On February 13, 2024, CIVS Associate Director for Operations Armin Silaen presented “Steel Industry Overview” at Argonne National Labs as part of the Center for Steel Electrification by Electrosynthesis (C-STEEL)’s first Full Program Meeting.

C-STEEL is a multi-institutional effort, which is funded by the U.S. Department of Energy (DOE) Office of Science for $19 million over four years and is led by Argonne National Laboratory, partnering with Oak Ridge National Laboratory, Case Western Reserve University, Northern Illinois University, Purdue University Northwest, and the University of Illinois Chicago. The center aims to develop an innovative and low-cost process that would replace blast furnaces in steelmaking and reduce greenhouse gas emissions by 85%. The U.S. Department of Energy’s Office of Science is the single largest supporter of basic research in the physical sciences in the United States and is working to address some of the most pressing challenges of our time.

“CIVS’s role in this project is to develop and validate a computational fluid dynamics (CFD) model to provide comprehensive understanding and parametric studies to optimize and intensify the reactor and for future scale-up of the laboratory-scale reactor.” -Dr. Armin Silaen, CIVS Associate Director for Operations

C-STEEL is a key project of the DOE’s Industrial Heat Energy Earthshot initiative, which aims to cut emissions from the energy-intensive process of industrial heating significantly. Partners in the center include Oak Ridge National Laboratory, Case Western Reserve University, Northern Illinois University, Purdue University Northwest, and the University of Illinois Chicago. The Department launched the Energy Earthshots Initiative to spur decarbonization efforts to help the United States meet President Biden’s ambitious climate and clean energy goals, including a 50% reduction in carbon emissions by 2030 and a net-zero carbon economy by 2050. C-STEEL also plans to implement outreach initiatives, mentorship programs, and career development opportunities for students and postdocs to excite the next generation of scientists.

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On February 9th, 2024, representatives from NLMK USA’s automation team visited CIVS to learn the methods used to develop and deploy the SMSVC Smart Ladle. CIVS Senior Research Engineer Nick Walla hosted the NLMK Machine Learning team that included:

Dan Whelan, Melt Shop Process Engineer
Ian Pearson, Production Automation Engineer
Josh Heaton, Production Automation Engineer

The visit is related to the SMSVC Smart Ladle, a software designed to use artificial intelligence to predict future temperatures in the ladle and casting processes of steel production. As part of the SMSVC, different member companies have worked with CIVS to build custom-designed implementations of the Smart Ladle for their locations.

The engineers at NLMK were interested in a deeper understanding of the process for preparing data and training the models used in the Smart Ladle. They were given a walkthrough of the Smart Ladle code and logic, as well as tips for preparing raw site data for machine learning usage.

Smart Ladle is an ongoing project to develop an AI tool that uses industry process data and machine learning to predict future behavior in the steel refining and casting processes. Originally started as part of an AIST Digital Transformation grant, the Smart Ladle has since become a continuing project as part of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC) Refining Ladle project.

Working with the SMSVC industry partners, CIVS students, staff, and faculty have developed a machine learning tool to process steel production data and build correlations between various production logs and sensor measurements to enable the prediction of steel temperatures at a critical stage of the steel manufacturing process.

NLMK USA is a member company of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC). NLMK USA is one of the leading steel companies in the United States. With production sites at NLMK Indiana, NLMK Pennsylvania, and Sharon Coating (NLMK Pennsylvania’s galvanizing operations), they produce flat-rolled steel essential to modern manufacturing.

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Commendatory remarks, smiles, and even a few enthusiastic “high-fives” were shared on Feb. 16 as representatives from the U.S. Department of Energy (DOE) and the office of U.S. Representative Frank Mrvan visited Purdue University Northwest’s (PNW) Center for Innovation through Visualization and Simulation (CIVS) to observe research and impacts for federally-funded steel decarbonization initiatives.

In celebration of several recent multimillion dollar research grants from the DOE’s Office of Renewable Energy and Efficiency for CIVS, Geri Richmond, DOE Under Secretary for Science and Innovation, and Rep. Mrvan toured the CIVS space and listened to brief presentations emphasizing the far-reaching impacts CIVS projects serve for industrial innovation, decarbonization, digital transformation, workforce development and community and industry relations.

“I have read about the things CIVS and this institution are doing, and now I am even more impressed,” said Richmond. “My story to take home to the Department of Energy is that it should be proud, and I am very proud to see what you are doing. It is so cool how my brain can go right in the middle of a blast furnace when you are simulating hydrogen and to see what the energy flow would look like.

“If you do not do things like CIVS does to simulate what happens under different conditions, you have to go to the lab and try over and over again. What CIVS has developed is a simulation system, artificial intelligence and machine learning to simulate what can happen, as well as go back and validate the research. I have done a lot of simulations in my own research, but nothing to this level.” Richmond also commented on how CIVS is collaborating with steel industry partners in prototyping and leading in reducing energy use and greenhouse emissions.

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On February 5, 2024, through February 9, 2024, CIVS researchers Orlando Ugarte, Sathvika Kottapalli, and Shiyu Wang attended Modern Electric Furnace Steelmaking – A Practical Training in Louisville, KY.

This seminar covered the basics of electrical and mechanical features of electric arc furnaces (EAF), including the role of refractories and raw materials. Multiple experts presented fundamental aspects of electric furnace steelmaking technology, such as using energy inputs, the steelmaking process, and electrode operation. Also, environmental concerns for electric steelmaking and decarbonization were presented. The seminar included extensive discussion of current operation procedures, troubleshooting and latest developing technologies in EAF.

Master’s student Shiyu Wang mentioned the importance of this seminar and how these topics relate to her current research in CIVS:

“This EAF seminar was very helpful to me, as most of the topics discussed in the presentations, such as energy loss, slag, energy balance, etc., are related to my research. There were also some topics I had never heard about before, such as the maintenance of EAF, which also helped me deepen my understanding of EAF.”

The series of presentations included “EAF Efficiencies and Slag Fundamentals” by Eugene Pretorius, Manager of Steelmaking Technology at Nucor Corp. His presentation covered EAF slag fundamentals, transient slags, understanding the C/O/Fe balance and how it impacts energy efficiency (electrical and chemical) material recoveries in the EAF, heel control in the EAF, slag retention, and bath level control. Dr. Pretorius represents Nucor, a member of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC), as an SMSVC Board member and has worked with CIVS and other SMSVC member companies to develop a comprehensive, integrated EAF CFD model with various simulators for different stages of EAF operations, such as preheating, melting, and refining. It has been used to simulate the whole EAF process and individual stages of EAF operations and provided fundamental insights and practical guidance to resolve several operation issues.

“Attending the seminar on Modern Electric Furnace Steelmaking was insightful. Especially the expert-led discussions by Dr. Eugene Pretorius and many others sparked my interest in industrial metallurgy. I’m ready to try and apply what I learned in my CFD models.” Sathvika Kottapalli, CIVS Graduate Research Assistant

For Orlando Ugarte, Postdoctoral Associate in CIVS, the seminar was a valuable experience for his EAF research activity:

“The EAF seminar has been a great experience as we have learned from experts in the industry. The presentations covered the fundamentals of the processes and real issues that the EAF operations deal with. The speakers were all experts in the industry, and it was valuable to learn from their experience and to know their thoughts for the future of EAF.”

The Modern Electric Furnace Steelmaking Seminar was organized by the Electric Steelmaking Technology Committee, one of the 29 technology committees of the Association for Iron & Steel Technology (AIST). AIST is a non-profit organization with 16,600 members from more than 70 countries.

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On February 1, 2024, CIVS research staff presented an overview of digital technologies for safety training and workforce development at the 2024 Winter Conference organized by the Eastern States Blast Furnace and Coke Oven Association in Pittsburgh, PA.

As the first of two conference keynote presentations, Senior Research Scientist John “Jack” Moreland presented “Innovative Safety Applications with Virtual Reality and Augmented Reality,” an overview of several examples of the authentic, immersive, and interactive scenarios the SMSVC safety simulators provided. The programs go beyond animation and invite users to interact in real-time with a virtual version of their company’s work areas and processes. The decision-based simulators include areas like fall protection, confined space, arc flash, and lock-out/tag-out. 360° video of real-world surroundings recorded in industrial environments provides immersive experiences such as mobile equipment inspection, portable fire extinguisher training, and hazard recognition. SMSVC safety simulators are created with the following goals in mind: Teach in an engaging way to increase knowledge retention, visualize hard-to-explain concepts and processes, improve productivity, reduce training time up to 70%, and reduce training budget expenditures.

Prior to the conference, the AIST Ironmaking and Cokemaking Technology Committees met jointly to review preparations for AISTech 2024 and technical presentations. Associate Director for Research Tyamo Okosun’s technical presentation entitled “Hydrogen Utilization in Ironmaking: Exploring Methods and Limitations” highlighted the integration of SMSVC digital technologies to advance decarbonization efforts for steel manufacturing, including hydrogen injection and use in the blast furnace process. The presentation also highlighted the research areas at CIVS that derived from issues facing the steel manufacturing industry: increasing energy efficiency, reducing pollutant emissions, reducing downtime, and managing process stability.

The purpose of the Eastern States Blast Furnace and Coke Oven Association is to promote good fellowship among its members and to provide a means for the presentation of papers and open discussion of innovations and challenges pertaining to the Blast Furnace and Coke Oven Industries.

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On January 5th, 2024, Steve Ryan, Manager of Process Technology at NLMK-Indiana, presented “EAF Practice and Evolution – Where We Are, How We Got Here, and Where We Are Going.” to CIVS research students, staff, and faculty in the Immersive Theater during the Friday student seminars held every semester.

In his presentation, Steve gave an overview of Electric Arc Furnace (EAF) history and highlighted the importance and growth of EAF for steel production in the United States. He detailed EAF basic components, EAF Types, process and chemistry basics, scrap quality, and supply. He also emphasized the need for process optimization, utilization of EAF models, and new technologies. Steve also talked about the current strategies and future directions of CO2 mitigation.

“The seminar was incredibly clear and informative, starting with the background of EAF development and then delving into its specific operations and material selection. Steve is very experienced, and his help was invaluable to our EAF project.” –Shiyu Wang, CIVS Research Assistant

NLMK Indiana operates an electric arc furnace, a ladle metallurgy furnace, and a continuous slab caster and converts slabs into coils in its hot strip mill. NLMK North America is a member of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC). Since 2016, CISV has worked with NLMK and other SMSVC member companies to develop a comprehensive, integrated EAF CFD model with various simulators for different stages of EAF operations, such as preheating, melting, and refining. It has been used to simulate the whole EAF process and individual stages of EAF operations and provided fundamental insights and practical guidance to resolve several operation issues.

“The seminar was important because it clarified EAF processes and their classifications. I was able to get a concise grasp of fundamental concepts and expand my understanding of the historical significance of the industry’s process changes.” -Abhishek Kolakotla, CIVS Research Assistant

 

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Public voting for the AIST Real Steel Video Competition is open for February!

 

Find out how robots and autonomous vehicles are transforming the steel industry from CIVS Research Assistant Sai Laya Mallineni, and give it a thumbs up on YouTube if you like it!

 

Take a moment to learn about the future of steel decarbonizing with hydrogen from CIVS Research Assistant Iftequar Iqbal Mohammed, and give it a thumbs up on YouTube if you like it!

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On November 16th, CIVS Director Chenn Zhou and CIVS Associate Director for Operations Armin Silean were invited to present the Gerdau-PNW CIVS Partnership at the Gerdau’s virtual seminar on “the 4.0 Best Projects GAB/GSB/GLN/GSN”.

The presentation highlighted the recent $10 million grant, supported by the U.S. Department of Energy’s Industrial Efficiency and Decarbonization Office (IEDO), for the Development and Demonstration of an Industrial Hydrogen-fired Steel Reheating Furnace (H2RF).

One of Gerdau’s reheating furnaces in Michigan will be used as the site for the first-of-its-kind demonstration under the leadership of Senior Director of Engineering for Gerdau, João Gonzaga, and Improvement Facilitator for Gerdau, Kevin Kondrat. The presentation also included impactful outcomes of other collaborated projects such as the Reheat Furnace, Electric Arc Furnace, and Smart Ladle.

Gerdau is the largest scrap metal recycler in Latin America and a leading global steel producer that operates a network of metals recycling locations, steel mills, and downstream facilities to transform 11 million tons of recycled scrap metal annually into a wide range of steel products. Gerdau is a member of the Steel Manufacturing Simulation & Visualization Consortium (SMSVC). Joao Gonzaga is a member of the SMSVC board representing Gerdau and an alumnus of Purdue Northwest.

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On January 9th, 2024, CIVS staff members Tyamo Okosun, Associate Director for Research, and Nicholas Walla, Senior Research Engineer, along with Kevin Kondrat, Improvement Facilitator at Gerdau Monroe, jointly presented “Energy Efficiency and Hydrogen Utilization for Blast Furnace and Reheating Furnace” to over 250 attendees at the AIST Midwest Chapter Dinner held at the Avalon Manor in Merrillville.

AIST Midwest Chapter Chair Michael Schwentor opened the evening’s presentation by acknowledging the over 30 Purdue Northwest students representing various project teams at CIVS and encouraging them to apply to the AIST Midwest Member Chapter’s Scholarship Program.

The keynote presentation highlighted two recently awarded DOE-funded projects:

“Integrated Virtual Blast Furnace for Real-time Energy Efficiency Improvement,” presented by Tyamo Okosun, is supported by a $7 million grant from the U.S. Department of Energy’s (DOE’s) Office of Energy Efficiency and Renewable Energy (EERE) and has made significant progress since its launch in September 2021. CIVS successfully completed the project’s first phase in March 2023 and entered phase two. The presentation emphasized the efficiency and effectiveness of integrating digital technologies and helped introduce the next project, which will adopt a similar process and application roadmap.

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On November 28th, 2023, CIVS staff members Tyamo Okosun, Associate Director for Research and Kyle Toth, Senior Research Engineer along with Purdue West Lafayette Professor Jun Chen and Post-Doctoral Researcher Weixiao Shang, completed a site visit to U. S. Steel Gary Works #14 Blast Furnace, hosted by Kosta Leontaras, Process Engineer and Jason Entwistle, Head of Blast Furnace Technology.

The visit included a meeting to review the current status of the physics-based reduced order models for the #14 blast furnace developed in the DOE-supported IVBF project. The meeting also provided a forum for feedback from U. S. Steel personnel on the user interface for the IVBF software, which is currently under development.

The goal of the visit was to complete a recording session to test calibrated measurement techniques for predicting flow rate at the blast furnace tap hole using the IVBF casting rate sensor developed by Professor Jun Chen and the project team members at Purdue West Lafayette.

A full casing session was successfully recorded with the imaging sensor, from drilling into the closing of the tap hole with the mud gun. Results will be analyzed to refine the sensor toward the first industrially installed prototype at U. S. Steel. Feedback on the IVBF user interface will be incorporated into the software for deployment at the end of this, the second of three project performance periods.

U. S. Steel, a charter member of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC), has been a critical partner in the IVBF project, providing a testbed and deployment site for all elements of the research. CIVS recently welcomed David Bormet, Director of Product Quality Development of U. S. Steel, as a new SMSVC Board Member serving as the representative for U. S. Steel. He is also a Purdue Northwest Alumni and has over 30 years of experience in the steel industry.

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