As a new semester starts, we want to acknowledge the hard work that went into the 2022 Senior Design Presentations. Students are required to demonstrate professional attitudes and attributes from conception to realistic design of their project, which concludes with the written report and formal oral presentation. These presentations are the culmination of a semester long Senior Design/Capstone Project that requires students to create innovative solutions to problems while implementing the use of computer graphics.

Senior Design students are supervised and mentored by faculty members to help explore research interests and develop strong project proposals. Students are also confronted with the applicable task of providing enough context for the project that a person outside of that discipline understands why this project needs to be done through non-technical language.

The following projects were presented by students in conjunction with CIVS faculty:

 

Numerical Simulation of wall shear stress and mixing in steel refining Ladle Furnace

Saleh Alshammari (ME), Ghazi Saad G Alharbi (ME)
Advisors: Chenn Zhou, Tyamo Okosun

This project research and work covers the three-dimensional Computational Fluid Dynamics simulations performed on a Gas-stirred ladle used for refining and mixing of steel. The purpose of this project is to do a research and explore the parameters which impact the life of these ladles and the phenomenon of refractory lining erosion and shear in the ladle wall which leads to its degradation . A real life scale model experiment is to be performed for validation of CFD results. Ansys applications were used to develop and run the simulation. Ansys workbench for development and Fluent for running the case.

 

Design of a Proof of Concept Software for Virtual Solar Farm Safety Training

David Gill (ECE), Cinthia Tafolla (ECE)

Advisors: Chenn Zhou, Kyle Toth

Technicians working in high power electricity face many possible dangers while working with their equipment. Prevention and mitigation are easier than treatment and effectively training employees in electrical safety is a large part of that, helping prevent more deaths and pose less risks to the workplace regarding safety. The main focus of our project was to complete a proof of concept for a virtual solar farm safety trainer to educate trainees in a simulated virtual environment to prevent risk to the trainee, equipment and easier accessibility to complete training. Additionally, a simulated environment has allowed us to perform different safety scenarios and present hazards to test the trainee’s knowledge, how to overcome these hazards in the workplace and safety practices to follow to maintain safety while working on a solar farm. To achieve this, the programs Unity, Blender and GIMP were utilized to create a virtual environment using 3D technology to simulate different scenarios. The virtual simulator features three different modules designed to train in using the proper personal protective equipment depending on the task, properly performing lock out tag out, and situational hazards. Utilizing this simulated training and even improving on it in the future may help further safety practices, the importance of utilizing these safety practices anytime they’re applicable, and preventing any electrical related workplace injuries.

 

Feasibility Study and Simulation of adding Hydrogen Fuel to a Combined Cycle Natural Gas Combustion Turbine at an Electric Generation Plant

Jon Heins (ME)
Advisors: Chenn Zhou, Tyamo Okosun, Mike Melvin

In the electric power industry, organizations are investigating transitioning combined cycle gas turbine (CCGT) power plants from natural gas to hydrogen combustion to decrease dependance on fossil fuels. Additionally, hydrogen can serve as a compliment to natural gas and syngas as an additional fuel source to protect organizations from price volatility. This design project reviews current work in the transition of CCGT engines to hydrogen fuel and develops a parametric combustion computational fluid dynamics (CFD) study of methane blended with hydrogen gas. The CFD study uses a generic can-combustor design and calculations were performed to determine the amount of blended fuel is required to produce an equitable amount of thermal energy to the baseline (100% methane) case. From the parametric study, the impact hydrogen has on the performance, materials, and flue gas composition of the combined cycle gas turbine engine combustor were determined.

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CIVS welcomed new and returning students this past week during the spring semester orientation.

Orientation provides an opportunity to meet fellow student workers and highlight some of the key CIVS goals and expectations that are vital to everyone’s success. It also helps start an open dialogue with students either preparing for their thesis defense or preparing to graduate from a master’s program.

The unique CIVS culture driven by Dr. Chenn Zhou creates a passion for cutting-edge research by opening the door to a wealth of technical knowledge. Students are motivated to use problem-solving, communication, and time-management skills that will inevitably open future leadership doors.

CIVS also hosts weekly Friday seminars in the immersive theater for research students that engage students on topics like industry standards, constructive feedback, recognition, and practice exposure.

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Congratulations to Yanan Song who recently graduated with his Master of Electrical and Computer Engineering after defending his thesis titled “Feature Fusion Deep Learning Method for Video and Audio Emotion Recognition.”

In his time at the Center for Innovation through Visualization and Simulation(CIVS), Song started as a Research Assistant and went on to work as a Research Engineer. He led three highly collaborative Machine Learning industry projects and mentored graduate and senior design students for research projects in the metallurgy industry.

Song’ work was integral to the Integrated Virtual Blast Furnace for Real-time Energy Efficiency Improvement Project. The project is expected to have a significant impact by reducing energy consumption by 4.5% to 10% in blast furnaces and downstream processes, improving productivity and product quality, and reducing emissions from the manufacturing process. The goal is to develop a tool for industrial iron and steelmaking companies to improve blast furnace energy efficiency and reduce carbon emissions, and to develop a virtual training model for workforce development.

The project includes SMSVC partners; ArcelorMittal USA, Oak Ridge National Laboratory, Praxair Inc.- a Linde Company, Purdue University West Lafayette, and U. S. Steel. Yanan Song’s hard work has led to an open offer from a charter member of the SMSVC.

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Congratulations to Ogochukwu Duruiheme who recently defended her thesis entitled: “Numerical Analysis of Dissolution Behavior of Microalloying Elements in Ladle Metallurgy Furnace.” Her advice for current and future students to successfully defend their thesis is to pick a topic early, Review the literature on it, and know the fundamentals. Time moves fast when you are working hard towards a goal. Managing your deadlines can save you a lot of headaches. Persistence and discipline were her greatest assets in garnering knowledge for her thesis.

 

“CIVS is the beginning everyone needs in kick-starting their technical career. It opens you up to a world of discipline and yearning to be better than you were by achieving and exceeding set expectations. The resources are already there, all you have to do is learn.” -Ogochukwu Duruiheme

In her academic career at Purdue Northwest, Ogochukwu Duruiheme worked on the Refining Ladle project, which involves facilities that cast steel to make a final product. The steel needs to be refined first. The industry standard practice is to use a refining ladle. The steel is treated with additives to remove impurities or add additional elements to create different alloys of steel. It then stirs via gas injection to ensure an even product mix and help with the steel cleaning process. Different additive materials can have different mixing behaviors. The goal is to use Computational Fluid Dynamics to model the steel mixing process for different materials and conditions. This optimizes the process more specifically.

This project involved real-world data provided by Nucor Steel and a partnership with other member companies of the Steel Manufacturing Simulation and Visualization Consortium.

 

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CIVS Graduate students Aleeha Zafar and Xibin Zhou, Senior Design students Qingyun Pu and Shiyu Wang, and CIVS mentor Kyle Toth, Senior Research Engineer, had the opportunity to spend a day touring Caster #1 at Burns Harbor, Cleveland-Cliffs’ second-largest U.S. facility, as part of their 3-D modeling work for the Continuous Caster Digital Twin project. The visit was led by Nicholas Gregurich, casting operations manager, and Lidia Yakovleva, operations technology engineer, who later received project various updates from the project team.

Their ongoing project regarding Continuous Caster Digital Twin Project, has utilized 3 D Modeling and drawings. This visit allowed students entering their second semester on the project to tour around Caster #1 at the Burns Harbor Plant and give project updates.

Cleveland-Cliffs is one of 15 member companies of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC). Since 2016, this nationwide, industry-led sustainable consortium established by CIVS at Purdue University Northwest has provided invaluable support for research and project development.

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The Times of Northwest Indiana (NWI Times) Newspaper reporter Joseph S. Pete published an article in the Business Headline on December 12th, 2022, entitled “Purdue Northwest’s CIVS helps steelmakers tackle industry’s biggest issues like decarbonization.” For the original news article, click the link here.

 

“We are working on the two most important topics for manufacturing: digitalization and decarbonization,” CIVS Director and Distinguished Professor of Engineering Simulation Chenn Zhou said.

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PNW’s Center for Innovation through Visualization and Simulation (CIVS) is at the forefront for researching two of the most important topics in manufacturing: digitalization and decarbonization.

Read The Times of Northwest Indiana’s coverage of recent CIVS projects and how researchers use cutting-edge tools for innovation with industry partners.

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CIVS students were among many who attended AIST Yong Professionals Night to start building their steel industry network. Member Chapters and Technology Committees allow student to meet peers and experienced professionals that have a wealth of knowledge to share.

“In order to keep working towards the mission of advancing the iron and steel industry, we must continue to support the rising generation of steel industry professionals. The Young Professionals of AIST are those that fall within the bracket of 30 years of age or younger. The AIST Foundation sponsors a free first year of membership and a discounted membership every year after that until the Young Professional turns 30. “

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CIVS Senior Research Scientist, Jack Moreland presented at the NADCA Research & Development Meeting on October 27, 2022. The presentation was on a VR Fire Safety Simulator for the die casting industry. NADCA (North American Die Casting Association) hosts 3 R&D meetings per year, attended by engineers and research personnel from the die casting industry and academia. CIVS worked with NADCA to develop the simulator through a grant from the Harvill Foundation.

The simulator teaches fire safety and lets users practice putting out different types of fires in a virtual die casting facility. The simulator includes scenarios for fires involving different casting metals (Aluminum, Zinc, and Magnesium), and enforces the industry standard PASS method (Pull the pin, Aim the nozzle, Squeeze the handle, Sweep back and forth). The simulator will be available to NADCA members on the Meta Quest 2 VR system.

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Thank you to around 60 SMSVC industry attendees for a very productive Annual Meeting on November 9th & 10th at CIVS. The meeting was opened with the CIVS & SMSVC overview by Dr. Chenn Zhou followed by SMSVC project technical presentations by CIVS students and staff with ending comments by project technical committee industry members. A special Decarbonization Forum was held, followed by Mr. Ben Knowing’s dinner keynote address on Steel Innovation and Fossil-Free Steel Production. The two-day event ended with the SMSVC Board meeting.

During the event, the advancement and implementation of models and simulators in the SMSVC projects were thoroughly reviewed and discussed, including safety, electrical arc furnace, blast furnace, reheat furnace, ladle, and continuous casting. Industry attendees and CIVS students and staff were actively engaged on technical contents and future project directions. In the Decarbonization Forum, Dr. Zhou reviewed funding opportunities and CIVS & SMSVC decarbonization activities and projects on electrification and Hydrogen utilization for reducing CO2 and other emissions. Industry members discussed the significance, needs, challenges, current practices, as well as short, mid, and long-term targets for decarbonization. All the SMSVC companies are committed to the goal of net zero by 2050. SMSMVC will update our decarbonization application roadmap according to the discussions in the Forum.

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