Numerical and experimental analysis of heat transfer behavior in a steel ladle during holding process

The efficient thermal management of steel ladle is critical for operational safety, refractory life, and energy efficiency in steelmaking. This study integrates a three-dimensional (3-D) finite element model with infrared radiation (IR) thermography experiment to analyze the steady-state heat transfer behavior of a 270-ton steel ladle during the holding process. The temperature-dependent refractory properties are considered in the analysis. Based on the available experimental data, the equivalent heat transfer coefficients for the model are modified iteratively. Mesh convergence and uncertainty propagation are performed to ensure model robustness. The simulation results reveal a maximum temperature of 260 °C in the ladle shell and are compared with the measured value. The variations in temperature differences are suspected of thermal damage to the refractory lining. This damage is discussed and presented from visual inspection. A concentrated high-temperature area appears at the slag line. The insulation layer shows a steep temperature drop, indicating an excellent performance in reducing heat loss. The heat dissipation from the barrel surface is the major pathway for the steel ladle and accounts for almost half of the total. These findings support targeted monitoring and insulation strategies for critical shell areas, enabling more accurate predictions of refractory material service life and reducing energy consumption in steel production process.