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The time dependent behaviour of the large-scale circulation in a Rayleigh-Bénard convection cell exhibits a rich set of different three-dimensional flow features like rotations or torsional modes. In this paper, the applicability of the contactless inductive flow tomography (CIFT) to visualise these flow features in a cylindrical cell filled with GaInSn is investigated numerically. The simulated flow in the cylinder with a diameter of 320 mm and a height of 640 mm serves as a basis to investigate the quality of the reconstructed velocity field by CIFT.

The focus of this presentation is on the numerical study of CIFT on the same RB cell, for an experimentally feasible case of 7x6 sensor configuration and developing the measurement system based on the applicability. The two excitation magnetic fields were kept in the order of 1 mT during the simulation. Sensors are kept outside the RB cell to detect the flow-induced perturbations. The original velocity fields were simulated using OpenFoam solver with a high temporal resolution of 0.5 seconds for 8000 seconds. For reconstruction, only the transient condition between 7000th to 8000th second was considered. Torsional mode analysis is also reported.

To achieve an optimal flow pattern in the mould of a continuous caster, it is desirable to use a tailored control of the flow using electromagnetic actuators (e.g. electromagnetic brakes or stirrers) based on the current flow condition in the mould. However, the rough environment provides a challenge. Contactless Inductive Flow Tomography (CIFT) is a technique that can provide information about the flow structure by visualizing the full velocity field in the mould. In order to reconstruct the flow, the perturbation of an applied magnetic field by the flow is measured. It is obvious that every change of the strength of the magnetic field of an electromagnetic brake influences the measured values. In this paper we cover the challenges of measuring the flow induced magnetic field in the range of nT in the presence of varying magnetic field of the electromagnetic actuators in the range of 100 mT.

Continuous casting is the primary means of production of steel semi-products. It is of paramount importance to keep the quality of the produced stock constantly at a high level to meet the tight margins of the steel industry. Flow conditions in the mould, where the solidification process starts, significantly impact the quality of the end product. Unfortunately, the harsh industrial environment limits the applicable measurement methods to detect any undesired flow conditions, thus limiting the viable control strategies.Contactless Inductive Flow Tomography (CIFT) was previously proposed to identify flow features in the mould of a continuous caster. While the Electromagnetic Brake (EMBr) is a common way to influence the flow, it has a disturbing influence on CIFT measurements which, however, can be compensated. In this work, we introduce the experimental setup, measurement technique, and discuss the control strategy derived from the CIFT flow reconstruction.

In metallurgy, gas is often injected into melts for mixing, degassing or refining. The knowledge of the two-phase flow behaviour is of utmost relevance for optimisation and process control. However, the measurement of the flow structure, the gas distribution and the characteristics of the bubbles is very challenging, because of the opaqueness and the high temperature of industrial relevant melts. Although numerical models have significantly improved recently, it is indispensable to validate the simulation results with experimental data. A new experimental facility has be designed and recently commissioned at Helmholtz-Zentrum Dresden - Rossendorf for systematic investigation of bubble plumes in liquid SnBn at 200 °C. The thermophysical properties of this alloy are very similar to those of steel. The experiment is a 1:5.25 model of an industrial 185 t ladle and consists of a cylindrical vessel with inner diameter of 600 mm, which is filled with 1.7 tons of SnBi. Gas can be injected at the bottom of the vessel at four different locations, which can be equipped with different plug types. Furthermore, low-pressure conditions for modelling VOD (Vacuum Oxygen Decarburization) application can be achieved by the use of a vacuum pump. The gas distribution was measured by an array of 64 resistive probes with a spacing of 10 mm and a time resolution of 1 kHz. This technique allows also the determination of bubble properties like bubble speed and diameter. The velocity of the liquid was measured by Ultrasound Doppler Velocimetry. The paper provides a description of the new setup in detail and presents measurement results characterizing the bubbly flow for varying gas flow rates and different configurations for gas injection.

The contactless inductive flow tomography (CIFT) allows for reconstructing the mean flow structure of liquid metals by measuring the flow induced perturbations of one or more applied magnetic fields, and subsequently inferring the flow field by solving a linear inverse problem. We will give an overview of the application of CIFT to two models of continuous casting available at Helmholtz-Zentrum Dresden – Rossendorf. These include a 1:8 cold model of a slab casting mould under the influence of an electromagnetic brake, and a 1:2 model of a slab mould operating at 250 °C.

The determination of the magnesium level in a titanium reduction retort by inductive methods is often hampered by the formation of titanium sponge rings which disturb the propagation of electromagnetic signals between excitation and receiver coils. We present a new method for the reliable identification of the magnesium level which explicitly takes into account the presence of sponge rings with unknown geometry and conductivity. The resulting inverse problem is solved by a look-up-table method, based on the solution of the inductive forward problems for several tens thousands of parameter combinations. The feasibility of that method is demonstrated by performing numerical simulations and measurements on a model experiment. This method is not limited to the production of titanium but can also be applied to other applications in metal production and processing.

The quality of steel produced by a continuous caster depends on the flow condition during initial solidification in the mould. While the understanding of the flow and its effects is highly desirable, high temperature, opaqueness of the liquid steel and harsh conditions during the production limit viable measurement methods. Contactless Inductive Flow Tomography (CIFT) can provide information about the dominant flow structure in the mould in real time. This information can be used in a control loop for the Electromagnetic Brake (EMBr). Due to the inductive nature of CIFT, every change of the magnetic field strength of the EMBr has a strong influence on the measurements. Changing the strength of the EMBr alters the magnetization vector in its ferromagnetic yoke, which, in turn, generates a signal up to a thousand times higher than the flow induced magnetic field. In this paper, we present a way to compensate these effects of EMBr on CIFT by filling a database containing compensation values. We will also present the preliminary results of a controller that utilizes CIFT and EMBr to actively control the flow in the mould during casting. The experiments are conducted on the Mini-LIMMCAST facility, a laboratory model of the mould of a continuous caster with the rectangular cross-section of 300 × 30 mm2. It is operated with the eutectic ally GaInSn.

Lack of appropriate flow measurement techniques for liquid steel during continuous casting limits the application of control strategies that could improve the quality of the end product. Contactless Inductive Flow Tomography (CIFT) is a promising measurement technique that can provide information about the flow structure in the mould to a real time controller. On this basis, electromagnetic actuators can be used to react on undesired flow conditions in the mould. However, because of their nature, these actuators pose a significant challenge for inductive measurement methods. In this work we describe the influence of an electromagnetic brake on CIFT in a laboratory environment. We also show how this influence can be fully compensated, which facilitates the viability of CIFT as a key ingredient of real time control of continuous casting.

Contactless inductive flow tomography (CIFT) can reconstruct the complex 3-dimensional flow structure of the large scale circulation in liquid metal filled Rayleigh-Bénard (RB) convection cells. The method relies on the precise measurement of weak magnetic fields induced by currents in the conducting liquid arising from the fluid motion in combination with primary excitation fields. The velocity distribution is reconstructed from the magnetic field measurements by solving a linear inverse problem using the Tikhonov regularization and L-curve method. A number of technical challenges have to be overcome to reach the desired accuracy of the measurement signals. In this paper we will describe our design of a new CIFT set-up for a large RB vessel with a diameter of 320 mm and a height of 640 mm. We outline the major factors perturbing the measurement signal of several tens of nanoteslas and describe solutions to decrease mechanical drifts by thermal expansion to a sub-critical level to enable CIFT measurements for high-Rayleigh number flows.

The control of the liquid steel flow in the mould of a continuous caster based on real time flow measurements is a challenging task due to the lack of appropriate measurement techniques. The opaqueness, the high temperature of 1500 C and the chemical aggressiveness of the melt require non-optical contactless methods. In order to reconstruct the complex flow structure in the mould, the Contactless Inductive Flow Tomography (CIFT) is a promising candidate, since it allows the visualization of the flow structure in the melt by applying a magnetic field to the melt, measuring the flow induced perturbation of that field and solving subsequently a linear inverse problem. The combination of this new measurement technique with typical electromagnetic actuators like electromagnetic brakes used in continuous casting, pose a challenge to the CIFT measurement system, because the flow induced magnetic field is in the range of 100 nT and has to be measured robustly on the background of the static magnetic field with the amplitude of 300 mT generated by the brake. In this work we will show recent developments regarding this topic for a small model of a continuous caster in the lab. Furthermore, we will present a new method on how the complex linear inverse problem can be solved in real time providing a time resolution of about 1 Hz.

The contactless inductive flow tomography is a measurement technique for the determination of the flow structure of an electrically conducting liquid. The procedure is based on the measurement of the magnetic field and can potentially be applied for visualisation and online-monitoring of industrial processes as, for example, continuous steel casting or the production of mono-crystalline silicon using the Czochralski crystal growth method. With the aid of the measured field values, the velocity field is reconstructed by solving a linear inverse problem that is described by a system of coupled integral equations. The frame rate of the field measurement is typically in the order of one frame per second, whereas the inversion of the integral equations usually takes about twenty times as long, since a regularisation parameter needs to be determined for each reconstruction. In order to reduce this discrepancy, a new algorithm is introduced in this article. The algorithm relies on the pre-computation of inverted matrices, so that the inversion can be determined solely by performing matrix-vector products. This technique reduces the time required for the inversion process at each reconstruction to same length of time a measurement cycle takes, i.e. about one second. The efficiency of the method will be demonstrated using a modified Rayleigh-Bénard experiment with liquid metal at room temperature.

Nozzle clogging contributes heavily to quality issues seen during the process of continuous casting. The presence of clogging in the Submerged Entry Nozzle (SEN) can significantly change the flow patterns in the mould and therefore impact the quality of the steel product. Also, there is a high risk of inclusions due to parts of the clogging material breaking off and entering the mould. In this paper, we propose a new sensor setup that allows us to detect clogging in the SEN by monitoring the angle of the exiting jet. Based on this clog detection setup, a switched MPC controller is used to keep the angle of the exiting jet between the optimum ranges using an Electromagnetic Brake. This allows the controller to keep the angle of the jet in the optimum range even when clogging occurs in the nozzle. Experimental data from a laboratory scale continuous caster is used to derive the models for the controller.

The common methods of spectral analysis for n-dimensional time series investigate Fourier transform (FT) to decompose discrete data into a set of trigonometric components, i. e. amplitude and phase. Due to the limitations of discrete FT, the data set is restricted to equidistant sampling. However, in the general situation of non-equidistant sampling FT based methods will cause significant errors in the parameter estimation. Therefore, the classical Lomb–Scargle method (LSM) was developed for one dimensional data to circumvent the incorrect behavior of FT in case of fragmented and irregularly sampled data. The present work deduces LSM for n-dimensional (multivariate) data sets by a redefinition of the shifting parameter \tau. An analytical derivation shows, that nD LSM extents the traditional 1D case preserving all the statistical features. Applications with ideal test data and experimental data will illustrate the derived method.

In order to determine the magnesium level in a titanium reduction retort by inductive methods, many interfering influences have to be considered to achieve precise measurement results. By using a look-up-table method, the magnesium level can be identified while taking into account the interfering effects of titanium sponge rings that are forming at the walls of the retort during the reduction process with their unknown geometrical and electrical parameters. This new method uses a combination of numerical simulations and measurements, whereby the simulation model is calibrated so that it represents the experimental setup as closely as possible. Previously we have presented purely theoretical studies on this method. Here, we demonstrate the practical feasibility of that method by performing measurements on a model experiment. This method is not limited to the production of titanium but can also be applied to other applications in metal production and processing.

We require a compact magnetic field measurement system that is able to measure alternating magnetic flux densities in the nanotesla range on the background of signals with constant amplitudes of some hundred millitesla. The signal of interest has a frequency of a few Hertz and must be measured with an amplitude error smaller than 0.1% and a phase error no larger than 10⁻¹ deg. For this we present theoretical and experimental analyses of absolute and first order gradiometric induction coil sensors with sensitivities larger than 500 V/T/Hz and diameters of 28 mm. From their equivalent circuits, we derive the associated complex-valued transfer functions and fit these to calibration measurements, thereby determining the value of the equivalent circuit components. This allows us to compensate their non-linear frequency-dependent amplitude and phase behaviour. Furthermore, we demonstrate the optimization of coils based on Brooks' design of equal squares in the adaptation by Murgatroyd, which maximizes the inductance (and thereby most likely the sensitivity) of the coils. Finally, we design a new coil with a diameter of 74 mm and a sensitivity of 577 V/T/Hz with an analytically predicted equivalent magnetic field noise of around 40 pT/√Hz in the 1 Hz frequency range, which is then confirmed by measurements on the manufactured prototype.

The flow structure in the mold of a continuous steel caster has a significant impact on the quality of the final product. Conventional sensors used in industry are limited to measuring single variables such as the mold level. These measurements give very indirect information about the flow structure. For this reason, designing control loops to optimize the flow is a huge challenge. A solution for this is to apply non-invasive sensors such as tomographic sensors that are able to visualize the flow structure in the opaque liquid metal and obtain information about the flow structure in the mold. In this paper, ultrasound Doppler velocimetry (UDV) is used to obtain key features of the flow. The preprocessing of the UDV data and feature extraction techniques are described in detail. The extracted flow features are used as the basis for real time feedback control. The model predictive control (MPC) technique is applied, and the results show that the controller is able to achieve optimum flow structures in the mold. The two main actuators that are used by the controller are the electromagnetic brake and the stopper rod. The experiments included in this study were obtained from a laboratory model of a continuous caster located at the Helmholtz-Zentrum Dresden Rossendorf (HZDR).

The contactless inductive flow tomography (CIFT) allows the reconstruction of the three-dimensional flow field in liquid metals by applying one or more primary magnetic fields to the melt and measuring the flow induced perturbation of those fields outside the melt. From these measurements, the flow is then reconstructed by solving a linear inverse problem using Tikhonov regularisation technique [1]. In recent experiments, CIFT was able to reconstruct the dynamics of the large scale circulation (LSC) in a small modified Rayleigh-Bénard convection cell which was filled with the eutectic alloy GaInSn and consists of a cylindrical vessel with a diameter and a height of 87 mm [2]. Typical time dependent features of the LSC like azimuthal rotations, cessations as well as torsional modes could be visualised by CIFT. Numerical simulations suggest that a sensor arrangement of 8 sensors in azimuthal direction in 3 planes equally spaced over the height of the vessel is a good choice [3]. The developed CIFT configuration allows for measurement times longer than 12 hours with an accuracy of about 20 nT. Encouraged by these promising results, the measurement system will be adapted to a larger cylindrical Rayleigh-Bénard cell with diameter of 320 mm and height of 640 mm. It is planned to use simultaneously CIFT and UDV in order to reconstruct the global flow while selected flow components are measured in high temporal and spatial resolution with UDV. In this paper we will present the first design of the arrangement of the excitation coils and the magnetic field sensors. Based on this new setup first reconstructions will be shown. Figure 1 shows a preliminary simulation of the flow in the cylindrical vessel as well as the flow induced magnetic field outside the vessel for a constant primary field in vertical direction with the strength of 1mT.

Die Erfindung betrifft eine Anordnung zur berührungslosen Bestimmung einer Geschwindigkeitsverteilung eines Schmelzvolumens in einer Stranggusskokille. Die erfindungsgemäße Anordnung soll eine Messung mit verbesserten Signal-Rausch-Verhältnis ermöglichen und in bestehende Bauteile integriert werden. Die Anordnung weist mindestens eine ein primäres Magnetfeld erzeugende Spule, deren primäres Magnetfeld das Schmelzvolumen durchdringt, und eine Mehrzahl von Magnetfeldsensoren zur Messung des durch die Wechselwirkung der Schmelzbewegung mit dem erzeugten primären Magnetfeld induzierten Magnetfeldes auf. Die Stranggusskokille weist mindestens ein Kokillenelement auf, welches in mindestens einem Bereich mit einem Anschlusselement verbunden ist. Spule und Magnetfeldsensoren sind derart innerhalb des Anschlusselements angeordnet, dass die Magnetfeldsensoren innerhalb des von der Spule umschlossenen Volumens des Anschlusselements angeordnet sind.

The flow pattern in the mould of the continuous casting is an important factor in determining the quality of the steel slabs that are produced in the end of the process. Hence it can heavily influence manufacturing costs due to the scrap percentage. Electromagnetic actuators are frequently used in the continuous casting process to stabilize the flow in the mould and therefore produce higher quality of steel slabs. Usually they are used in open loop but their effect on the flow pattern may be much better directed if they are used as a part of closed loop control based on real time measurements. In this paper, a closed loop controller is proposed that adjusts the magnetic field of an electromagnetic brake using the real time measurement of the angle of the jet flowing from the Submerged Entry Nozzle (SEN). The angle is kept within a specific range by the controller in order to prevent a deeper jet impingement into the mould; this allows us to achieve the desirable double roll flow pattern, and to avoid the entrapment of slugs. The controller is based on a model of the relationship between brake current and jet angle that was obtained using experimental data from a laboratory scale continuous casting plant.

Meniscus velocity in continuous casting process is critical in determining the quality of the steel. Due to the complex nature of the various interacting phenomena in the process, designing model-based controllers can prove to be a challenge. In this paper a NARX neural network model is trained to describe the complex relationship between the applied magnetic field from an Electromagnetic Brake (EMBr) and the meniscus velocity. The data for the model is obtained using a laboratory scale continuous casting plant. The next step was to use Adaptive Model Predictive Control (MPC) to deal with the non-linearity of the model by adapting the prediction model to the different operating conditions. The controller will utilize the EMBr as an actuator to keep the meniscus velocity within the optimum range, and reject disturbances that occur during the casting process such as changing the casting speed.

An overview of current research on inductive level measurement techniques in liquid metals at the HZDR.

This talk represents an introduction into inductive measurement techniques for liquid metals.

This talk represents an introduction into measurement techniques for liquid metals including invasive probes, ultrasonic and inductive methods as well as x-ray radiography.

FIELD: metallurgy. SUBSTANCE: invention relates to the metallurgy industry. Magnesium level and the skull characteristics in the titanium reduction reactor determining method, based on the EMF measurements in the receiving coil, induced by the electromagnetic field from located around the retort the exciting windings set, contains the steps, on which for the determination currents of different frequencies are used, at that, first, by the electrodynamics equations numerical solving, developing the reference base of the EMF calculated values in the located above the reactor receiving coil, with the molten magnesium different specified levels, different titanium skull given positions and sizes for the supply current given set of frequencies in the range of 1–50 Hz, and then, in the process of titanium reduction, with the same set of current parameters in the excitation coils, measuring the EMF values in the receiving coil, which are compared with the reference ones, and the least standard deviation is determined by the smallest standard deviation method, and the molten magnesium level, the titanium skull position and size are judged by it. EFFECT: increase in the molten metal level determining accuracy and the expansion in the method possibilities. 5 cl, 13 dwg