Blast Furnace – Operation Stability Monitoring Program

Results of computer simulation

Ironmaking is a capital and energy intensive process. The blast furnace process is a counter current moving bed chemical reactor to reduce iron oxides to iron, which involves complex transport phenomena and chemical reactions. There are many important parameters to evaluate the operation stability in the blast furnace. With the Blast Furnace Operation Stability Monitoring Program, it will make operators easier to monitor the operation.

Batch Anneal Furnace CFD Simulation and Optimization

Detailed View inside the Inner

Annealing is a heat treatment process widely used in the steelmaking industry to transform metal products into a more ductile and useable form. This process is usually performed by heating the material to above the recrystallization temperature for a prolonged period of time before cooling. Improving the product quality and optimizing the operating efficiency are goals of this project. In order to obtain a better understanding of the current annealing process which influences the cycle time and coil temperature, Computational Fluid Dynamics (CFD) was employed to simulate the annealing process.

LCCBF Prototype CFD Thermal Modeling

Anode Furnace Overview

The Lazar Continuous Carbon Baking Furnace (LCCBF) has been designed by Lazar Company. In order to complete the designs phase within the time and capital budget, Computational Fluid Dynamics (CFD) was employed at CIVS to evaluate the performance of the existing design as well as to optimize and finalize the blue print before the construction phase. Through the CFD, a three-dimensional geometry model has been created and the anode baking process has been simulated, and temperature profiles have been focused on.

Pipe Sliding Support Analysis

Support colored by scaled deformation from gravity

Many industries require large amounts of piping to transport air, steam, water, and other fluids across long distances. These installations must often account for the slight movement of the piping due to internal and external effects such as thermal expansion or force applied to the piping. One method of accounting for these movements is by mounting the pipes to a sliding support which is capable of allowing small amounts of movement. However, the addition of these supports can introduce a new point of failure if they are structurally weaker than a fixed mounting point.

Vertical Edger FEA Structural Analysis

Simulation of a vertical edger

The vertical edger is a very important component in a steel mill. The reduction of steel slabs applies considerable amount of force on the vertical edgers as the slabs are molded into a much longer, thinner strip in preparation for the finishing mill. There has been a recent failure in the gear housing at one of the steel mills. The amount of force that the housing can withstand is unclear and the remaining life of each component is hard to predict. As the components life is determined by many factors, a comprehensive structural analysis was conducted using Finite Element Analysis (FEA).