Materials Processing Fundamentals: Process Optimization
Sponsored by: TMS Extraction and Processing Division, TMS Materials Processing and Manufacturing Division, TMS: Process Technology and Modeling Committee
Program Organizers: Samuel Wagstaff, Oculatus Consulting; Alexandra Anderson, Gopher Resource; Adrian Sabau, Oak Ridge National Laboratory
Monday 2:00 PM
March 20, 2023
Room: 25B
Location: SDCC
Session Chair: Samuel Wagstaff, Oculatus Consulting
2:00 PM Introductory Comments
2:05 PM Cancelled
Magnetohydrodynamics Computational Framework for Submerged Arc Furnace: A Review: Yonatan Afework Tesfahunegn1; Pascal Bayrasy2; Hákon Haraldsson1; Thordur Magnusson3; Merete Tangstad4; Gudrun Saevarsdottir1; 1Reykjavik University; 2Fraunhofer Institute for Algorithms and Scientific Computing SCAI; 3Stakksberg ehf; 4Norwegian University of Science and Technology
Magnetohydrodynamics (MHD) is a sub-field of fluid mechanics which involves the interaction between electromagnetic fields and the flow of conducting fluids. In submerged arc furnaces (SAF), the electric currents passing through fluids such as liquid metal, slag, or plasma, interact with strong electromagnetic fields and require full MHD analysis for representative modeling. The governing equations that explain MHD combine the Navier-Stokes equations of fluid dynamics and Maxwell’s equations of electromagnetism. Numerical modeling has become one of the primary predictive tools in designing and analyzing systems. Due to the advancement of high computing power, the demand for highly coupled numerical modeling, like MHD, has steadily increased over the past years. This work will review the existing MHD modeling approaches tailored to SAF and propose an MHD computational framework applied to SAF.
2:25 PM
Modeling of Macro-scale Reaction Effects in a Secondary Lead Reverberatory Furnace: Nicholas Walla1; Emily Higley1; Armin Silaen1; Alexandra Anderson2; Joseph Grogan2; Chenn Zhou1; 1Purdue University Northwest; 2Gopher Resource
A long-standing and effective way to recycle lead-acid battery materials is through processing of lead compounds into lead product within a reverberatory furnace. Exploration of process and design changes through unit modification can be costly, time consuming, and potentially harmful to operational efficiency. Modeling of process behavior, including furnace heat transfer and material reduction/decomposition, can however be difficult. To this end, a method for reflecting the production capabilities of a lead reverberatory furnace under various operational conditions has been developed. Reactions of the lead compounds have been approximated within a steady-state computational fluid dynamics simulation by adding or removing heat from the domain depending on local thermal conditions. With this, process and design changes can be explored in the simulated environment before moving onto more-advanced stages of modeling or experimentation.
2:45 PM
A Study on Behavior of Post Combustion in 2-Ton Converter Simulator: Jia Lee1; Jeong Whan Han1; 1Inha University
Post combustion technology in converter steelmaking has the advantage of compensating for heat by burning CO gas. Through this technology, by increasing the amount of scrap iron used in the converter, it is possible to reduce the hot metal ratio and finally reduce the CO2 emission. Therefore, it is necessary to study the effective heat transfer condition in the lower part of the converter by post converter.In this study, in order to confirm the gas behavior into the 2-ton converter simulator according to the post combustion, the cavity shape was derived by O2 gas injected from the supersonic nozzle, and the post combustion reaction analysis was calculated by applying this shape. Cavity shape was calculated by 3D multiphase flow analysis using VOF method, and combustion reaction was calculated by 3D steady-state analysis using finite rate-eddy dissipation model.
3:05 PM
Post Processing Approach to Model Microsilica Formation: Kurian J. Vachaparambil1; Kristian Etienne Einarsrud2; Stefan Andersson1; Halvor Dalaker1; 1SINTEF Industry; 2Norwegian University of Science and Technology (NTNU)
Understanding the underlying the physics involved in the formation of microsilica, which is a byproduct in the silicon furnaces, is critical as the size and quality of these particles determine its applications. To the best knowledge of the authors, there has been a single attempt to develop a model to describe this (Gonalez-Farina et al. SIAM J. Appl. Math (2020) 80(2) 1003-1033).Inspired by that work, we present an OpenFOAM based framework to model microsilica formation. The approach is dubbed as a post-processing method as it decouples the combustion reaction from the microsilica formation (based on an assumption used in the previous work). In this paper we perform combustion of SiO and CO using a turbulent reacting flow solver in OpenFOAM and use the results in a new population balance solver (based on the QMOM approach) to simulate microsilica nucleation/growth as well as its coupling to the SiO2 concentration field.
3:25 PM Break
3:45 PM
Comparative Statistical Analysis of Gold Processing Plant Recovery Data: Martin Beyuo1; Eric Agorhom1; Ishmael Quaicoe1; Clement Owusu1; 1University of Mines and Technology
Gold recovery is the most important performance indicator for the leaching process and has a significant impact on the overall yield and production efficiency. Most of the gold produced globally is by the Carbon-in-Pulp (CIP) and Carbon-in-Leach (CIL) technologies. Several parameters affect gold recovery in a CIL/CIP plant including to slurry flow rates, gold grade, pH, temperature, slurry density, particle size, oxygen, cyanide concentration, surface area of gold exposed, retention time, agitation and the presence of other minerals in the ore. These parameters together form a data matrix with recovery as an output variable. The interactions of these parameters would either have a synergic effect (or otherwise) on recovery. Gold recovery data from different mines are obtained for the same period for this work. This work seeks to explore the character extracted from these data matrices to create a common platform for comparison of metallurgical efficiencies between different processing plants.
4:05 PM Cancelled
Correlation Between Edge Failure and Edge Geometry of Advanced High-Strength Steels Using the Image Processing: Kyucheol Jeong1; Yuhyeong Jeong1; Gisuk Chung2; Jaewook Lee2; Jonghun Yoon1; 1Hanyang University; 2POSCO Global R&D Center
The environmental regulation demands to keep the automotive lightweight and the driver safe. To meet the regulations advanced high strength steel (AHSS) has been utilized for the vehicle due to the high strength-weight ratio. However, crack during edge stretching process is limiting its application. Also, the high variation of edge stretchability makes the forming process even harder. To overcome this problem local damage measurement is required for analyzing the characteristics of crack initiation. We introduce a method for measuring the distribution of the burnish and fracture along the sheared edge. The whole area of sheared edges of AHSS under different cutting conditions are captured with a CCD camera. Each area is distinguished automatically based on their texture. Afterward the length of each pixel line is calculated. A relation between length of each zone, crack initiation spot and fracture strain are analyzed.