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Title: Electromagnetic and Thermal-flow Modeling of a Cold-Wall Crucible Induction Melter

Abstract

An approach for modeling cold-wall crucible induction melters is described. Materials in the melt and melter are non-ferromagnetic. In contrast to other modeling works reported in the literature, the numerical models utilize commercial codes. The ANSYS finite element code is employed for electromagnetic field simulations and the STAR-CD finite volume code for thermal-flow calculations. Results from the electromagnetic calculations in the form of local Joule heat and Lorentz force distributions are included as loads in the thermal-flow analysis. This loosely-coupled approach is made possible by the small variation in temperature and, consequently, small variation in electrical properties across the melt as well as the quasi-steady state nature of the thermal flow calculations. A three dimensional finite element grid for electromagnetic calculations is adapted to a similar axisymmetric finite volume grid for data transfer to the thermal-flow model. Results from the electromagnetic model compare well with operational data from a 175 mm diameter melter. Results from the thermal-flow simulation provide insight toward molten metal circulation patterns, temperature variations, and velocity magnitudes. Initial results are included for a model that simulates the formation of a solid (skull) layer on the crucible base and wall. Overall, the modeling approach is shown to producemore » useful results relating operational parameters to the physics of steady state melter operation.« less

Authors:
; ;
Publication Date:
Research Org.:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
15020519
Report Number(s):
PNNL-SA-39091
TRN: US200521%%16
DOE Contract Number:  
AC05-76RL01830
Resource Type:
Journal Article
Journal Name:
Metallurgical and Materials Transactions. B, Process metallurgy and materials processing science, 36B:141-152
Additional Journal Information:
Journal Volume: 36B
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; CRUCIBLES; ELECTRICAL PROPERTIES; ELECTROMAGNETIC FIELDS; LORENTZ FORCE; COMPUTERIZED SIMULATION; CERAMIC MELTERS; THERMODYNAMICS; electromagnetic; modelling; induction melter; metal

Citation Formats

Fort, James A, Garnich, Mark R, and Klymyshyn, Nicholas A. Electromagnetic and Thermal-flow Modeling of a Cold-Wall Crucible Induction Melter. United States: N. p., 2005. Web. doi:10.1007/s11663-005-0014-3.
Fort, James A, Garnich, Mark R, & Klymyshyn, Nicholas A. Electromagnetic and Thermal-flow Modeling of a Cold-Wall Crucible Induction Melter. United States. https://doi.org/10.1007/s11663-005-0014-3
Fort, James A, Garnich, Mark R, and Klymyshyn, Nicholas A. 2005. "Electromagnetic and Thermal-flow Modeling of a Cold-Wall Crucible Induction Melter". United States. https://doi.org/10.1007/s11663-005-0014-3.
@article{osti_15020519,
title = {Electromagnetic and Thermal-flow Modeling of a Cold-Wall Crucible Induction Melter},
author = {Fort, James A and Garnich, Mark R and Klymyshyn, Nicholas A},
abstractNote = {An approach for modeling cold-wall crucible induction melters is described. Materials in the melt and melter are non-ferromagnetic. In contrast to other modeling works reported in the literature, the numerical models utilize commercial codes. The ANSYS finite element code is employed for electromagnetic field simulations and the STAR-CD finite volume code for thermal-flow calculations. Results from the electromagnetic calculations in the form of local Joule heat and Lorentz force distributions are included as loads in the thermal-flow analysis. This loosely-coupled approach is made possible by the small variation in temperature and, consequently, small variation in electrical properties across the melt as well as the quasi-steady state nature of the thermal flow calculations. A three dimensional finite element grid for electromagnetic calculations is adapted to a similar axisymmetric finite volume grid for data transfer to the thermal-flow model. Results from the electromagnetic model compare well with operational data from a 175 mm diameter melter. Results from the thermal-flow simulation provide insight toward molten metal circulation patterns, temperature variations, and velocity magnitudes. Initial results are included for a model that simulates the formation of a solid (skull) layer on the crucible base and wall. Overall, the modeling approach is shown to produce useful results relating operational parameters to the physics of steady state melter operation.},
doi = {10.1007/s11663-005-0014-3},
url = {https://www.osti.gov/biblio/15020519}, journal = {Metallurgical and Materials Transactions. B, Process metallurgy and materials processing science, 36B:141-152},
number = ,
volume = 36B,
place = {United States},
year = {Tue Feb 01 00:00:00 EST 2005},
month = {Tue Feb 01 00:00:00 EST 2005}
}