Two CIVS research papers were presented at the ASME International Mechanical Engineering Congress & Exposition (IMECE) in Portland, OR on November 17 – 21.

Sai Bhuvanesh Nandipati (CIVS RA, MSME) presented “Investigating the Effects of Spray Nozzle Clogging in Continuous Casting of Steel” authored by CIVS RAs Dianzhi Meng, Sai Bhuvanesh Nandipati, CIVS Associate Director for Operations Armin Silaen, and CIVS Director Chenn Zhou.

Xipeng Guo presented “Numerical Investigation of Flow Field and Mixing Efficiency in the Kanbara Reactor” authored by CIVS RAs Mohammed Abdul Razzak, Xipeng Guo, Imran Syed, CIVS Senior Research Engineer Nicholas Walla, Hongbin Yin (ArcelorMittal), and CIVS Director Chenn Zhou.

The International Mechanical Engineering Congress and Exposition (IMECE) is ASME’s largest research and development (R&D) conference focused primarily on mechanical engineering while encompassing perspectives from many engineering disciplines. Each year, roughly 2,400 papers, presentations, and posters are presented at IMECE in 17 core tracks. Attendees include the leading researchers in their representative disciplines from academia, government, and industry R&D labs. The greatest strength of IMECE is the breadth of research presented. With approximately 30 parallel sessions running over a 4-day technical program, every field is addressed. From critical advancements in mature fields to new and innovative areas of R&D.

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Congratulations to CIVS Associate Director for Research, Dr. Tyamo Okosun, for being recognized at the 2024 PNW Society of Innovators Luncheon at PNW’s Westville campus on November 20 as the individual inductee winner. Dr. Okosun was inducted for his innovation of the Integrated Virtual Blast Furnace (IVBF).

The Individual Innovator inductee category recognizes the individuals behind Northwest Indiana’s most innovative products, services and initiatives. To be considered, the individual’s innovation must have been developed in the Northwest Indiana region in the last 4 years. The Society of Innovators annual awards celebration focuses on the spirit of creativity and ingenuity by discovering, honoring, and celebrating innovators from across the seven-county region of Northwest Indiana.

The IVBF integrates multiple components and technologies, utilizing a foundation of high-fidelity 3D CFD modeling performed with HPC, machine learning, and industrial know-how to develop a first-of-its-kind IVBF for both real-time and off-line applications. The IVBF can be used by front line technical and operating groups both off-line and in real time for 1) real time visualization and analytics, 2) rapid off-line modeling for fast and accurate predictions to allow operators to quickly adapt to changing conditions and investigate “what-if” scenarios, and 3) high-fidelity analysis to develop new alternative fuel injections and virtual training.

Click here to watch Dr. Okosun’s Society of Innovators Inductee Video.

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The U.S. Department of Energy (DOE) Industrial Efficiency and Decarbonization Office (IEDO) recently awarded PNW CIVS a grant with $7,158,034 for the decarbonization of Electric Arc furnace (EAF). The project is entitled “Technical Development and Industrial Demonstration of Net-Zero Carbon EAF Steelmaking with Alternative Injection and Stirring Technologies”. The principal investigator of the project is Dr. Tyamo Okosun (CIVS Associate Director for Research). The co-principal investigators are Dr. Armin Silaen (CIVS Associate Director for Operations) and Dr. Chenn Zhou (CIVS Director).  Other key project participants include Drs. Chris Pistorius and Valeria Karplus from Carnegie Mellon University, Joe Maiolo from Linde, and Dr. Eugene Pretorius from Nucor.

This project will leverage expertise from industry and academia in a nationwide collaboration to pioneer an industrial-scale demonstration of alternative refining injection technology and electromagnetic stirring (EMS) in the Electric Arc Furnace (EAF) process. Through industrial trials, PNW CIVS and its partners aim to demonstrate a range of alternative stirring, oxidation, and foaming technologies in a commercial scale EAF. The team will develop novel gas injection technologies aimed at delivering low carbon reducing gases deep into the steel bath, utilize ‘soft’ oxidation technologies (such as CO2 to enable efficient mixing), develop alternative foaming agents, and ultimately culminate in a first-of-a-kind demonstration of EAF steelmaking using no fossil-carbon injectants supplemented by electromagnetic stirring technology. EAF steelmaking is dominant in the U.S. and the elimination of fossil carbon injection in its processing will reduce direct emissions by 40%. The project includes the development of an integrated virtual electric arc furnace (IVEAF) platform to give steelmakers the tools to optimize their own processes and achieve widespread emissions reductions.

The team will integrate various efforts and technologies to develop and implement a demonstration of alternate injectants with EMS in an industry EAF. An integrated approach employing high-fidelity computational modeling, LCA & TEA, advanced visualization, detailed lab experimentation, industrial field demonstration will be used to 1) provide knowledge and guidance for replacing fossil-carbon injection and optimizing oxidation in industrial EAFs for CO2 reduction, and to 2) develop a multifunctional Integrated Virtual Electric Arc Furnace (IVEAF) platform as a guidance and analysis tool for developing strategies and evaluating impacts of different operating conditions on alternative injection EAF operation, and 3) benefit underserved communities through workforce development, virtual training, and reduced fossil fuel use.

EAF steelmaking is dominant in the U.S.  Fossil-carbon injection is a common element of EAF steelmaking for slag foaming and FeO recovery. A successful industrial demonstration replacing particulates with controlled oxidation, gaseous reductant injection, and alternative slag foaming, supported by EMS, is key to establishing that these technologies can be combined to reduce CO2 emissions without negatively impacting productivity and product quality.

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Congratulations to CIVS Graduate Research Assistants on being selected as recipients of PNW Graduate Research Grant Awards for the 2024-2025 Academic Year, sponsored by Graduate Studies Office at PNW. The students and their projects are listed below:

• Abhishek Kolakotla: “Simulating Hydrogen Fuel Blends in Reheating Furnace”
• Rohit Kumar Kovvuri: “Virtual Crane Training Simulation for Enhancing Safety and Training”
• Sai Bhuvanesh Nandipati: “Centerline Segregation in a Cast Slab”
• Sowjanya Yelluripati: “CFD Analysis of Novel Alternative Injected Fuels in Blast Furnace”
• Sathvika Kottapalli: “CFD Prediction and Validation of Refining Stage of Industry-Size EAF”

 

Proposals were evaluated by the review committee on:

• Completeness of application
• Project eligibility
• Student eligibility
• Quality of proposal overall
• Budget/budget justification
• Goals and significance
• Project design/approach
• Bibliography/literature review
• Any previous research

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Congratulations to CIVS Senior Research Engineer Kyle Toth as the principal investigator (PI) for the 2024 AIST Don Daily Safety Grant. The grant was awarded for the project “AI-AAI Artificial Intelligence-Assisted Accident Investigation”. Co-PIs include CIVS Senior Research Scientist John “Jack” Moreland and CIVS Director Chenn Zhou.  The industry mentors for the projects are Nathan Berry and Erik Archer from Cleveland-Cliffs.

This project will develop a software tool to assist accident investigations by combining AI (Artificial Intelligence) and historical accident data into a chatbot interface that helps investigators collect and analyze information surrounding incidents that occur across different sites at a single plant, or across multiple plants, for compiling trend data or consistencies to see if there are issues in safety, training, or awareness that need to be addressed at a site/plant/company level.

The Don B. Daily Safety Grant was established in 2011 by the Steel Manufacturers Association (SMA) and the AIST Foundation to commemorate the life and industry service of Mr. Daily, a compassionate man who truly cared about the safety of all employees working in the steel industry.  His enduring mark on the mini-mill steel industry of North America has been the establishment of numerous safety and health initiatives that have significantly improved the workplace. The objectives of the grant are to promote a safe workplace for the steel manufacturing industry, to increase the number of students who study health and safety awareness relative to the manufacturing environment, to provide direct student interaction for awareness of the steel industry and recruit more students for employment in the steel industry. Only one project is selected per year.

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On October 28-29, CIVS Director Chenn Zhou presented a joint keynote at the North American Green Steel Summit in Detroit, MI. Dr. Zhou presented “Accelerating Energy Efficiency and Use of Hydrogen for the Green Transition of Steel Production”. Co-contributor to the presentation is Dr. Joachim von Schéele, Global Director Commercialization at Linde. Linde is a charter member in the Steel Manufacturing Simulation & Visualization Consortium (SMSVC) and also a team member for multiple DOE decarbonization projects led by CIVS.

Dr. Zhou was also a panel moderator. The panel topic was “Journey to Sustainable Steel”. Panelists included Joachim Stolz, SVP of Operations, Outokumpu Stainless USA, LLC, Christopher Hessler, Environmental and Regulatory Affairs Manager, Gerdau Special Steel NA, Jamie Price, President of Ovako North America, Ovako Group, and Brian Kristofic, Director – Strategic Initiatives, BlueScope North America.

Various topics at the summit included:

• Shaping the Future of Green Steel in NA: Navigating the Regulatory Landscape and Addressing Talent Needs
• Green Hydrogen and Related Pathways for Decarbonizing Steel Industry
• Panel Discussion I: Renewables, Complementary Technologies, and Low Carbon Minerals to Supply a More Sustainable Steelmaking
• Panel Discussion II: Journey to Sustainable Steel
• Accelerating Energy Efficiency and Use of Hydrogen for the Green Transition of Steel Production
• From Molten Salt to Molten Steel: An Advanced Nuclear Solution for Carbon-Free Industry
• Panel Discussion III: Vision for a Carbon-Neutral Future
• “Do Better Things” – What We Can Do Now to Help in the Difficult Global Green Steel Transition
• Overview of the Iron and Steel Industry Transition to Green
• Green Steel Strategy and Circular Economy at Swiss Steel Group
• Processes Electrification & Digitalization – Pave the Way for Carbon Neutrality of Steel
• Panel Discussion IV: Steel Emissions Reduction from the Angle of Use End

Over 100 industry leaders from North America were in attendance. The NAGSS brought together professionals from the iron and steel industry as well as other relevant stakeholders to discuss the situation and trends of green steel development in the NA region, and to delve into the latest achievements in steel carbon reduction.

Key stakeholders across the green steel value chain who engage to drive innovation, collaboration, and actionable solutions for green steel and keep themselves stay ahead of industry trends and emerging technologies that will redefine the future of steel.

Summit background: Due to the increasing climate challenges faced by the world, the decarbonization has increasingly become a global consensus, and the green transformation of the steel industry has become the key to solve these bottleneck problems of environment, energy and resources, as steel production is accounting for 7% of total man-made greenhouse gas emissions. North America has been committed to decarbonization and it is happening at full speed. The region is currently with the lowest carbon emissions from steel production in the world, as a result of the combination of economic, financial and technological factors. With the global decarbonization process accelerates, it is expected that the demand for green steel will continue to grow. In the future, green steel in North America will reflect its growth rate through specific indicators such as capacity expansion, market share, significant decline in carbon emissions, economic benefits and social influence. In order to achieve sustainable, rapid and high-quality development in the future, it needs to solve several problems such as technical economic development, energy infrastructure transformation, policy support, industrial chain coordination and environmental and social licensing.

 

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Neil Banwart, MachH2 Chief Integration Officer, was the keynote speaker at the SMSVC annual meeting dinner on November 6. His speech was an overview of the Midwest Alliance for Clean Hydrogen (MachH2).

Over 80 attendees included professionals from SMSVC industry collaborators and CIVS faculty, staff, and students. Neil’s keynote presentation opened an impactful discussion in which the audience gained insight on MachH2 and how the Midwest Hydrogen Hub will enable decarbonization through strategic hydrogen uses including steel and glass production, power generation, refining, heavy-duty transportation, and sustainable aviation fuel.  The Midwest Hydrogen Hub plans to produce hydrogen by leveraging diverse and abundant energy sources, including renewable energy, natural gas, and low-cost nuclear energy.

As Chief Integration Officer, Neil’s responsibilities include ensuring MachH2 maximizes all sources of funding and also working to continually expand the reach and impact of MachH2. In conjunction with the CEO, he also represents MachH2 in public-facing matters such as media interviews, on panels, and at tradeshows.

To learn more about MachH2 and its initiatives, visit machh2.com.

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Approximately 80+ industry collaborators and CIVS faculty, staff, and students met at CIVS for the SMSVC Annual Meeting on November 6 and 7. The events included 1) technical presentations by CIVS staff and students in 6 topics (safety, ironmaking, EAF, Continuous Casting, Ladle, and Reheating Furnace), 2) A Dinner Keynote, 3) Project Technical Committee meetings, and 4) the SMSVC board meeting. Active discussions were held throughout the two-day event, with excellent feedback on the project progress and outcomes as well as the quality of presentations.

This annual event facilitates the advancement and implementation of models and simulators for SMSVC projects. The thorough review and discussions ensure continued project success and future directions to address the industry’s needs. SMSVC’s collaborative efforts toward the implementation of smart manufacturing will continue to impact the sustainability and competitiveness of the steel industry by addressing critical issues in process optimization, digitalization, productivity, and safety. The goal of CIVS and SMSVC is to maintain their position at the forefront of industrial decarbonization, energy transition, smart manufacturing, and workforce development through research partnerships with industries and communities.

The annual event included a keynote speech on November 6 by Neil Banwart, Chief Integration Officer of MachH2, entitled “Midwest Alliance for Clean Hydrogen (MachH2) Overview”. The presentation highlighted MachH2, one of 7 regional clean hydrogen hubs awarded by the U.S. Department of Energy.

The Steel Manufacturing Simulation and Visualization Consortium (SMSVC) is a nationwide, industry-led sustainable consortium launched in 2016 by the Center for Innovation through Visualization and Simulation (CIVS) at Purdue University Northwest and is supported by more than 16 companies and organizations. The consortium is focused on supporting the development and implementation of simulation and visualization technologies to address major technological issues and related barriers that inhibit the growth of advanced manufacturing in the steel industry to ensure a competitive advantage for steel manufacturing.

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CIVS hosted multiple groups of students from area schools with teachers who participated in the 6-week NSF Research Experiences for Teachers (RET) program at CIVS this summer. Hobart Middle School visited on October 18, and Merrillville High School visited on November 19. During their visits, students learned about simulation, steel-related research and careers, and a variety of projects happening at CIVS. The students also talked with CIVS students and staff, participated in hands-on demonstrations like operating a virtual crane to move giant ladles of molten steel, and using a fire safety simulator. Other demonstrations included harvesting coral from an underwater nursery and learning about sharks in VR as part of NSF DREAMSTEM project being developed with College of the Florida Keys.

One of the RET teachers, Hobart Middle School science teacher Michelle Moreland, conducted her summer research at CIVS focused on decarbonization using CFD to simulate using hydrogen instead of natural gas for power generation. She also learned to use Unity software and developed an app for her science students to explore the simulation, collect data, and analyze it. Mrs. Moreland is also piloting a new Game Development course using Unity and teaching students how to develop their own software.

When asked about the visit, Mrs. Moreland said, “I wanted the students to learn about the research going on at CIVS. They really liked the crane simulator and understood the importance of using simulators for training.”

Another RET teacher, Aaron Longacre from Merrillville High School, brought his Digital Electronics class and showed them the research he did at CIVS over the summer which involved testing 3D-printed materials and designs for a custom controller used as part of the Crane Training Simulator for the steel industry. Mr. Longacre said, “The kids thoroughly enjoyed the day, and I’m sure some of their eyes were open to future career and college possibilities.”

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On September 30-October 3, CIVS Senior Research Engineer Nicholas Walla attended and presented at the AFRC Industrial Combustion Symposium in Calgary, Alberta Canada. Nicholas presented “Large Eddy Simulations of Hydrogen Burner”.

The symposium was held by the American Flame Research Committee (AFRC). The AFRC is composed of representatives of industrial and research organizations and associated eminent combustion expert members in the United States, Canada and Mexico. The AFRC sponsors open forums in North America on applied combustion technology and research and supports the applied combustion research activities of the International Flame Research Foundation (IFRF).

The steel industry is a cornerstone of U.S. manufacturing, infrastructure, and defense, supplying one of the most vital materials. The slab reheating furnace, a crucial process in steelmaking, is highly energy-intensive and produces substantial CO2 emissions due to natural gas combustion. Computational fluid dynamics (CFD) simulation has emerged as a powerful research and development tool to optimize furnace performance, enhance energy efficiency and productivity, and investigate alternative fuels like hydrogen to reduce CO2 emissions. Currently, in the real-world furnaces using natural gas, pre-heated air is used for combustion, whereas the natural gas inlets are kept at room temperature. But while transitioning to hydrogen combustion, this may not be required. This paper showcases state-of-the-art CFD simulations of industry-scale reheating furnaces that use methane-hydrogen fuel blends with varying air inlet temperatures. Using a hydrogen fuel blend can potentially lead to significant reductions in CO2 emissions. Examples from the PNW Center for Innovation through Visualization and Simulation (CIVS) and the Steel Manufacturing Simulation and Visualization Consortium (SMSVC) will be included.

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