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:

Wind2

3D Wind Field Construction with High Performance Computing and VR Visualization

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 by the efficiency of the blade. If the airflow over wind turbine blades could be controlled fully, the ...

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 ...

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 ...

Simulation of gas velocity distributions.

Blast Furnace – Co-Injection of Natural Gas and Pulverized Coal

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 such as natural gas and pulverized coal can effectively contribute to the improvement of blast furnace in the last two ...

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 ...

Schematic of the CFD Model

Blast Furnace – Fuel Rate Minimization

The blast furnace (BF) process is a counter-current moving-bed chemical reactor to reduce iron oxides to iron, which involves complex transport phenomena and chemical reactions. The fuel economy of the blast furnace process is directly coupled to the gas and burden distributions. The knowledge of gas distributions and its influential factors in a blast furnace ...

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 ...

Blast furnace hearth

Blast Furnace Hearth Flow and Erosion Model

The campaign life of a blast furnace is highly dependent on residual thickness of refractory lining in the hearth. The progress of hearth lining erosion is greatly affected by hot metal flow patterns and heat transfer in refractory under different operating conditions. Thus it is of great importance to monitor the hearth erosion and adjust ...

Geometry and charging setup

Blast Furnace Shaft CFD Model

In recent years, improving the blast furnace efficiency and lowering the consumption of metallurgical coke is become increasingly important for iron making industry. Advanced in-house blast furnace shaft Computational Fluid Dynamics (CFD) in-house code has been previously developed for design and trouble shooting of the blast furnace. The user-friendly interface is important for the user ...

Several diagrams of simulation results.

Boiler – Simulation of Industrial Boiler Firing Metallurgical Gases

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. The goal is to improve the energy efficiency so that less fuel would be needed (especially natural gas which has to be ...

The ESP of the city of Hamilton, OH Municipal Electric Plant

Boiler MACT Compliance

The city of Hamilton, OH Municipal Electric Plant (Hamilton), operates a pulverized coal fired boiler (No. 8) subject to the boiler Maximum Achievable Control Technology (MACT) standards issued by the US EPA. EQ Engineers, LLC (EQE) has been employed by Hamilton to study and evaluate options for achieving MACT standards on a consistent basis as ...

Computational geometry

CFD Analysis of a Torpedo Car for Desulphurization

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.

Blast Furnace Process

CFD Model for Blast Furnace Pulverized Coal Injection and Coke Combustion Model

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 and other technical barriers. Understanding of the essential behavior and the combustion process of pulverized coal with natural gas co-injection is very important. Due to the ...

Detailed single nozzle

CFD Simulation of Top Spray Cooling System in a Blast Furnace

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 ...

Detailed View inside the Inner

CFD Simulations and Optimization of a Batch Anneal Furnace

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 ...

Two types of blades and three different tank configurations

CFD Simulations of Solid Liquid Mixing in a Stirred Tank for Troubleshooting and Optimization

A process to remove impurities from iron ores by chemical leaching is under development. The chemical leaching process can be used to remove one or more components of a solid phase that can be dissolved into a liquid phase. The leaching process is often accomplished through the use of a mechanical agitation system in ...

Anode Furnace Overview

CFD Thermal Modeling of a Prototype LCCBF

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 ...

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 ...

Diagram of the transient temperature distribution.

Exhaust Manifold

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 and then sends it to a turbocharger. The manifold suffers from relatively high operating temperature which can lead to significant thermal expansion. Therefore, expansion causes significant thermal stress ...

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 ...

Geometry for the heater

Heater Ductwork Pressure Swing

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 is 0.2 in WC.

The swings in draft are causing burner stability problems resulting in partially combusted ...

Hydrogen_revised1

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 ...

Geometry of hydrotreater furnace inlet pipe

Hydrotreater Furnace

In the petroleum refining industry, the oil hydrotreater produces low-sulfur feed for the downstream units. An oil and hydrogen mixture is delivered by a piping system to the hydrotreater furnace. Uneven splitting and/or phase separations of the original stream can cause uneven heating as well as high furnace tube metal temperature, which can lead to ...

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 ...

Simulation results showing distribution of stress.

Life Prediction in an Overhead Crane

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 as Finite Element Analysis can reduce the costs and dangers of scheduled maintenance. United States Steel Corporation (U. S. Steel) has ...

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 ...

A collection of images showing CIVS simulations and visitors watching the visualizations with 3D glasses.

NIST: AMTech Planning Grant

In order to maintain global competitiveness, steel manufacturing in the U.S. needs to optimize its manufacturing capabilities, and improve both efficiency and workforce training. Newly developed and emerging simulation and visualization technologies have recently provided efficient, effective, and economical tools for improving process and product design, troubleshooting, optimization, and workplace safety, while also providing state-of-the-art, ...

Contours of velocity distribution in feet per second

Orifice Plate Reversal

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 reversal of an orifice plate can results in a ...

Isometric view of the boiler

Power Plant Boiler

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 2D representations are limited therefore field observation is needed to complete the training. However, due to the extreme heat and toxic gases, the internals ...

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 ...

Condenser Loop Geometry

Power Station Condenser

NiSource Bailey Power Station uses a pair of coal-fired boilers to generate electricity via steam turbines. Water drawn from Lake Michigan is used for several condensers to recycle liquid water. However, lake water carries a large quantity of sand and sediment which could petentially clog the condenser system. Meanwhile, the West-West condenser box is having ...

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 ...

QBOP Vessel Sketch and Computational Geometry

QBOP Vessel

The QBOP process for steelmaking is a variation of the basic oxygen process (BOP), which involves blowing high-purity oxygen through a bath of molten pig iron. Figure 1 shows the sketch of a QBOP vessel which is used in the production of low-alloy steel. The QBOP vessels being investigated experience excessive material buildup (“kidney”) on ...

Radio_Frequency_Propagation_in_an_Airplane_v2_Fig3

Radio Frequency Propagation in an Airplane

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 for terrestrial cellular systems – the prediction of signal propagation is essential to wireless network planning. Improvement of ...

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 ...

Flow distribution under three separate conditions.

Scrubber Duct

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). The current Flooded Disc Scrubber system has been experiencing a significant decrease in the overall efficiency. This project aims ...

Geometry of the sinter cooler

Sinter Cooling Simulation

The sinter cooler is a tall rotary cooler with permeable metallic hearth and it is used to cool the hot sinter particles before they can be charged into the blast furnace. The cooling efficiency of the sinter cooler is significant to productivity and the sinter quality. In addition, reducing cooling time by optimizing the operation ...

velocity streamline distribution inside and outside of tank

Storage Tank

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. The size of the ventilation opening must be large enough to allow outside air to flow in ...

Visualization showing heat distribution around tuyere.

Thermal and Cooling Water Flow Modeling of AM Tuyere Nose Using CFD

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 loss to the company. IH7 has had an unacceptably high rate of tuyeres failures at the furnace. Currently, ...

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, ...

NH3 formation at the top and at the spray nozzles.

Urea Decomposition Chamber

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 initiated, but was unable to complete due to internal temperature gradients below the expected 550 °F. One major point of concern ...

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 ...

Gas-distribution-through-the-cohesive-zone-img1

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 ...

Virtual Groundwater isometric view

Virtual Groundwater

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 obtain data to assess the current pollution situation or to predict contaminates’ movement trend. The problem also renders challenges in education. Civil Engineering Students are easy to get ...

3D views of the circulating inlet system

Water Inlet System

NIPSCO’s Bailly Generating Station draws water from Lake Michigan to be used as a coolant. However, sand from the lake is also brought into the water inlet system. This sand must be cleaned out periodically to prevent buildup and damage to equipment. NIPSCO would like to have a study performed to evaluate its ...

Wind-turbine-simulator-software-img2

Wind Energy

The issue of transferring learned concepts to practical applications is a widespread problem in postsecondary education. Related to this issue is a critical demand to educate and train a generation of professionals for the wind energy industry. With initiatives such as the U.S. Department of Energy’s “20% Wind Energy by 2030” outlining an exponential increase ...

DAQ System Panels below Wind Turbine in SUL

Wind Turbine and Data Acquisition System

The burning of fossil fuels to produce energy is costly and has detrimental effects on the environment. Wind Energy has become one the fastest growing alternative energies in the United States. It provides a source of clean energy for not only commercial use, but also for urban areas. The Majority of electricity produced from wind ...