Blast furnace simulation software

Various operational problems like irregular casting intervals, damage to lining, low blast intake, furnace pressurization, and so forth are normally encountered when liquid levels in the hearth exceed a critical limit where hearth coke and deadman. Special simulation software which mapped all the plant and equipment as well as process scenarios was used to plan the relining. Because dem faithfully reproduces the characteristics of powder behavior, it has become one of the representative powder simulation methods covering multi phase process analysis for blast furnaces by the discrete element. Pdf information modeling system for blast furnace control. However, wood which is what charcoal is made from was becoming more expensive, as forests were being cleared for farmland and timber. The model decision support system for control of blast furnace smelting is designed and operated. Blast furnace online simulation model springerlink. The principle of blast furnace operational technology and. In section iii simulation and analysis, the modeling has been done and.

The automation division of tata steel ltd has developed a level2 system blast furnace and implemented a h blast furnace at tata steel jamshedpur. Blast furnaces have been used for iron production since centuries. Computer simulation of thermal and stressstrain state of blast furnace tuyeres springerlink. This webinar will introduce edem bulk material simulation software and explain how it can be used to optimize a range of operations and processes as part of the steelmaking process. The widespread introduction of computer simulation does.

Blast furnace is a large furnace which is used in metallurgical field to produce metals, especially pig iron. Process simulation and control optimization of a blast. A comprehensive modeling and analysis of blast furnace cooling stave based on thermal stress and heat transfer analysis written by akash shrivastava, r. The user friendly software package named blast furnace shaft simulator bfss. In future this tool will also be used during ongoing operations at the blast furnace. Constructing an energy and material balance model of the blast furnace process using aspen plus. Several numerical approaches have been proposed in the literature to simulate the behavior of modern blast furnaces. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. In this simulation you will play the role of plant metallurgist in charge of the blast furnace operations.

The simulation produced a great deal of insight about how material flows through the hopper. The program compares nucleotide or protein sequences to sequence databases and calculates the statistical significance of matches. Aspen plus simulation of coal integrated gasification. Continuous 120 kw pilot plant dual circulating fluidized bed system cold flow models of fluidized bed systems validated modeling tools for scaleup and feasibility studies.

This is a very complicated chemical process in which the layered coke and ore particles descend from the furnace top due to gravity. Blast furnace phenomena and modelling springerlink. Jan, 2015 3d interactive blast furnace for training civspnw. A mathematical model of the ironmaking blast furnace bf is presented. Control and fewer variations in the blast furnace process. Dem simulation of charge distribution in a blast furnace. Dem simulation of charge distribution in a blast furnace hopper see how the simulation of charge distribution in a blast furnace hopper using an integrated dem study found the ideal geometry for industrial use. Blast furnace bf ironmaking is an important technology by which iron is efficiently reduced from ironbearing particles. Modelling and simulation cold flow model studies continuous chemical looping operation oxygen carrier testing and characterization facilities. At optimal operation conditions, co 2 emissions of the process can be reduced by. Conceptual design and simulation analysis of thermal behaviors of tgr blast furnace and oxygen blast furnace. Welcome to blast furnace, a state of the art recording and mixing facility 10 minutes walk from derry city centre. Blast furnaces are used to produce pig iron from iron ore for subsequent.

It is the major production route for recycling steel scrap, often into higher quality steel. Dry granulation and waste heat recovery via a moving bed is an attractive alternative to the conventional water quenching method due to energysavings and the reduction in water consumption. In this realtime simulation you must first select the. May 29, 2014 the inhouse blast furnace shaft cfd model has been intergraded to the interface software and a communication port has been setup between the cfd model and the interface software. Integrating wellestablished thermodynamic database factsage. Is it possible to simulate blast furnace performance.

Simulated blast furnace geometries of a full 3d model, b slot model, and c sector model, together with d circumferential periodic boundary conditions pbc for particles. Aspen plus simulation of coal integrated gasification combined blast furnace slag waste heat recovery system. As a valuable byproduct of the ironmaking process, blast furnace slag with temperature up to 14501650 c contains a tremendous amount of sensible heat. The blast furnace burden consists of alternative layers of iron ore and coke. In the present section, the summary and conclusion of the simulation of blast furnace cooling stave is thoroughly discussed. Our technology base covers the entire blast furnace process route from hot blast and raw material handling, through the furnace and casthouse, to gas cleaning and hot metal slag processing. Gasliquid two phase flow simulation in spipe duration. Analysis of fuel injection system in blast furnace with the help of cfd software approach gourav kumar thakur. Simulation of injecting pure hydrogen into the blast furnace as an auxiliary reducing agent. Austin2 1school of materials science and engineering, university of new south wales, sydney, nsw 2052, australia 2bhp steel research laboratories, p. Simulation of slaggas and slagiron interface tilting in blast furnace hearth during slag tapping. This screen shows the parameters for the sintering furnace featured in this case study. Recently, however, various in furnace phenomena have become the subject of serious scientific study, largely as the result of the dissection of dead furnaces, together with the development of advanced monitoring and control techniques. Since the large accumulation amount of blast furnace slag bfs with recycling value, it has become a hot topic for recovery utilization.

Our research group developed a novel dry cooling granulation experiment. The javabased blast furnace simulator is constructed by integrating existing partial simulators. This paper introduces javabased blast furnace simulator and describes visualization system. Finally, integrating geometry parameters, rocky, and modefrontier can readily be applied to other applications in our case, identifying two different devices that improve charge distribution in a blast furnace hopper. Your results are shown in terms of the mass and heat balance achieved with these setting. But our study is confined to the extraction of iron from its ore. Review on modelling and simulation of blast furnace article pdf available in steel research international 891. This includes raw materials and their preparation, important reactions and operating practice in the blast furnace, instrumentation and process control. The blast furnace bf that converts iron ore into molten iron is. Simulation of slaggas and slagiron interface tilting in. A blast furnace represents the predominant ironproducing process in north america.

Numerical simulation of ironmaking blast furnace shaft by dong fu. The visualization system provides integrated visualization information of real measured data and simulation result in order to support blast furnace operation. A technical, environmental and economical assessment the results were used to simulate the behaviour of torrefied biomass in the blast furnace using a blast furnace simulation software available at the company, called mmhf. Box 202, port kembla, nsw 2505, australia abstract. Optimization for blast furnace slag dry cooling granulation. Aerosolved is a computational fluid dynamics code, based on the openfoam software package, for simulation of the generation, transport, evolution and deposition of multispecies aerosol mixtures. Nov 25, 2019 the simulation produced a great deal of insight about how material flows through the hopper.

Drain rate and liquid level simulation in blast furnace. The measurement data are reconciled by an interface routine which yields boundary conditions obeying the conservation laws of atoms and energy. Pdf in this paper, we present a simulation model of a blast furnace. Discrete particle simulation of gassolid flow in a blast furnace. Automatic control software for the blast furnace shop.

Simulation two phases flow in blast furnace main runner youtube. Visualisation of a mathematical model of blast furnace operation for. To complete this module an interactive simulation is planned, allowing you to take control of the blast furnace. Understanding the solid burden flow and the formation of the cohesive zone in the blast furnace is also critical to ensure performance and stability. Blast furnace simulation cfd online discussion forums. A comprehensive modeling and analysis of blast furnace. Taking into account the cooling stave hot simulation of the boundary conditions, respectively to calculate the temperature distribution, thermal stress and deformation of rolled copper cooling stave and cast copper cooling stave embedded copper. Conceptual design and simulation analysis of thermal. Computer simulation of thermal and stressstrain state of. Primetals technologies has provided blast furnace engineering, project excellence and expertise to customers worldwide for over a century. The linz steel works produces approximately five million tonnes of pig iron in its steel division a year the large blast furnace a alone supplies approximately.

Blast furnace is a vertical shaft with circular cross section. Pdf a system dynamics simulation model of a blast furnace. Base on the idea of blast furnace gas deco2 circulating as reducing agent and the idea of pure oxygen blast decreasing the thermal reserve zone temperature, process modeling is conducted with aspen plus. May 10, 2017 the automation division of tata steel ltd has developed a level2 system blast furnace and implemented a hblast furnace at tata steel jamshedpur. Operate a blast furnace to produce iron for use in steelmaking. Using the finite element software ansys to establish thermal structure coupling model of copper cooling stave. Using siemens simulation software and virtual commissioning, it was possible for the linz steel works to refurbish the largest blast furnace in austria despite a tight time window. Thermal simulation study on copper cooling stave of blast. Software and equipment are selected and adapted to meet the specific conditions for each task, material and process. This site is like a library, use search box in the widget to get ebook that you want. A research has been conducted to study the effect of the thickness of a thermal insulation insert inside the air passage of a blast furnace tuyere and the size of the air gap separating it from an.

Analysis of fuel injection system in blast furnace with. Energysaving blast furnace nippon steel engineering. Taking into account the cooling stave hot simulation of the boundary conditions, respectively to calculate the temperature distribution, thermal stress and deformation of rolled copper cooling stave and cast copper cooling stave embedded copper pipe under high temperature. Thermal simulation study on copper cooling stave of blast furnace.

Proper understanding and control of drainage of hot metal and slag from hearth are essential for a stable and efficient blast furnace operation. Your aim is to optimise production of hot metal from your blast furnace by selecting appropriate raw materials, production statistics and charging rates. A study of the flow characteristics of blast furnace slag is important to record the softening and melting phenomena in blast furnace which greatly influence the extent and location of the cohesive zone having a direct say on the blast furnace. To help illustrate the benefits of design software, an analysis of a furnace was performed first using manual calculations and then using furnxpert software.

Blast furnace operation guidance by javabased simulator. The purpose of the basic oxygen steelmaking bos process is to refine the hot metal produced in the blast furnace into raw liquid steel, which may be subsequently refined in the secondary. From mine to blast furnace optimizing the steelmaking process. Blast furnace simulation download ebook pdf, epub, tuebl. Numerical simulation of ironmaking blast furnace shaft. 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. Himte published on 20121129 download full article with reference data and citations.

Blast furnace shaft cfd model center for innovation. Process evaluations and simulations of co capture from. Sintef objectives process design and basis for simulation simulation studies summary tobiesen, f. Pellet reduction properties under different blast furnace. Phoenics cfd simulation of a blastfurnace gravity dust. The inhouse blast furnace shaft cfd model has been intergraded to the interface software and a communication port has been setup between the cfd model and the interface software. Blast furnace, a vertical shaft furnace that produces liquid metals by the reaction of a flow of air introduced under pressure into the bottom of the furnace with a mixture of metallic ore, coke, and flux fed into the top. This is the cfddem simulation of a blast furnace, a device heavily used for the production of hot metal. Click download or read online button to get blast furnace simulation book now. From mine to blast furnace optimizing the steelmaking.

Dem simulation of charge distribution in a blast furnace hopper. Sample pages to be followed exactly in preparing scripts blast furnace knowledgebased control by means of simulation kostial i. Up to 1709, furnaces could only use charcoal to produce iron. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through the top of the furnace, while a hot blast of air sometimes with oxygen enrichment is blown into the lower section of the furnace through a series of pipes called tuyeres, so that the chemical reactions take place throughout the furnace as the. Process analysis for blast furnaces by the discrete. Heat recovery process modelling of semimolten blast furnace. Feb 03, 2020 the basic local alignment search tool blast finds regions of local similarity between sequences. Simulation procedure the model geometry is based on a. The interface software is used to input furnace geometry, burden distribution, operation condition in a userfriendly environment. In todays competitive engineering markets, mathbased furnace simulation can cover. For furnace designers, the software also calculates various heat losses, heat requirements for the parts, and overall furnace efficiency. Automation of blast furnaces at tata steel with netbeans. Blast refers to the combustion air being forced or supplied above atmospheric pressure. Previously we have worked with simulation of blast furnace gases in the ulcos project.

First software is a modeling software proe, in which a model of cooling stave is made and the other software is finite element method software called as ansys, which is used to do the analysis or the calculations. The phase components of the bf slag sample were characterized by xrd and the jada 5. As ironmakers are well aware, it was only a few decades ago that the blast furnace was viewed as a strange black box. Modeling and simulation of hydrogen injection into a blast. Typically, material is added to the furnace in layers, and. Established in 1995, we have built a solid reputation for highquality output and professionalism in a wide range of services for musicians and filmmakers alike. Compared with the existing various bfs granulation process, the dry granulation process can promote the use of blast furnace granulated slag as cement substitute and concrete admixtures. Numerical simulation of solids flow in a blast furnace.