Molten steel flows through a tundish with Multi-Hole-Double-Baffles, removing micro-inclusions.

Clean Steel Revolution: How New Tech is Purifying Metal at the Micro-Level

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Elliot Brynn in Tech & Innovation December 2025 • 4 min read.

"Innovative tundish design tackles micro-inclusions, promising stronger, cleaner steel for demanding applications."


In the relentless pursuit of superior materials, the steel industry constantly seeks innovations to enhance the quality and reliability of its products. A key focus is the removal of non-metallic inclusions, microscopic impurities that can compromise the mechanical properties of steel. Traditionally, techniques like turbulence inhibitors and gas-curtain devices have been employed within the tundish, the vessel that acts as a crucial metallurgical reactor during continuous casting, to address these issues. However, with ever-increasing demands for ultra-pure steel, especially in high-speed casting environments, more effective solutions are needed to target even the smallest inclusions.

Micro-inclusions, ranging from 1 to 50 micrometers in size, pose a particular challenge. Existing tundish designs often struggle to efficiently remove these tiny particles. To combat this, researchers have developed the Multi-Hole-Double-Baffles (MHDB) device, a novel flow control system engineered to optimize the removal of these micro-inclusions. The core of this technology lies in its ability to manipulate the flow of molten steel within the tundish, creating an environment that encourages the aggregation and subsequent removal of these unwanted particles.

This article delves into the groundbreaking research surrounding the MHDB device, exploring its design, functionality, and the underlying mechanisms that enable it to achieve superior micro-inclusion removal. Through a combination of numerical simulations and physical modeling, scientists have gained valuable insights into how this technology can revolutionize steelmaking practices, leading to cleaner, stronger, and more dependable steel for a wide range of applications.

How Multi-Hole-Double-Baffles (MHDB) Works?

Molten steel flows through a tundish with Multi-Hole-Double-Baffles, removing micro-inclusions.

The MHDB system represents a significant advancement in tundish technology, offering a precise method for controlling the flow of molten steel and enhancing the removal of micro-inclusions. The core of the MHDB device is its unique baffle design, featuring multiple holes strategically positioned to influence the movement of the liquid steel. This design allows for the manipulation of flow patterns, residence time, and turbulence within the tundish, all factors that play a crucial role in the separation and removal of impurities.

The effectiveness of the MHDB device hinges on several key design elements:

  • Hole Array Configuration: The arrangement of holes in the baffles directly impacts the trajectories of inclusions within the molten steel. Different configurations can promote specific flow patterns, optimizing either inclusion collision and growth or their capture at the surface.
  • Baffle Placement: The position of the double baffles within the tundish is critical for maximizing their influence on the overall flow field. Careful placement can ensure that the entire volume of molten steel is effectively treated, minimizing dead zones and promoting uniform inclusion removal.
The design variations of the MHDB primarily focus on the arrangement of guide-holes within the baffles. The research investigated three distinct configurations: Upper-In-Lower-Out (UILO), Lower-In-Upper-Out (LIUO), and an X mode. In the UILO configuration, molten steel enters through upper holes in the first baffle and exits through lower holes in the second baffle. The LIUO configuration reverses this flow, while the X mode combines elements of both, creating a more complex flow pattern. Each configuration is designed to create unique flow dynamics that influence the behavior and removal of micro-inclusions.

The Future of Clean Steel

The development and implementation of the MHDB device represent a significant step forward in the pursuit of cleaner, higher-quality steel. By precisely controlling the flow dynamics within the tundish, this technology enables the efficient removal of micro-inclusions, leading to improved mechanical properties and enhanced reliability of steel products. As the demand for ultra-pure steel continues to grow, innovations like the MHDB device will play an increasingly vital role in meeting these stringent requirements and driving advancements across various industries.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.3390/met8080611, Alternate LINK

Title: Removal Mechanism Of Microscale Non-Metallic Inclusions In A Tundish With Multi-Hole-Double-Baffles

Subject: General Materials Science

Journal: Metals

Publisher: MDPI AG

Authors: Yan Jin, Xiaosen Dong, Fu Yang, Changgui Cheng, Yang Li, Wei Wang

Published: 2018-08-06

Everything You Need To Know

1

What exactly is the Multi-Hole-Double-Baffles (MHDB) device?

The Multi-Hole-Double-Baffles (MHDB) device is a novel flow control system designed to optimize the removal of micro-inclusions from molten steel within the tundish. These micro-inclusions are microscopic impurities, ranging from 1 to 50 micrometers in size, that can compromise the mechanical properties of steel. The MHDB utilizes a unique baffle design with strategically positioned holes to manipulate the flow of molten steel, encouraging the aggregation and removal of these unwanted particles. Its significance lies in its ability to produce cleaner, stronger, and more reliable steel, which is crucial for various demanding applications.

2

Why is the MHDB device considered important in steelmaking?

The MHDB device is important because it addresses the challenge of removing micro-inclusions in steel, which are particularly difficult to eliminate using traditional methods. These impurities can significantly impact the mechanical properties of the steel, making it less reliable for critical applications. The MHDB’s design offers a more effective solution by precisely controlling the flow of molten steel within the tundish, enhancing the removal of these tiny particles. This is particularly important with increasing demands for ultra-pure steel across various industries.

3

How does the MHDB system work to remove impurities from molten steel?

The MHDB system works by manipulating the flow of molten steel within the tundish through a strategically designed baffle system. This system features multiple holes that influence the movement of the liquid steel. The effectiveness of the MHDB is determined by the hole array configuration, the placement of the double baffles, and the specific flow patterns created. The different configurations such as Upper-In-Lower-Out (UILO), Lower-In-Upper-Out (LIUO), and X mode are designed to create unique flow dynamics to influence the behavior and removal of micro-inclusions, optimizing the removal of unwanted particles.

4

What are the broader implications of using the MHDB device in steel production?

The implications of the MHDB device are far-reaching. By enabling the production of cleaner steel, the MHDB technology leads to improved mechanical properties, such as increased strength and durability. This results in steel products that are more reliable and suitable for demanding applications. This advancement is particularly vital in industries where the integrity of the steel is critical, such as in automotive, aerospace, and construction, where the performance of materials directly impacts safety and product lifespan. The ability to meet stringent requirements for ultra-pure steel drives innovation and progress across various industries.

5

What are the different configurations of the Multi-Hole-Double-Baffles (MHDB) device and how do they differ?

There are three main configurations of the MHDB device investigated. These are: Upper-In-Lower-Out (UILO), Lower-In-Upper-Out (LIUO), and X mode. In the UILO configuration, molten steel enters through the upper holes in the first baffle and exits through the lower holes in the second baffle. The LIUO configuration reverses this flow, while the X mode combines elements of both. Each configuration creates unique flow dynamics within the tundish, influencing the behavior and removal of micro-inclusions. The specific arrangement of the holes impacts the flow patterns and the efficiency of inclusion removal, allowing for optimized performance based on the application requirements.