Numerical Analysis of Melting and Holding Furnaces in Secondary Aluminum Production

En esta tesis, dos hornos de aluminio diferentes se analizan numéricamente: 1) un nuevo prototipo de horno de fundición; 2) un nuevo prototipo de horno de mantenimiento. Estos dispositivos son claves en la producción de aluminio secundario. Los modelos utilizados tienen en cuenta la conducción de calor en las partes sólidas, la convección en el aire y de aluminio fundido, las interacciones entre las zonas de gas-líquido-sólido, cambio de fase de la carga y la transferencia de calor por radiación. Con el objetivo de desarrollar una herramienta de cálculo para asistir en el diseño y escalado de hornos industriales, se evalúan diferentes estrategias de cálculo concernientes a la economía computacional y su precisión de cálculo de diferentes parámetros importantes. Las estimaciones de las temperaturas en los hornos se comparan con las mediciones experimentales realizadas en prototipos reales en ciclos de operación típicos

Challenges and Prospects of Steelmaking Towards the Year 2050

The world steel industry is strongly based on coal/coke in ironmaking, resulting in huge carbon dioxide emissions corresponding to approximately 7% of the total anthropogenic CO2 emissions. As the world is experiencing a period of imminent threat owing to climate change, the steel industry is also facing a tremendous challenge in next decades. This themed issue makes a survey on the current situation of steel production, energy consumption, and CO2 emissions, as well as cross-sections of the potential methods to decrease CO2 emissions in current processes via improved energy and materials efficiency, increasing recycling, utilizing alternative energy sources, and adopting CO2 capture and storage. The current state, problems and plans in the two biggest steel producing countries, China and India are introduced. Generally contemplating, incremental improvements in current processes play a key role in rapid mitigation of specific emissions, but finally they are insufficient when striving for carbon neutral production in the long run. Then hydrogen and electrification are the apparent solutions also to iron and steel production. The book gives a holistic overview of the current situation and challenges, and an inclusive compilation of the potential technologies and solutions for the global CO2 emissions problem

Phase I: Design and Analysis of a Process for Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides

The proposed research would be conducted in 3 phases. Each of the phases would be carried out over a one-year period. Phase I includes model development, analysis, and the selection of a new casting furnace design. The work discussed in this report was completed as Phase I. Phase II of the program will lead to more modeling and validation to evaluate the proposed furnace concept. Phase III would be a joint effort between UNLV and Argonne National Laboratory (ANL) to demonstrate the acceptable use of the new furnace in a simulated remote environment. The Phase III work would include the design and modification/fabrication of a small test furnace for remote operation. Some of the casting furnace techniques that will be evaluated include an induction skull melter, continuous casting, and the modification of the present process to operate at higher pressures. The groundwork laid this past year developed a set of modeling tools to assist in the design of a realistic fabrication technique. The primary technical hurdle to overcome in the fabrication of a 21 metallic alloy fuel is that of efficiently including the highly volatile actinide elements (i.e., americium). A comprehensive model for the mass transport has been developed and will be implanted in year two of the project

Simulation of Heat Transfer Phenomenon in Furnace Using Fluent-Gambit

In this project work the simulation of heat transfer and the temperature curve in the furnace is computed out using gambit and fluent software. Comparison of temperature profiles of the material in the furnace using constant temperature heat source and linearly varying temperature of the heat source for unsteady state is done. Also the time for temperature to become steady is compared. The material used in the furnace is aluminum and conduction is the mode of heat transfer, the side walls are adiabatic and maintained at ambient temperature. Also the density variation and solidification-melti ng curve of material filled inside are compared for both conditions. The geometry used is very simple, similar to muffle furnace. The problem will be solved by using the software package FLUENT – GAMBIT. FLUENT is a computational fluid dynamics (CFD) software package to simulate fluid problems. It uses the finite-volume method to solve the governing equations for a fluid. It provides the capability to use different physical models such as incompressible or compressible, in viscid or viscous, laminar or turbulent, etc. Geometry and grid generation is done using GAMBIT which is the preprocessor bundled with FLUENT

Numerical model building based on XFEM/level set method to simulate ledge freezing/melting in Hall-Héroult cell

Au cours de la production de l'aluminium via le procédé de Hall-Héroult, le bain gelé, obtenu par solidification du bain électrolytique, joue un rôle significatif dans le maintien de la stabilité de la cellule d'électrolyse. L'objectif de ce travail est le développement d'un modèle numérique bidimensionnel afin de prédire le profil du bain gelé dans le système biphasé bain liquide/bain gelé, et ce, en résolvant trois problèmes physiques couplés incluant le problème de changement de phase (problème de Stefan), la variation de la composition chimique du bain et le mouvement de ce dernier. Par souci de simplification, la composition chimique du bain est supposée comme étant un système binaire. La résolution de ces trois problèmes, caractérisés par le mouvement de l'interface entre les deux phases et les discontinuités qui ont lieu à l'interface, constitue un grand défi pour les méthodes de résolution conventionnelles, basées sur le principe de la continuité des variables. En conséquence, la méthode des éléments finis étendus (XFEM) est utilisée comme alternative afin de traiter les discontinuités locales inhérentes à chaque solution tandis que la méthode de la fonction de niveaux (level-set) est exploitée pour capturer, implicitement, l'évolution de l'interface entre les deux phases. Au cours du développement de ce modèle, les problématiques suivantes : 1) l'écoulement monophasique à densité variable 2) le problème de Stefan couplé au transport d'espèces chimiques dans un système binaire sans considération du phénomène de la convection et 3) le problème de Stefan et le mouvement du fluide qui en résulte sont investigués par le biais du couplage entre deux problèmes parmi les problèmes mentionnées ci-dessus. La pertinence et la précision de ces sous-modèles sont testées à travers des comparaisons avec des solutions analytiques ou des résultats obtenus via des méthodes numériques conventionnelles. Finalement, le modèle tenant en compte les trois physiques est appliqué à la simulation de certains scénarios de solidification/fusion du système bain liquide-bain gelé. Dans cette dernière application, le mouvement du bain, induit par la différence de densité entre les deux phases ou par la force de flottabilité due aux gradients de température et/ou de concentration, est décrit par le problème de Stokes. Ce modèle se caractérise par le couplage entre différentes physiques, notamment la variation de la densité du fluide et de la température de fusion en fonction de la concentration des espèces chimiques. En outre, la méthode XFEM démontre sa précision et sa flexibilité pour traiter différents types de discontinuité tout en considérant un maillage fixe.During the Hall-Héroult process for smelting aluminium, the ledge formed by freezing the molten bath plays a significant role in maintaining the internal working condition of the cell at stable state. The present work aims at building a vertically two-dimensional numerical model to predict the ledge profile in the bath-ledge two-phase system through solving three interactive physical problems including the phase change problem (Stefan problem), the variation of bath composition and the bath motion. For the sake of simplicity, the molten bath is regarded as a binary system in chemical composition. Solving the three involved problems characterized by the free moving internal boundary and the presence of discontinuities at the free boundary is always a challenge to the conventional continuum-based methods. Therefore, as an alternative method, the extended finite element method (XFEM) is used to handle the local discontinuities in each solution space while the interface between phases is captured implicitly by the level set method. In the course of model building, the following subjects: 1) one-phase density driven flow 2) Stefan problem without convection mechanism in the binary system 3) Stefan problem with ensuing melt flow in pure material, are investigated by coupling each two of the problems mentioned above. The accuracy of the corresponding sub-models is verified by the analytical solutions or those obtained by the conventional methods. Finally, the model by coupling three physics is applied to simulate the freezing/melting of the bath-ledge system under certain scenarios. In the final application, the bath flow is described by Stokes equations and induced either by the density jump between different phases or by the buoyancy forces produced by the temperature or/and compositional gradients. The present model is characterized by the coupling of multiple physics, especially the liquid density and the melting point are dependent on the species concentration. XFEM also exhibits its accuracy and flexibility in dealing with different types of discontinuity based on a fixed mesh

Modeling and Simulation of Metallurgical Processes in Ironmaking and Steelmaking

In recent years, improving the sustainability of the steel industry and reducing its CO2 emissions has become a global focus. To achieve this goal, further process optimization in terms of energy and resource efficiency and the development of new processes and process routes are necessary. Modeling and simulation have established themselves as invaluable sources of information for otherwise unknown process parameters and as an alternative to plant trials that involves lower costs, risks, and time. Models also open up new possibilities for model-based control of metallurgical processes. This Special Issue focuses on recent advances in the modeling and simulation of unit processes in iron and steelmaking. It includes reviews on the fundamentals of modeling and simulation of metallurgical processes, as well as contributions from the areas of iron reduction/ironmaking, steelmaking via the primary and secondary route, and continuous casting

Review of magnetohydrodynamic pump applications

AbstractMagneto-hydrodynamic (MHD) principle is an important interdisciplinary field. One of the most important applications of this effect is pumping of materials that are hard to pump using conventional pumps. In this work, the progress achieved in this field is surveyed and organized according to the type of application. The literature of the past 27years is searched for the major developments of MHD applications. MHD seawater thrusters are promising for a variety of applications requiring high flow rates and velocity. MHD molten metal pump is important replacement to conventional pumps because their moving parts cannot stand the molten metal temperature. MHD molten salt pump is used for nuclear reactor coolants due to its no-moving-parts feature. Nanofluid MHD pumping is a promising technology especially for bioapplications. Advantages of MHD include silence due to no-moving-parts propulsion. Much progress has been made, but with MHD pump still not suitable for wider applications, this remains a fertile area for future research

Process Modeling in Pyrometallurgical Engineering

The Special Issue presents almost 40 papers on recent research in modeling of pyrometallurgical systems, including physical models, first-principles models, detailed CFD and DEM models as well as statistical models or models based on machine learning. The models cover the whole production chain from raw materials processing through the reduction and conversion unit processes to ladle treatment, casting, and rolling. The papers illustrate how models can be used for shedding light on complex and inaccessible processes characterized by high temperatures and hostile environment, in order to improve process performance, product quality, or yield and to reduce the requirements of virgin raw materials and to suppress harmful emissions

Sensor fusion for intelligent process control.

An integrated system for the fusion of product and process sensors and controls for production of flat glass was envisioned, having as its objective the maximization of throughput and product quality subject to emission limits, furnace refractory wear, and other constraints. Although the project was prematurely terminated, stopping the work short of its goal, the tasks that were completed show the value of the approach and objectives. Though the demonstration was to have been done on a flat glass production line, the approach is applicable to control of production in the other sectors of the glass industry. Furthermore, the system architecture is also applicable in other industries utilizing processes in which product uniformity is determined by ability to control feed composition, mixing, heating and cooling, chemical reactions, and physical processes such as distillation, crystallization, drying, etc. The first phase of the project, with Visteon Automotive Systems as industrial partner, was focused on simulation and control of the glass annealing lehr. That work produced the analysis and computer code that provide the foundation for model-based control of annealing lehrs during steady state operation and through color and thickness changes. In the second phase of the work, with PPG Industries as the industrial partner, the emphasis was on control of temperature and combustion stoichiometry in the melting furnace, to provide a wider operating window, improve product yield, and increase energy efficiency. A program of experiments with the furnace, CFD modeling and simulation, flow measurements, and sensor fusion was undertaken to provide the experimental and theoretical basis for an integrated, model-based control system utilizing the new infrastructure installed at the demonstration site for the purpose. In spite of the fact that the project was terminated during the first year of the second phase of the work, the results of these first steps toward implementation of model-based control were sufficient to demonstrate the value of the approach to improving the productivity of glass manufacture