Engineering

Virtual Engineering is a technology that integrates and combines geometric models, analysis, simulation, optimization and other decision making tools within a virtual environment to facilitate multidisciplinary and collaborative product realization. The objective is to use advanced simulation and visualization to help industry for process/product design, trouble shooting and optimization to address issues on productivity, energy, environment, and quality.

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…
Airplane RF Propagation

Airplane RF Propagation

THE PROBLEM Air to ground (ATG) communication systems are emerging as an effective way to provide broadband services to the airborne commercial market, because it provides a relatively inexpensive connectivity solution. For ATG systems – as is the case…
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…
Blast Furnace

Blast Furnace

Pulverized Coal Injection in a Blast Furnace THE PROBLEM High rate pulverized coal injection (PCI) has been recognized as an attractive technology in the iron-making process. However, high PCI rate may be limited because of incomplete coal burning…

Blast Furnace – Iron Making

Project Description Severstal Dearborn operates a single blast furnace at its Dearbom (MI) facility. The furnace was rebuilt and extensively modernized in 2007 and is a high productivity furnace. Severstal Dearborn is interested in gaining an …
Blast Furnace Co-Injection

Blast Furnace Co-Injection

THE PROBLEM To improve the efficiency of the blast furnace, it is necessary to achieve a considerable decrease of coke and total energy consumption for primary metal production along with minimal environmental impacts. Injection of auxiliary fuels…
Boiler

Boiler

THE PROBLEM In modern iron and steel plant, boiler units provide heat and electrical power for iron-making processes. Units in ArcelorMittal’s facility suffer from low efficiency and sidewall overheating which could lead to operation shutdown. T…
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…
Exhaust Manifold

Exhaust Manifold

Thermal Stress for a Liquid-Cooled Exhaust Manifold THE PROBLEM Liquid-cooled exhaust manifolds are widely used in turbocharged diesel engines. The exhaust manifold which is mounted on the cylinder head of an engine collects the exhausted gas…
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…
Heater Ductwork Pressure Swing

Heater Ductwork Pressure Swing

THE PROBLEM The heater in one local refinery is used to preheat the distillate and hydrogen before the reactors. Recent operation of the heater has been challenging. The heater has exhibited swings exceeding 1 in WC but the target operating draft…
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…
Life Prediction in an Overhead Crane

Life Prediction in an Overhead Crane

THE PROBLEM Many large-scale industrial processes require scheduled maintenance and repairs.  Industrial repair is costly and can often be dangerous due to environmental hazards such as height. The application of modern computational methods such …
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…
Orifice Plate Reversal

Orifice Plate Reversal

THE PROBLEM An orifice plate is a plate with a hole in the center that is placed in a pipe in which a fluid flows. The fluid is forced to converge through the orifice. The shape of the orifice induces changes in velocity and pressure.  The accidental …
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…
Scrubber Duct

Scrubber Duct

THE PROBLEM ArcelorMittal Plant, Burns Harbor (AM-BH) operates a sintering plant. Sinter produced is used as a supplement additive during iron producing process. The flue gas generated during the process is cleaned by a Flooded Disc Scrubber (Fig.1)….
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…
Storage Tank

Storage Tank

THE PROBLEM BP Whiting Refinery often experienced problems with its above ground gasoline storage tanks in the winter as snow would be blown into the tanks through their center and peripheral vents and accumulate on their internal floating roofs.  …

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….
Tuyere

Tuyere

THE PROBLEM IH7 blast furnace uses copper, water-cooled nozzles (tuyeres) as the injection point for high velocity, pre-heated air mixture to the blast furnace for iron oxide reduction.  These tuyeres periodically fail and each failure a significant …
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…
Urea Decomposition Chamber

Urea Decomposition Chamber

THE PROBLEM The Decomposition Chamber inspections indicate significant debris formation in the chamber. The presence of white debris coating the inner liner walls, floor, lances, and the burner swirler indicate that the urea to ammonia conversion…
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…
Virtual Boiler

Virtual Boiler

THE PROBLEM Boiler-operations trainees at NIPSCO coal-fired power stations receive comprehensive training in boiler operation procedures and are given 2D, non-scaled representations of the plant’s steam, coal cycle, and limited key components. These 2…
Virtual Groundwater

Virtual Groundwater

Simulating Solute Transport in Groundwater THE PROBLEM Groundwater, as the major contributor to the fresh water resource, has been contaminated by agricultural and industrial activities in recent years. However, it is extremely difficult to…
Wind Energy

Wind Energy

  Mixed Reality Simulators for Wind Energy Education US Dept. of Education – FIPSE Award: $749,853 January 1, 2011 – December 31, 2013 Click here for the full FIPSE project page THE PROBLEM The issue of transferring learned …
Wind Flow Simulations

Wind Flow Simulations

INTRODUCTION Wind energy, as one of the cleanest renewable energy, is becoming increasingly important. Both the installed wind power and the generated energy are increasing by 30% per year world-wide. Economical performance of a wind turbine is determined…
Campus Turbine Simulation

Campus Turbine Simulation

INTRODUCTION As part of efforts in wind  energy education, Purdue University Calumet will be installing a wind Vertical Axis Wind Turbine (VAWT) on the Classroom Office Building (CLO) to generate electricity and provide students with a functional …