Live Video and 3D Modeling Present a Complete Picture of Past, Present and Future Investments
The RDA had funded numerous improvements throughout the region. The question before the organization in early 2012 was, how can these investments be effectively communicated to legislators in Indianapolis, virtually none of whom had ever visited Northwest Indiana or seen the changes?
The answer was provided by (CIVS). Working closely with RDA staff, CIVS faculty and students developed an eight-minute 3D presentation featuring all of the RDA’s initiatives and laying out the economic impact of its projects, as well as, the overall return on investment to Northwest Indiana. The project, which took approximately three months to complete combined satellite and aerial photography, live video and 3D modeling of projects under construction to present a complete picture of past, present and future RDA investments.
“We could not have been more please by the results of this partnership with CIVS and Purdue Calumet,” says RDA President and CEO Bill Hanna. “They gave us a spectacular tool with which to tell our story, and produced it on a very tight schedule and on a very reasonable budget. We plan to keep working with CIVS to update the video as we complete existing projects and move on to new initiatives in the region.”
President and CEO
Indiana Regional Development Authority
Edge Results Using State-of-the-Art Technologies
“The creation of the shaft simulator has been an enormous challenge, but I believe the key components that have been developed are already shedding new light on what affects blast furnace fuel rate. They will undoubtedly also form the basis for awesome training modules, removing some of the ‘mystery’ and ‘rules of thumb’ that have dominated blast furnace practice for decades. CIVS is an excellent concept that offers cutting- edge results using state-of-the- art technologies.”
Strategic Industrial Markets Project Manager
Union Gas Limited
CIVS Project Saves NIPSCO 1.9 Million Dollars Annually
Purdue Calumet and research engineers from CIVS collaborate with NiSource and its power subsidiary NIPSCO with results that will save NIPSCO 1.9 million dollars in yearly savings. This project is one of many where CIVS has created positive outcomes for the client. Through the use of sophisticated technologies and cutting edge research the center is able to provide its industry partners with solutions to their intricate industry specific problems.
“After completing the installation of pollution control equipment on our smaller Unit 7, we found that we could no longer get full flow or load through the larger Unit 8. We experienced what’s considered a derate of roughly 20 megawatts out of the 320 net megawatts of capacity. The CFD study initially conducted by the students showed recirculation in the duct downstream of the “Y” where the output of the two units is combined. Further CFD study resulted in an optimized arrangement of turning vanes, thereby improving flow in the ducts. Those vanes were installed and the derate went away.
Using rather rough estimates of a 20 MW derate, 10 months per year of operation of Unit 7 and Unit 8, combined with 14 hours per day of full load operation of both units, we used a cost/benefit model to estimate the benefits coming from resolving that derate. The result is an estimated $1,900,000 annual savings.”
Bailly Generating Station
CFD for Problem Solving
“In recent years ArcelorMittal has come to the Purdue Calumet CFD Lab for help simulating a number of industrial problems including; mixing tanks for raw materials preparation, blast furnace fuel utilization and campaign life, billet reheat furnace energy efficiency, a sinter plant venturi scrubber for reducing operating downtime and cost, and now the strip heating uniformity problem described above. In each case CFD simulation has allowed us to gain valuable insight into the complex heat transfer and fluid flow phenomenon that occur in these processes which has led to significant process improvements. We believe that simulation is a very powerful and economic tool for process advancement. The Center’s new 3D visualization capabilities will now bring process understanding and speed of solutions to an even higher level. “
“CFD models developed by Purdue Calumet have helped us solve a variety of complex problems in the steel industry over the last several years. CFD is now widely accepted in the industry as a quick and economical problem solving and design tool. The addition of virtual reality will now bring process understand to a much higher level as the modeler/designer can step inside the process and really get a “feel” for what is going on. “
Director, Process Research
ArcelorMittal R&D – East Chicago
CFD Helps Students to Visualize
“With the help of tools like CFD, today’s student can visualize fluid mechanics at a “micro-level,” he said. “Historically, engineers solved problems in the field by measuring variables at a couple of different locations, often great distances apart. Then, they would use the available data to draw conclusions about large systems. Thanks to the ability to run complex computer simulations, today’s student can work with individual droplets inside a pipe, instead of streamlines.”
“With this new technology, our engineers can take a look inside a pipe, for example, and examine it at a much closer level to identify corrosion or other emerging issues, just like a doctor can now use MRI technology to better examine a patient in a non-invasive manner.”
Benefits of Visualization
“When we evaluate a situation, it’s difficult for us to gain a clear picture of exactly what’s happening inside, because we’re only able to look at raw data. But when Purdue Calumet installed its (CIVS) visualization lab, it allowed us physically to see everything. It makes it so everybody can see the exact same thing.”
“You would actually run air through the model and drop in particles to see how it operated, “but that only shows you how flows work in normal air. The CFD, on the other hand, takes into account all those other factors that a normal physical model cannot, such as temperatures and factors that impact the air flow. Additionally, CFD allows you to adjust any particular aspect by programming it in; you can get a different look each time. It’s simply more time consuming to conduct the same simple test on a physical model.”
Manager of Maintenance and Engineering
NIPSCO’s Bailly Generating Station
Practical Application for Better Understanding
“I can understand why students are so excited about these projects. They have practical applications and present the information in a manner that almost anyone can understand.”
American Society of Mechanical Engineering
Chicago Section Chair
Virtual Reality to the Rescue!
Purdue Calumet’s new center for Innovation through Visualization and Simulation troubleshoots for industry, offers unique learning experience for students.
Project Manager for Lazar Anode Technologies LLC
Find out what Michael Snyder’s experience was like after working with CIVS in simulation development and how he was introduced to CIVS. Click here to see presentation slides covering Lazar’s experience with CIVS.
Engineering Supervisor for Bailly Generating Station
Hear Tim Wright’s thoughts on collaborating with CIVS, pursuing an effective trial and error process, and how the chosen simulation design saved NIPSCO $1.9 million per year.
General Manager for Global R&D East Chicago – ArcelorMittal
Listen on how CIVS has continually improved processes for ArcelorMittal using our advanced science applications.
Chenn Q. Zhou
Director for Center for Innovation through Visualization and Simulation
Through the eyes of Professor Chenn Zhou, learn how CIVS was founded and how it established a strong connection with the industry.