star-ccm+ modeling of steel making processes simon...
TRANSCRIPT
![Page 1: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/1.jpg)
STAR-CCM+ modeling of steel making
processes
Simon Lo
![Page 2: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/2.jpg)
Blast Furnace
Basic Oxygen Furnace (BOF)
Continuous casting
Steel making processes
![Page 3: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/3.jpg)
Blast furnace
![Page 4: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/4.jpg)
DEM - Charging of particles
4
![Page 5: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/5.jpg)
Lifting of particles by air flow
5
![Page 6: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/6.jpg)
6
With heat transfer
![Page 7: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/7.jpg)
Thermal expansion of particles
In Blast furnace, the effect of solid
expansion due to temperature may
be important
STAR-CCM+ has the capability
– Using variable density model
7
![Page 8: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/8.jpg)
8
Unloading of particles
![Page 9: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/9.jpg)
Bulk flow validation
Unloading quazi-2D blast
furnace – stagnant zone
formation
Paper: Z. Zhou, H. Zhu, ISIJ
Vol 45, 2005
STAR-CCM+ results in
agreement with both
experiment and independent
code results
9
![Page 10: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/10.jpg)
Analysis of volume fraction distribution
– Predicted the amount of load lifting after staring injecting air
Computation time for a million particles is getting close to
reasonable
– 1,003,146 particles
– Simulated 0.2 seconds of physical time
– Took ~48 hours on 96 cores
– Used DEM timestep ~ 5.3E-6 s
Summary of coupled DEM-CFD BF simulation
10
![Page 11: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/11.jpg)
Eulerian multiphase model
11
• Full size furnace:
• 25m height
• 7.2m hearth diameter
• 2D axisymmetric model
• Multi-component Eulerian phases:
Gas phase: CO, CO2, N2
Solid phase: Ore, Coke, Fe, Fe2O3, C
• Two reactions:
Fe2O3 + 3CO -> 2Fe + 3CO2
C + CO2 -> 2CO
![Page 12: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/12.jpg)
Temperatures
12
![Page 13: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/13.jpg)
Fe/Ore mass fractions
13
![Page 14: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/14.jpg)
CO/CO2 mass fractions
14
![Page 15: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/15.jpg)
Basic Oxygen Furnace (BOF)
Oxygen is blown onto
the metal bath to
oxidize elements such
as silicon and
phosphorous.
Due to strong stirring
inside the vessel
oxides are transferred
from metal to slag.
![Page 16: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/16.jpg)
Liquid steel is pour from converter
to ladle through taphole.
Dart designed to float at interface
between steel and slag.
Near end of tapping, dart is sucked
into the taphole blocking the flow
and limit slag carry-over into the
ladle.
Basic Oxygen Furnace (BOF)
Converter in tapping
position
![Page 17: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/17.jpg)
Dart sucked into the taphole
![Page 18: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/18.jpg)
Continuous casting of steel
![Page 19: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/19.jpg)
Continuous casting of steel
![Page 20: STAR-CCM+ modeling of steel making processes Simon Lomdx2.plm.automation.siemens.com/sites/default/files... · Continuous casting Steel making processes . Blast furnace . DEM - Charging](https://reader036.vdocuments.us/reader036/viewer/2022062505/5ecf8444ebbc2c47d835407b/html5/thumbnails/20.jpg)
Continuous casting of steel