Manufacturing

Projects:

Air Distributor

Air Distributor

INTRODUCTION 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 a…
Blast Furnace

Blast Furnace

Development of a Comprehensive Blast Furnace Package THE PROBLEM 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…
Cooling Tower

Cooling Tower

THE PROBLEM 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…
Diesel Engine Exhaust Manifold

Diesel Engine Exhaust Manifold

INTRODUCTION 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 …
Diesel Engine Intake Manifold

Diesel Engine Intake Manifold

INTRODUCTION 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…
FCC Regenerator

FCC Regenerator

THE PROBLEM 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….
FCC Riser

FCC Riser

THE PROBLEM 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…
GOHT Piping

GOHT Piping

INTRODUCTION 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…
Hydrogen Reformer

Hydrogen Reformer

THE PROBLEM 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…
Mixing Tank

Mixing Tank

INTRODUCTION 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…
Power Plant Components

Power Plant Components

Optimization of Coal-Fired Power Plant Exhaust Air Ducts THE PROBLEM 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 exhau…
Preheating Furnace

Preheating Furnace

INTRODUCTION 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….
Reheating Furnace

Reheating Furnace

THE PROBLEM 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…
Skin Thermocouple

Skin Thermocouple

THE PROBLEM 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…
Spray Cooling

Spray Cooling

THE INTRODUCTION The purpose of this system is to cool chloride gasses 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…

Torpedo Car Analysis

Analysis of Torpedo-Car for Improved Mixing Process Project Description 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….
Ultraformer Reactor

Ultraformer Reactor

THE PROBLEM A 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…
Venturi Scrubber

Venturi Scrubber

THE PROBLEM 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…