Development of an on-line aqueous particle sensor to study the performance of inclusions in a 12 tonne, delta shaped full scale water model tundish

Detection of particulate matter thinly dispersed in a fluid medium with the aid of the difference in electrical conductivity between the pure fluid and the particles has been practiced at least since the last 50 to 60 years. The first such instruments were employed to measure cell counts in samples of biological fluid. Following a detailed study of the physics and principles operating within the device, called the Electric Sensing Zone (ESZ) principle, a new device called the Liquid Metal Cleanliness Analyzer (LiMCA) was invented which could measure and count particles of inclusions in molten metal. It provided a fast and fairly accurate tool to make online measurement of the quality of steel during refining and casting operations. On similar lines of development as the LiMCA, a water analogue of the device called, the Aqueous Particle Sensor (APS) was developed for physical modeling experiments of metal refining operations involving water models. The APS can detect and measure simulated particles of inclusions added to the working fluid (water). The present study involves the designing, building and final application of a new and improved APS in water modeling experiments to study inclusion behavior in a tundish operation. The custom built instrument shows superior performance and applicability in experiments involving physical modeling of metal refining operations, compared to its commercial counterparts. In addition to higher accuracy and range of operating parameters, its capability to take real-time experimental data for extended periods of time helps to reduce the total number of experiments required to reach a result, and makes it suitable for analyzing temporal changes occurring in unsteady systems. With the modern impetus on the quality of the final product of metallurgical operations, the new APS can prove to be an indispensable research tool to study and put forward innovative design and parametric changes in industrially practised metallurgical operations.