Manufacturing

Projects:

Air Distributor

Air Distributor

The air distributor is a duct system that distributes air from one inlet to eleven outlets that feed into a hydrogen reformer. The objective of the project is to analyze the the mass flow rate of air through the different outlet and have a uniform mass flow rate at each outlet. Combustion air ...

The computational geometry of the air distributor

Air Distributors

Combustion air distributors are widely used in many areas such as the automotive industry, petroleum industry and steel industry. Air distributors in this project are duct systems that distribute air from one inlet to eleven outlets that feed into a hydrogen reformer. Three inner distributors are arranged in the middle and two outer distributors are ...

Support colored by scaled deformation from gravity

Analysis of a Sliding Pipe Support

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 ...

Anode Furnace Overview

Anode Baking Furnace

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 ...

Detailed View inside the Inner

Batch Annealing

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 ...

Looking into a model of a blast furnace

Blast Furnace – Comprehensive Package

The driving forces for technological improvements are particularly strong in the iron making process, since the extraction of iron from ore is capital and energy intensive. A blast furnace represents the predominant iron-producing process in North America. Due to difficulty in measurements, advanced Computational Fluid Dynamics (CFD) simulation has been recognized as a powerful technology ...

Results of computer simulation

Blast Furnace – Operation Stability Monitoring Program

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 ...

computational domain of the suction bay

Cooling Tower

Two cooling water units were being constructed at the BP Whiting Refinery facility. BP Whiting Refinery would like some assurance that, with the current design, surface vortex would not form in the cooling pump suction bay. Surface vortex could reduce pump water delivery and reduce pump reliability. Computational Fluid Dynamics (CFD) was used to model ...

Velocity and pressure distribution of exhaust system

Diesel Engine Exhaust Manifold

An exhaust manifold is a part of the internal engine that collects the exhaust gases from multiple cylinders into one pipe. In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide emissions reduction technique used in diesel engines. EGR works by recirculating a portion of an engine’s exhaust gas back to the ...

Velocity magnitude and EGR mass fraction distribution of intake system

Diesel Engine Intake Manifold

An intake manifold is one of the primary components regarding the performance of an internal combustion engine. In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide emissions reduction technique used in diesel engines. EGR works by recirculating a portion of an engine’s exhaust gas back to the engine cylinders. A typical intake ...

Fig. 2 -Virtual Reality Regenerator Visualization

FCC Regenerator

Fluid catalytic cracking (FCC) is the most important conversion process used in petroleum refineries, and FCC regenerator is a key part of an FCC unit to recover solid catalyst activity by burning off the coke deposit on the catalyst surface. There are very limited ways to observe the flow and reactions inside. BP Refining and ...

Image of virtual reality visualization of an FCC Riser

FCC Riser

In the petroleum refining process, heavy crude oil is broken into lighter and more valuable products – such as gasoline and olefinic gases – through fluid catalytic cracking (FCC) process. Hot powdered catalysts are mixed with crude oil to heat up the crude oil to above its boiling temperature to break its long chain molecules. ...

Goht Piping

GOHT Piping

A new Gasoil Hydrotreater (GOHT) is design to produce low-sulfur feed for the Fluidized Catalytic Cracking (FCC) Units by combining high-sulfur gasoil with hydrogen and passing the mixture through a catalyst bed at high temperature and pressure. Uneven splitting and/or phase separation of the original stream can lead to higher mass flow in some ...

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Hydrogen Reformer

A hydrogen reformer furnace is used to convert natural gas into hydrogen through a series of catalytic reactions. The combustion process in the furnace provides the heat to maintain the chemical reaction inside the catalyst tubes.

Temperature control of the catalyst tubes is a fundamental design requirement of the hydrogen reformer furnace, as the temperature should ...

Diagram showing ladle geometry

Ladle Heat Loss

Approximately 100 million tons of liquid steel are produced at an estimated value of $22 billion annually in the United States. And the energy consumption is very high during the ladle process. The quality control of the molten steel in the ladle is an extremely important requirement for profitable steel mill operations. During the ladle ...

Mixing Tank

Mixing Tank

The mixing tank is a little like the mixer that you have in your kitchen, except much larger. It’s used to remove impurities from iron ore before the ore is put into the blast furnace. The goal of this project is to analyze a mixing tank and understand why an uneven distribution of ore existed ...

Simulation Result of Logistic System

Plant Logistic Optimization Study

Due to the development of factory X, the outbound shipment needs to be increased to meet the market demand. Therefore, factory X is considering optimizing its logistic system to maximize the shipment capability of the logistic system. The main problems are focused on how to better understand the operation conditions of factory, decrease traffic jams ...

CFD Simulation Results

Power Plant Components

NIPSCO Bailly Generating Station had a problem with a coal fired boiler. After completing the installation of pollution control equipment, the exhaust air ducts, through which exhaust gas from coal combustion is discharged to pollution control units, were operating at just 85 to 90 percent of maximum capacity. The reduced operating capacity ...

Preheating Furnace

Preheating Furnace

On an aluminizing line, the steel is first passed through a preheating furnace to help bring the strip up to temperature. The preheating furnace in this case is a DFF ( Direct Fired Furnace ) and has a total of 40 natural gas burners. The goal of this project is to get a better understanding ...

geometry of the reheating furnace fig2

Reheating Furnace

A reheating furnace is a critical component in value-added steel production. These furnaces can have a significant impact on both product quality and total cost. In order to obtain a better understanding of the furnace operation, a Computational Fluid Dynamics (CFD) analysis had been conducted to examine a reheating furnace at ArcelorMittal. The comparison of ...

Figure 3

Skin Thermocouple

Skin thermocouples are a widely used type of temperature sensor for measurement and control. However, local hot spots sometimes occur in thermocouples during operation. This phenomenon will result in the inaccurate measurement of the temperature. In

addition to the inaccuracies, hot spots can also reduce the lifetime of the heater pipes. For this reason, there are ...

Detailed single nozzle

Spray Cooling

The purpose of this system is to cool chloride gases to below the aqueous dew point which will help prevent corrosion in systems further down the line. The main method of lowering the temperature is to spray water droplets in the flow. The main objective of this project is to use CFD and other calculations ...

Computational geometry

Torpedo Car

Torpedo cars in steel plant are used to deliver liquid iron which will be processed by the basic oxygen furnace in the steel making workshop. Desulphurization is performed during the liquid iron delivery process by injecting desulphurization agents into the liquid iron with nitrogen as the carrier gas.

Torpedo Car Analysis

Transport of hot metal, produced in blast furnace, to the basic oxygen furnace, is carried out in special designed vessels of elongated cylindrical shape known as torpedo-car. Hot metal pretreatment e.g., desulfurization can be carried out in torpedo-car by injecting CaO powder, MgO powder or combination of both. A detailed analysis of fluid flow and ...

Velocity-contours-on-vertical-planes-inside-the-reactor

Ultraformer Reactor

An Ultraformer at a refinery produces a high-octane blending component and mixed xylenes for chemical feedstock from hydrotreated heavy naphtha (sulfur and nitrogen removed to non-detectable limits) by converting paraffins and naphthenes to aromatics. It has been observed that hotspots develop in the tail reactor and large amounts of coke form in the catalyst bed, ...

Simulation Results

Venturi Scrubber

A venturi scrubber is a device which utilizes liquid to remove fine particulates from gaseous streams. ArcelorMittal USA has developed a pollution control process using venturi scrubber for removal of particulates from the exhaust gas in a sinter plant. However, excessive wear on the side wall of the throat has been found leading to considerable ...

Simulation of a vertical edger

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 ...

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Virtual Blast Furnace

The blast furnace is one of the most energy and capital intensive processes in iron and steelmaking. Complex phenomena and difficulties in taking measurements have led to using computational fluid dynamics (CFD) numerical simulations for optimization and better understanding of processes within blast furnaces. However, increasingly complex CFD results are difficult to interpret and communicate ...