The development of a spherical impact pads in ladles and tundishes for high-quality steel grades
Technical University of Kosice Faculty of Materials, Metallurgy and Recycling

Introduction


Technical University of Kosice Faculty of Materials, Metallurgy and Recycling

Slovak Research and Development Agency

APVV project - 21-0396 - The development of a spherical impact pads in ladles and tundishes for high-quality steel grades

Project ID: APVV-21-0396

Solution time: 01.07.2022 - 30.06.2025
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Basic information about the project



Project ID:
APVV-21-0396

Date of submission:
10. 11. 2021

Project title:
The development of a spherical impact pads in ladles and tundishes for high-quality steel grades

R&D specialization:
20806 - Metallurgy

R&D characterization:
Development

Project start:
01.07.2022

Project end:
30.06.2025

Co-ordinating organization:
Technical Universityof Kosice
Faculty of Materials, Metallurgy and Recycling

Cooperating organization:
I.P.C. Refractories spol. s r.o.

Acronym:
SPHERIC

Statutory representative:
Dr. h. c. prof. h. c. prof. Ing. Stanislav Kmeť, CSc.

Annotation:
This project is aimed on development of spherical impact pads for ladles and tundishes. A spherical impact pads create a unique flow pattern, which helps to increase of refining potential of given aggregate from inclusions, what is most suitable for casting of high quality steel grades and also to decrease of wearing of refractory materials. For the project solution, the utilization of synergic effect of joining and application the state of art mathematical simulation tools comparing with outputs from high-end physical models of key components of continuous casting machine. The obtained knowledge about spherical impact pads in this project will results in the significant scientific contribution in continuous casting at home and abroad. The obtained results can be applicable in conditions of every steel plant which uses continuous casting process. The newest hardware and software equipment, including the „Laboratory for simulation of flow processes“ combined with mathematical simulations at laboratory SiMet will be used to the achievement of all aims of the proposed project interconnected also with statistical and experimental methods. The outcomes of this projects will form the keystone to implement the idea of the Industry 4.0. into the process of steel casting. This will enable to product very high-quality steel respecting high reproducibility of the process and effective yield of used materials.

Key words:
numerical simulations, physical simulations, thermodynamic simulations, spherical impact point

Project objectives:
The primary objective of the proposed project is to design and optimisation of unique spherical impact pads, focused on casting of high-quality steel grades. The project itself will also include partial goals that will be implemented and achieved gradually over the project's timeframe:
  1. Objectives of the numerical simulations
    • Creation of a suitable calculation grid based on the grid quality according to orthogonality and skew criteria. When refining the mesh, it will be a priority for the cells to have as little shape deformation as possible relative to their ideal shape and for the mesh to capture the modelled action as much as possible.
    • Selection of suitable mathematical model for individual models of devices based on turbulent flow.
    • Selecting the correct size and number of time steps and the maximum number of iterations per time step.
    • Verification of the resulting values from mathematical simulations according to 5 criteria (flow rate, flow pattern, tracer behaviour in volume, shape of concentration curves and residence time values) with physical models.
    • Selection and assembly of the most accurate mathematical models of steel flow in the process of continuous steel casting in individual parts of CCM.
  2. Objectives of the physical simulations
    • The results of physical simulations will serve as a supporting data source for setting up mathematical simulations.
    • Verification of the resulting values from mathematical simulations or modification of the measurement methodology on physical models.
  3. Objectives of the thermodynamic simulations
    • Thermodynamic and thermochemical calculations and simulations of steel refining processes during continuous steel casting in HSC Chemistry 9, focusing on steel-slag refining reactions.
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Principal investigator


Name and surname:
Branislav Buľko

Academic and scientific degree:
doc. Ing. PhD.

Phone:
+421 55 602 3151, +421 948 122 166

E-mail:
branislav.bulko@tuke.sk

CC and impacted (state impact factor) publications in last 5 years with number of citations (max. 20 publications)
  • [1] Bul’ko B., Molnár M., Demeter P., Baricová D., Pribulová A., Futáš P.: Study of the Influence of Intermix Conditions on Steel Cleanliness, Metals 2018, 8, 852. doi: 10.3390/met8100852, ISSN 2075-4701 Karentovaný časopis, Impakt faktor – 2.731, kvartil Q1 v Metallurgy & Metallurgical Engineering

  • [2] Baricová D., Pribulová A., Futáš P., Buľko B., Demeter P.: Change of the chemical and mineralogical composition of the slag during oxygen blowing in the oxygen converter process, Metals. - Basel (Švajčiarsko): MDPI Roč. 8, č. 10 (2018), s. 1-14, ISSN 2075-4701 Karentovaný časopis, Impakt faktor – 2.731, kvartil Q1 v Metallurgy & Metallurgical Engineering

  • [3] Bul’ko B., Priesol, I., Demeter P., Gašparovič, P., Baricová D., Hrubovčáková, M..: Geometric modification of the tundish impact point, Metals 2018, 8, 852. doi: 10.3390/met8100852, ISSN 2075-4701 Karentovaný časopis, Impakt faktor – 2.731, kvartil Q1 v Metallurgy & Metallurgical Engineering

  • [4] Vasková, I., Varga, L., Prass, I., DARGAI, V., CONEV, M., HRUBOVČÁKOVÁ, M., BARTOŠOVÁ, M., BUĽKO, B., DEMETER, P.: Examination of Behavior from Selected Foundry Sands with Alkali Silicate-Based Inorganic Binders, Metals 2020, Roč.10, Č.2. doi: https://doi.org/10.3390/met10020235, Karentovaný časopis, Impakt faktor – 2.731, kvartil Q1 v Metallurgy & Metallurgical Engineering

  • [5] LEGEMZA, J., FINDORÁK, R., BUĽKO, B., BRIANČIN, J.: New Approach in Research of Quartzes and Quartzites for Ferroalloys and Silicon Production, In: Metals 2021, Roč.11, Č.4. doi: https://doi.org/10.3390/met11040670, Karentovaný časopis, Impakt faktor – 2.731, kvartil Q1 v Metallurgy & Metallurgical Engineering

  • [6] Buľko, B., Molnár, M., Demeter, P.: Physical Modeling of Different Configurations of a Tundish for Casting Grades of Steel that Must Satisfy Stringent Requirements on Quality, In: Metallurgist. Vol. 57, no. 11-12 (2014), p. 976-980. - ISSN 0026-0894 Karentovaný časopis, Impakt faktor – 0,244

  • [7] BUĽKO, Branislav - KIJAC, Jozef - BOROVSKÝ, Tomáš: The influence of chemical composition of steel on steel desulphurization, Archives of Metallurgy and Materials. Vol. 56, no. 3 (2011), p. 605-609. - ISSN 1733-3490, http://www.imim.pl/files/archiwum/Vol3_2011/05.pdf

Non-CC publications in foreign and domestic peer reviewed journals in last 5 years (max. 20 publications)
  • [1] Rega, V., Molnár, M., Buľko, B., Demeter, P., Jusko, M., Kijac, J.: Impact of cast speed on the occurrence of the non-metallic inclusions in steel, Acta Metallurgica Slovaca, Volume 22, Issue 1, 2016, Pages 4-13

  • [2] Buľko, B., Demeter, P., Havran, J.: The influence of slag on degradation of tundish working lining, Acta Metallurgica Slovaca, Volume 20, Issue 3, 27 August 2014, Pages 318-325

  • [3] Rega, V., Molnár, M., Šolc, M., Buľko, B., Demeter, P., Jusko, M.: Impact of interstitial aluminium content on occurence of non-metallic inclusions in steel, In: Acta Metallurgica Slovaca, Vol. 22, 2016, No. 2, p. 88-94 - ISSN 1335-1532

  • [4] Molnár, M., Tréfa, G., Hertneky, S., Beháň, B., Steranka, E., Rega, V., Jusko, M., Legemza, J., Buľko, B., Demeter, P.: Influence of chemical reheating at RH degasser on cleanliness of IF steel grades, In: Acta Metallurgica Slovaca, Vol. 22, 2016, No. 2, p. 95-101 - ISSN 1335-1532

  • [5] Buľko, B. et al.: Identification of factors causing nitridation of crude steel in BOF before tapping/ In: Acta Metallurgica Slovaca. Vol. 20, 2014, No. 1, p. 11-17, ISSN 1335-1532

  • [6] Buľko, B. - [et al.]: Analysis and optimization of intermix slab length in: Acta Metallurgica Slovaca - Conference: Iron and Steelmaking: 23. International scientific conference: 16. - 18.10.2013, Vysoké Tatry, Štrbské Pleso, Košice, TU, 2014, p. 114-119, ISSN 1338-1660

  • [7] Baricová, D., Pribulová, A., Buľko, B., Demeter, P.: Final chemical and mineralogical composition of oxygen converter slag, International Multidisciplinary Scientific GeoConference Surveying Geology and Mining Ecology Management, SGEM Volume 19, Issue 1.3, 2019, Pages 827-834

  • [8] BUĽKO, B. - MOLNÁR, M. - DEMETER, P.: Physical Modeling of Different Configurations of a Tundish for Casting Grades of Steel that Must Satisfy Stringent Requirements on Quality / B. Buľko, M. Molnár, P. Demeter - 2014. In: Metallurgist. Vol. 57, no. 11-12 (2014), p. 976-980. - ISSN 0026-0894

  • [9] BUĽKO, B. - PRIESOL, I. - DEMETER, P. - VRÁBĽOVÁ, N. - BARICOVÁ, D. - ATYAFIOVÁ, I. - CHOMIČ, V.: Optimization of the impact area in tundishes / Branislav Buľko ... [et al.] - 2017. In: Iron and Steelmaking. - Ostrava: VŠB-TU, 2017 P. 191-200. - ISBN 978-80-248-4120-5

  • [10] ATYAFIOVÁ, I. - BUĽKO, B. - DEMETER, P.: The comparison of influence of tundish impact pads Turbostop® and Spheric on steel flow in the tundish / Ivana Atyafiová, Branislav Buľko, Peter Demeter - 2017. In: Iron and Steelmaking. - Ostrava: VŠB-TU, 2017 P. 227-237. - ISBN 978-80-248-4120-5

  • [11] BARICOVÁ, D. - PRIBULOVÁ, A. - BUĽKO, B. - DEMETER, P.: Final chemical and mineralogical composition of oxygen converter slag / Dana Baricová ... [et al.] - 2019. In: SGEM 2019 conference proceedings. 1.3. Science and technologies in geology, exploration and mining: exploration and mining mineral processing. - Sofia (Bulharsko): STEF92 Technology s. 827-835 [print]. - ISBN 978-619-7408-78-2 - ISSN 1314-2704

  • [12] BUĽKO, B. - KIJAC, J. - BEĽUŠ, Š. - MOLNÁR, M. - DEMETER, P.: Analysis and optimization of intermix slab length / Branislav Buľko ... [et al.] - 2014. In: Acta Metallurgica Slovaca - Iron and Steelmaking - Košice: TU, 2014 S. 114-119. - ISSN 1338-1660

  • [13] VRÁBĽOVÁ, N. - PRIESOL, I. - BUĽKO, B. - DEMETER, P.: Geometrické úpravy dopadových miest v panvach a medzipanvách / Nikola Vrábľová ... [et al.] - 2016. In: Žiaromateriály, pece a tepelné izolácie. - Košice: TU, 2016 S. 87-93. - ISBN 978-80-553-2531-6

  • [14] BUĽKO, B. - DEMETER, P. - PARILÁK, Ľ. - BUČEK, P. - PETRÍK, J. - BLAŠKO, P. - BARICOVÁ, D. - CHOMIČ, V. - VESELOVSKÝ, P.: The influence of ladle shroud misalignment on steel flow in three strand T-shape tundish / Branislav Buľko ... [et al.] - 2019. In: METAL 2019 - Ostrava (Česko): Tanger

  • [15] BUĽKO, Branislav - DEMETER, Peter - BARICOVÁ, Dana - ATYAFIOVÁ, Ivana: Modeling of continuous casting processes / - 2018. In: Modern Production of Metal Materials and its Ecological and Economic Aspects. - Ostrava (Česko): Vysoká škola báňská – Technická univerzita Ostrava s. 79-99 [print]. - ISBN 978-80-248-4204-2

  • [16] BARICOVÁ, Dana - PRIBULOVÁ, Alena - DEMETER, Peter - BUĽKO, Branislav: The origin, development, processing and utilization of steelmaking slags chapter 10/ - 2018. In: Modern Production of Metal Materials and its Ecological and Economic Aspects. - Ostrava (Česko): Vysoká škola báňská – Technická univerzita Ostrava s. 154- 176 [print]. - ISBN 978-80-248-4204-2

Expertises, consultation and other outcomes with direct exploitation in economic and social practice in last 5 years
  • [1] Branislav Buľko, Dana Baricová, Peter Demeter, Róbert Findorák, Jozef Kijac , Jaroslav Legemza, Ľuboš Popovič: Matematický model využitia rôznych druhov vápna v kyslíkovom konvertore, medzinárodný výskumný projekt s firmou Carmeuse Belgicko, doba riešenia 2018-2020

  • [2] BUĽKO, Branislav - DEMETER, Peter: Úvodná štúdia k vodnému modelu ZPO ŽP, a.s SIMCONT/ - Košice : Hutnícka fakulta - 2016. - 62 s..

  • [3] BUĽKO, Branislav - DEMETER, Peter: Optimálna poloha hrádzok v kombinácii s dopadovou doskou "Spheric" / - Košice : Hutnícka fakulta - 2016. - 40 s..

  • [4] BUĽKO, Branislav - DEMETER, Peter: Vytvorenie spoločného laboratória „Fyzikálny model medzipanvy ŽP a.s.- SimConT“ / - Košice : TU - 2017. - 39 s..

  • [5] BUĽKO, Branislav - DEMETER, Peter: Analýza vplyvu vychýlenia ochrannej trubice o 3° smerom k zadnej stene medzipanvy na zmenu podmienok prúdenia ocele v medzipanve číslo objednávky: AG219BH1275/ - Košice : TU - 2017. - 17 s..

  • [6] BUĽKO, Branislav - DEMETER, Peter: Analýza možností použitia vyžíhaných oceľových kordov z pneumatík na výrobu ocele alebo liatiny / - Košice : Ústav materiálov - 2017. - 7 s..

  • [7] LEGEMZA, Jaroslav - FINDORÁK, Róbert - BUĽKO, Branislav - SEMANOVÁ, Zuzana - ČIŽMÁROVÁ, Miroslava: Výskum vysokoteplotnej stability a redukovateľnosti kremencov (resp. kremeňov) Záverečná správa výskumnej úlohy č. P-102-004618/ - 1. vyd. - Košice : Technická univerzita v Košiciach - 2018. - 75 s. [print].

  • [8] LEGEMZA, Jaroslav - FINDORÁK, Róbert - BUĽKO, Branislav: Výskum vysokoteplotnej stability a redukovateľnosti kremencov (resp. kremeňov) – 2. etapa záverečná správa výskumnej úlohy č. P-102-005518/ - 1. vyd. - Košice : Technická univerzita v Košiciach - 2019. - 39 s. [print].

  • [9] LEGEMZA, Jaroslav - FINDORÁK, Róbert - BUĽKO, Branislav: Výskum vysokoteplotnej stability a redukovateľnosti kremenca Pliešovce (SR) – 3. etapa záverečná správa výskumnej úlohy č. P-102-005518-II/ - 1. vyd. - Košice: Technická univerzita v Košiciach - 2019. - 32 s. [print].

  • [10] LEGEMZA, Jaroslav - FINDORÁK, Róbert - BUĽKO, Branislav: Výskum vysokoteplotného slinovania brikiet na báze dolomitického vápna záverečná správa

  • [11] HALAMA, Maroš - FINDORÁK, Róbert - LEGEMZA, Jaroslav - BUĽKO, Branislav - SLOVENSKÝ, Peter - KLEMAN, Tomáš: Homogenita a reaktivita zmesi plynov s významným obsahom vodíka, spoločný výskum s SPP

  • [12] BUĽKO, Branislav - DEMETER, Peter - DZURŇÁK, Róbert - ATYAFI, René - HUBATKA, Slavomír - FOGARAŠ, Lukáš - ŠABÍK, Vladimír: Experimenty v spoločnom laboratóriu SimConT „Fyzikálny model medzipanvy ŽP, a.s. “za rok 2020, výskumná správa v spolupráci so ŽP VVC, s.r.o.

  • [13] Branislav Buľko, Peter Demeter, Gabriel Tréfa, Marek Molnár, Iveta Vasková, Slavomír Hubatka, Vladimír Šabík, Lukáš Fogaraš: Fyzikálne modelovanie vybraných dizajnov dopadových dosiek v medzipanve pre prevádzkové podmienky ZPO1, 2021, výskumný projekt v spolupráci s USS KE

List of projects of the principal investigator realized in last 5 years in structure: name of project, grant scheme, years of realization, project cost, position of principal investigator in the project
  • VEGA project 1/0212/21 The study of the nature of steel flow processes during continuous casting and analyse of the high temperature interactions in complex metallurgical systems using thermodynamical and physical tools supported with mathematical simulations, duration: 2021-2023, budget 83014 Eur, position of principal investigator in the project: principal investigator.

  • VEGA 1/0868/17 The study of the nature of steel flow processes during continuous casting and analyse of the high temperature interactions in complex system consists of slag – metal – refractory respecting thermodynamical and physical criterions applicable in praxis, duration 2017-2019, budget 79485 Eur, position of principal investigator in the project: principal investigator.

  • VEGA-1/0265/21: Study of possibilities of treatment, processing, and utilization of waste from the foundry process, duration: 2021-2023, budget 78924 Eur, position of responsible researcher: researcher.

  • VEGA-1/0759/21: Study of used and development of new additives in cast and molding mixtures for the foundry industry, duration: 2021-2023, budget 68626 Eur, position of responsible researcher: researcher.

Project solvers

Name and surname Titles Job/position Organization
Branislav Buľko doc. Ing. PhD. Associate Professor UMET TUKE
Jaroslav Legemza prof. Ing. PhD. Professor UMET TUKE
Róbert Findorák doc. Ing. PhD. Associate Professor UMET TUKE
Peter Demeter doc. Ing. PhD. Associate Professor UMET TUKE
Róbert Dzurňák Ing. PhD. Assistant Professor UMET TUKE
Lukáš Fogaraš Ing. PhD student UMET TUKE
Peter Futáš doc. Ing. PhD. Associate Professor UMET TUKE
Martina Hrubovčáková Ing. Bc. PhD. Assistant Professor UMET TUKE
Slavomír Hubatka Ing. PhD student UMET TUKE
František Kyseľ Ing. Company employee IPC REFRACTORIES spol. s.r.o.
Alena Pribulová prof. Ing. CSc. Professor UMET TUKE
Ivan Priesol Ing. Executive manager of the company IPC REFRACTORIES spol. s.r.o.
Vladimír Šabik Ing. PhD student UMET TUKE

Project schedule

Begin of phase End of phase Phase name
01.07.2022 31.12.2022 1. stage is focused on creating geometries of individual monitored objects such as ladle shrouds, tundishes, and ladles
01.01.2023 31.12.2023 2. stage is focused on testing of various designs and locations of spherical impact pads using physical and mathematical models of ladles and tundishes
01.01.2024 31.12.2024 3. stage is aimed on final proposal of spherical impact points in tundishes and ladles using the results of mathematical simulations, which will be verified according to 5 criteria with mathematical models
01.01.2025 30.06.2025 4. stage is focused on the publication of a monograph dealing with the latest knowledge and trends for the casting of high-quality steel grades, including unique techniques and the use of state-of-the-art physical and numerical modelling tools

Budget of the project

  • Required funds from APVV: 238 116,0 €
  • Co-financing of the project: 14 374,00 €
  • Total cost of the project: 252 490,00 €

Outcomes

Category Outcomes 2022 2023 2024 2025 2026 2027 2028
Publications and citations 1.02 Interantional current contents publications 1 1 1 1
Publications and citations 1.04 SCI citations of the publications originated within project in international current contents journals 1 1 1
Publications and citations 1.07 Publications in international peer-reviewed scientific journals 1 2 1
Publications and citations 1.10 Scientific monographs in SR 1
Publications and citations 1.12 University textbooks issued in SR 1
Proprietary and marketoriented outcomes 2.1.01 Patent applications in SR 1
Proprietary and marketoriented outcomes 2.1.03 European patent applications 1
Proprietary and marketoriented outcomes 2.2.05 Industrial design in SR 1
Proprietary and marketoriented outcomes 2.2.06 Industrial design abroad 1
Outputs into education and popularization of science 4.3 Master theses accomplished within project 1
Outputs into education and popularization of science 4.4 PhD students which will be trained within project 1
Outputs into education and popularization of science 4.6 Popularization activities 3 3 3
Other outcomes 5.3 Electronic documents 1 1 1
Other outcomes 5.6 Other outcomes (conceptual frameworks, methodologies, studies, etc.) 1 1