Short Article Proceedings of IDMME - Virtual Concept 2010

Bordeaux, France, October 20 – 22, 2010

IDMME_P57 -1- Copyright of IDMME - Virtual Concept

VISUALIZING THE BLAST FURNACE

Ren Ren, Daniel Ratko, Guoheng Chen, Dr. Chenn Q. Zhou

Department of Mechanical Engineering Purdue University-Calumet, Hammond IN 46323

219-989-2665/219-989-2898 E-mail : {renr; dratko; chen142; qzhou }@calumet.purdue.edu

Abstract: In the iron making industry a blast furnace is used in order to process iron. The blast furnace consists of many different physical components, complex phenomenon, and different reactions. The blast furnace under normal operating conditions is an inhospitable environment making direct observations impossible. Geometric and numerical computational fluid dynamics models have been used to explain detailed information about the furnace, but are usually very difficult to understand in their basic form. This work presents an introduction to a virtual blast furnace package that will provide an easy communication medium for even some of the most complex numerical and geometric data related to the blast furnace. Also included in this package is a training tool that will help explain the many facets of the blast furnace to people of many different backgrounds. These tools can be used to enhance blast furnace understanding and communication.

Key words: Virtual Reality, Blast Furnace, CFD (Computational Fluid Dynamics), Training

1- Introduction

The blast furnace is one of the main components used in the steel and iron industry as it processes the raw material iron ore into a more useful substance known as “pig iron”. The blast furnace consists of many different complex reactions and phenomenon [1]. Since the blast furnace itself is inhospitable to humans and is not always conducive to taking direct measurements, different techniques are used to explain the internal reactions and phenomenon [2]. Many different complicated models using computational fluid dynamics (CFD) [3] and various custom computer programs have been created to explain some of internal processes of the blast furnace with great quantitative detail. As the depth of understanding and research into complicated blast furnace operations increases it becomes more difficult to non-experts to understand. In this research, a “virtual blast furnace” (VBF) [4] has been created to present the data found by researchers in a virtual reality (VR) system [5]. Virtual reality helps the user experience the different components and complexities in a visually intuitive way. The VBF is designed to be the closest a

human can get to actually being inside a blast furnace and making virtual observation about the many different details. The safe intuitive experience and quantitative data available in the VBF make it an ideal setting for training people from different backgrounds as well as designing, optimizing, and troubleshooting blast furnace components.

2- Blast Furnace Geometric Visualization

Since there are many different physical features inside a blast furnace for the most part 2-D detailed engineering drawings are the standard method used to communicate information among different people working on the blast furnace. As these prints usually contain a high level of detail and are written using specific standards it is not always possible for untrained people to understand exactly what the drawings are presenting. These drawings can be converted to 3-D models and added to the VR system making objects of any size or detail easily understood. These models [6], as shown in Figure 1 [4]Error! Reference source not found., can also be shown virtually in their local environment making it easier for people to relate to. Textures and motion can also be added to the 3-D models replicating realistic conditions.

Figure 1: VBF Outer Geometry [4]

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IDMME - Virtual Concept 2010 Short Article Title

IDMME_P57 -2- Copyright IDMME - Virtual Concept

3- Visualizing Simulation Data

Using CFD has been used to model and predict very descriptive data sets in many different portions of the blast furnace. Due to the complexity of reactions in blast furnace CFD codes are created and combined commercially available CFD packages to fully model the blast furnace operations. Typical 2-D contour plots can be used to present data, but they are not always easy for non-experts to understand. Using VR techniques, the simulation data can be used to generate a complete 3-D model able to present the applicable simulation data [7, 8]. People can easily get into the VR model to observe the comprehensive simulation results. For instance, Figure 2 shows the observer inside the raceway [9, 10] to check combustion results of different fuel and oxidizer combinations. The user is surrounded by the entire data set allowing the exploration of the geometry, temperature, and concentrations in context instead of simply comparing 2-D slices.

Figure 2: Immersive Raceway Simulation

Traditional CFD postprocessors allow for the creation of streamlines, or continuously plotted lines depicting flow patterns and colored to represent the chosen properties (temperature, pressure, velocity) available from the data. The streamlines, as shown in Figure 3 [4], can be combined with the geometry and other data in the VR system communicating large amounts of information in a single intuitive setting [4].

Figure 3: Streamlines Through Cohesive Zone [4]

4- Blast Furnace Visualization Effects

The whole process of the operating blast furnace can be created using several techniques. The raw material charged from the top part is animated by the physics motion simulation in 3D animation modeling software [17]. The process of burden decent which consists of coke and iron ore is build using 3D modeling software [17] based on custom code.

Improving the overall visual understanding of blast furnace has not been limited to the use of simulation or geometric modeling data. Particle systems [16] animations have been applied to show flames, dripping, iron/slag levels, and blast furnace drainage. At this time particle systems animations are not used for quantitative data, but play an important role in qualitatively presenting important details about the blast furnace and some of its components. Figure 4 shows the liquid iron dripping from the melting zone into the hearth and coming out through the taphole [6].

Figure 4: Dripping and Liquid Level Effects

Many other techniques can be used to enhance the visual understanding of numerical data. A package known as “flowing vectors” has been created to help the user better understand the speed and direction of the streamlines. The vectors start at the beginning of the streamline path and continuously follow them to their end. This process allows a user to see the path of the data as it would in reality.

5- Virtual Blast Furnace Training Package

A virtual reality blast furnace has been created to help train people from a variety of different backgrounds as well as aiding with design, optimization, and troubleshooting. Combining virtual reality, CFD data, 3-D geometries, and qualitatively representative effects users are able to fully experience the blast furnace scientifically and intuitively.

Before the virtual blast furnace is operating, text descriptions are added to each of the component [6] in the empty shell model as seen in Figure 5. The user can easily identify and also move though each component like they experience in the real world. Using this 3-D components model help users get more familiar with the real blast furnace hopefully reducing the amount of time required for training.

Figure 5: Component Description for Training

IDMME - Virtual Concept 2010

When the iron ore is charged into the stack, areaction will happen [1, 6]. Each reaction zone is different colors and shows a chemical reaction addition to the burden reaction zones the iron dripping zone, stagnant coke zone, slag and hot metal zone are also identified. A view of the described features can be found in below.

Figure 6: Reaction Zones for Training

Each of the different training zones in the VBF can be combined and packaged to best suit the intended audience. The users can virtually through each different while learning the names, components details, and reactions. Virtual reality will help the trainee to relate to the real components that might not be physically accessible

6- Conclusion

Incorporated into the VBF are several different models that allow a user to move through the blast furnace observing each of its physical features, reactions, and other phenomenonGeometry of any size or location can be investigated in 3virtual reality and compared improving the efficiency of the design process. Since it is impossible to get inside an operational furnace and see features directly virtual reality can be used to display numerical models representative of each of the phenomenon. Numerical models traditionalhigh level of expertise to understand because they require taking multiple 2-D slices and comparing them. Virtual reality allows a user to be immersed in the data proving an intuitive experience that allows people less experienced to interprenumerical models. CFD data can be presented using streamlines, contour plots wrapped on the geometry, static vectors, or flowing vectors. In addition to geometric models, and numeric data the VBF uses different effects to qualitatively show blast furnace phenomenon. These effects show some of the things that cannot or currently have not been represented by numerical data.

The VBF is essentially a training and communication tool allowing the user to visually interface with a computer or computer data that are directly related to the blast furnace. more data from ongoing blast furnace research becomes available there is an increased demand for easy communication of this data. The VBF has been designed to meet the current

a series reduction . Each reaction zone is identified by

chemical reaction description. In addition to the burden reaction zones the iron dripping zone, stagnant coke zone, slag and hot metal zone are also identified. A view of the described features can be found in Figure 6

: Reaction Zones for Training

zones in the VBF can be est suit the intended audience.

through each different part of the blast while learning the names, components details, and reactions.

the trainee to relate to the real accessible.

VBF are several different models that allow a user to move through the blast furnace observing each of its physical features, reactions, and other phenomenon. Geometry of any size or location can be investigated in 3-D

ing the efficiency of the design process. Since it is impossible to get inside an operational furnace and see features directly virtual reality can be used to display numerical models representative of each of the phenomenon. Numerical models traditionally required a high level of expertise to understand because they require

D slices and comparing them. Virtual reality allows a user to be immersed in the data proving an intuitive experience that allows people less experienced to interpret the numerical models. CFD data can be presented using streamlines, contour plots wrapped on the geometry, static vectors, or flowing vectors. In addition to geometric models, and numeric data the VBF uses different effects to qualitatively

urnace phenomenon. These effects show some of the things that cannot or currently have not been represented by

communication tool to visually interface with a computer or

that are directly related to the blast furnace. As more data from ongoing blast furnace research becomes available there is an increased demand for easy communication of this data. The VBF has been designed to meet the current

demands and attempts to anticipate future requirements of blast furnace research communication.displaying research data, the VBF will be used for training people in the blast furnace field. Different packages have been created to try and train people from a vdifferent backgrounds.

7- References

[1] J. H. Strassburger, (Ed.) “Blast furnace, theory and practice”, Gordon and Breach, vol. 2, 1969.

[2] Y. Omori, (Ed.) “Blast furnace phenomena and modeling,” The Iron and Steel Institute of Japan,Applied Science, London, 1987.

[3] H K BERSTEEG & W MALALASEKERA, “Computational Fluid Dynamics Finite Volume Method

[4] Bin Wu, Dan Ratko, Ren Ren, Li Jin, Chenn Q. Zhou. “Development of a Virtual Reality Blast Furnace Package Using CFD,” AISTech, US, 2010.

[5] Bin Wu, Guoheng Chen, Dong Fu, John Moreland, Chenn Q.Zhou, “Integration of Virtual Reality with Computational Fluid Dynamics for Process Optimization”, 6th International Symposium on Multiphase Flow, Heat Mass Transfer and Energy Conversion, 2

[6] John A. Ricketts, “The Iron Making Blast Furnace & The Integrated Steel Plant,” ArcelorMittal, US, April 2008.

[7] Shahnawaz, V. J., Vancde J. M., and Sasikuma“Visualization of Post-Processed CFD Data In A Virtual Environment,” ASME Design Engineering Technical Conferences, Las Vegas, Nevada, 1999.

[8] Dong Fu, Bin Wu, John Moreland, Guoheng Chen, Chenn Q.Zhou, “CFD Simulations and VR Visualization for Process Design and Optimization”, In ProceedinUECTC-RE ’09, 2009.

[9] Gu, M., Chen Z., Selvarasu N. K., Huang, D., Chaubal, P., and Zhou, C. Q., “Simulation of Pulverized Coal Injection in a Blast Furnace”, ASME IMECE, Chicago, Illinois

[10] A.S. Jamaluddin, T.F. Wall and J.S. Truelove, “Mathematical modeling of combustion in blraceways, including injection of pulverized coal”, Ironmaking and Steelmaking, vol. 13, pp. 91

[11] http://www.paraview.org

[12] http://www.infitec.net

[13] http://www.intersense.com

[14] http://www.vrjuggler.org

[15] http://www.vesuite.org

[16] http://www.openscenegraph.org

[17] http://www.3dsmax.org

Short Article Title

anticipate future requirements of bl-ast furnace research communication. In addition to displaying research data, the VBF will be used for training people in the blast furnace field. Different packages have been created to try and train people from a variety of

J. H. Strassburger, (Ed.) “Blast furnace, theory and practice”, Gordon and Breach, vol. 2, 1969.

Blast furnace phenomena and ” The Iron and Steel Institute of Japan, Elsevier

H K BERSTEEG & W MALALASEKERA, Computational Fluid Dynamics Finite Volume Method.”

Bin Wu, Dan Ratko, Ren Ren, Li Jin, Chenn Q. Zhou. Development of a Virtual Reality Blast Furnace Package

Bin Wu, Guoheng Chen, Dong Fu, John Moreland, Chenn Q.Zhou, “Integration of Virtual Reality with Computational Fluid Dynamics for Process Optimization”, 6th International Symposium on Multiphase Flow, Heat

Transfer and Energy Conversion, 2009.

John A. Ricketts, “The Iron Making Blast Furnace & The Integrated Steel Plant,” ArcelorMittal, US, April 2008.

Shahnawaz, V. J., Vancde J. M., and Sasikumar, V. K., Processed CFD Data In A Virtual

gn Engineering Technical , 1999.

Dong Fu, Bin Wu, John Moreland, Guoheng Chen, Chenn Q.Zhou, “CFD Simulations and VR Visualization for Process Design and Optimization”, In Proceedings of

n Z., Selvarasu N. K., Huang, D., Chaubal, P., and Zhou, C. Q., “Simulation of Pulverized Coal Injection in a Blast Furnace”, ASME IMECE, Chicago, Illinois, 2007.

A.S. Jamaluddin, T.F. Wall and J.S. Truelove, “Mathematical modeling of combustion in blast furnace raceways, including injection of pulverized coal”,

ol. 13, pp. 91-99.