • Comparison of heat transfer from the liquid metal through the hot top based on the different temperature gradients produced from the above points • The intent of this work is to quantify and gain a thorough understanding of the benefits of this exothermic reaction beyond the exfoliation and creation of porosity (changes to the insulating properties) in hot top materials.

6. Hot Top Board Insulating Properties • Background • Hot top boards are commonly used in the production of ingots in order to maintain a liquid feeder into the ingot during solidification, improving both quality and yield. The hot top boards may be insulating or exothermic type. For exothermic versions, the boards are expected to act as insulators after the reaction to keep heat within the hot top. This is partially aided by the porosity created by the exothermic reaction. The insulating boards solely rely on their insulating properties to keep heat within the hot top.

7. Hot Top Board Insulating Properties • The proposed study is to identify and put in use a method of evaluating the insulating properties of hot top side boards. • Will require literature study to find out what test method is most representative of environment in an ingot hot top during solidification • Once identified, this test method is to be used to determine the effectiveness of insulating boards versus spent exothermic boards to determine if there is any difference in performance.

8. Senior Design Projects • Several Universities were contact about possible senior design projects (versus a research project). Some of the differences are noted below: • Senior design projects are handled by undergraduates versus graduate students • Smaller in scope (usually with more defined objectives) • Shorter in duration (1-2 semesters), but does include at least one presentation of results/status (could be at IMF meeting) • Lower in price (~$5000 for most universities) • The senior design projects also have the added benefit of exposing undergrads to heavy manufacturing industry • Company tour is usually included or recommended