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<p>Preheating hot metal ladles is essential for steelmaking thermal balance and lining protection, yet conventional designs suffer from low efficiency, severe heat loss, and uneven heating. This study proposes a plunger-type hot metal ladle with an internal adjustable plunger to reduce heating volume and enable directional heat transfer. A coupled numerical model (<i>k</i>–<i>ε</i> turbulence, P-1 radiation, eddy dissipation combustion) was developed in Fluent to investigate the effects of plunger volume ratios (0–60%) on preheating performance and NO<sub><i>x</i></sub> emissions during 30&#xa0;min of oxy-fuel combustion of converter gas. The results show that increasing the plunger volume ratio transforms the flow field to wall-attached flow, elevates average ladle temperature (1233.6&#xa0;K to 1311.7&#xa0;K) and improves thermal efficiency (9.43% to 12.21%). NO<sub><i>x</i></sub> emissions remain consistently at a low level when the plunger volume ratios is ≤ 40%, while exceeding 40% causes ultra-high local temperatures (&gt;2850&#xa0;K) and exponential NO<sub><i>x</i></sub> rise due to thermal NO<sub><i>x</i></sub> mechanisms. A 40% plunger volume ratio is determined as optimal, providing theoretical support for the industrial design and process optimization of plunger-type hot metal ladles.</p>

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Efficiency Enhancement and Emission Reduction of Plunger-Type Hot Metal Ladle Preheating via Oxy-fuel Combustion Parameter Regulation

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Lin Zhu,
  • Guangqiang Liu,
  • Lanyue Xu,
  • Xinyi Cong

摘要

Preheating hot metal ladles is essential for steelmaking thermal balance and lining protection, yet conventional designs suffer from low efficiency, severe heat loss, and uneven heating. This study proposes a plunger-type hot metal ladle with an internal adjustable plunger to reduce heating volume and enable directional heat transfer. A coupled numerical model (k–ε turbulence, P-1 radiation, eddy dissipation combustion) was developed in Fluent to investigate the effects of plunger volume ratios (0–60%) on preheating performance and NOx emissions during 30 min of oxy-fuel combustion of converter gas. The results show that increasing the plunger volume ratio transforms the flow field to wall-attached flow, elevates average ladle temperature (1233.6 K to 1311.7 K) and improves thermal efficiency (9.43% to 12.21%). NOx emissions remain consistently at a low level when the plunger volume ratios is ≤ 40%, while exceeding 40% causes ultra-high local temperatures (>2850 K) and exponential NOx rise due to thermal NOx mechanisms. A 40% plunger volume ratio is determined as optimal, providing theoretical support for the industrial design and process optimization of plunger-type hot metal ladles.