On August 21, CIVS Director Chenn Zhou, CIVS Associate Director for Research Tyamo Okosun, and CIVS Graduate Research Assistant Samuel Nielson attended the Scaling H2 DRI Year 1 Project Meeting at Carnegie Mellon University in Pittsburgh, PA.

The meeting was focused on the DOE-funded project “Scaling Hydrogen-Direct Reduced Iron Pathways to Decarbonize Iron and Steelmaking.” This project is led by Dr. Chris Pistorius at CMU, co-director of the Center for Iron and Steel Research. PNW is contributing to the effort by leading the development of a new CFD model to simulate direct reduction ironmaking (DRI) in both industrial and laboratory environments. CIVS is collaborating with CMU to calibrate the model based on experimental measurements of chemical reactions, assist in the development of new experiments based on expected conditions within different parts of the DRI shaft furnace, and will support the analysis of Hydrogen-based DRI using the CFD model to simulation real-world industrial operations under this low-carbon environment.

Attendees included representatives from Nucor, U. S. Steel, and the U.S. Dept. of Energy, in addition to PNW and CMU researchers actively working on the project. Dr. Pistorius and Dr. Valerie Karplus from CMU presented an introduction to the project, followed by presentations from project team members on the progress on development of the DRI reactor CFD model (presented by CIVS Graduate Research Assistant Samuel Nielson), experimental analysis of iron ore pellet reduction, techno-economic analysis of the process, and a Diversity, Equity, Inclusion, and Accessibility session helmed by faculty and staff from CMU.

 

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Congratulations to CIVS RA Misbahhuddin Syed on receiving his MSME degree and starting a new job at a company in NW Indiana. At CIVS, his research focused on CFD simulation of reheat furnaces. This allowed him to blend rigorous academic knowledge with practical industrial applications and to learn problem-solving skills. He analyzed fluid flow, heat transfer, combustion, scale formation, and stresses within the furnaces to optimize their efficiency.  He also explored induction heating to reduce CO2 emissions.

Misbah successfully defended his thesis titled “Numerical Simulation of Induction and Combustion-Based Reheat Furnaces” on July 29th in the CIVS Immersive Theater. He also accomplished highlightable achievements such as:

Receiving a research grant in 2023 for his paper “Simulating Induction Heating of Steel Products using a Harmonic Balance Model”
Presenting his poster at PNW Days of Discovery 2024 entitled “Scale Formation in the Reheat Furnace”
Serving as President of The Material Advantage Club

The Material Advantage Club was made by and for students seeking to optimize their materials engineering journey. It provides students with access to multiple prominent materials-based societies. This empowers students to enhance their academic pursuits and establish a strong basis for professional engagement after graduation.

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CIVS recently upgraded its Immersive Theater, enabling exciting state-of-the-art visualization capabilities, while supporting the center’s long-term mission of conducting cutting edge research in Visualization and Simulation. The more modern 24′ x 9′ LED curved screen supports a much higher resolution than the old projector-based system. It also still allows for backward compatibility with a lot of the content that the previous system was used for. There are also new features that the system can support, such as better support for VR devices, better connectivity options for external laptops and devices, and adjustable brightness for the screen that can be adjusted on the fly based on the content being shown.

The new system will support continued and updated immersive experiences for industry, university, and community partners and visitors, and be a facet of CIVS for years to come.  Since its completion in July, CIVS project demonstrations in the new curved

screen has already been impressed by a number of visitors including our PNW Chancellor Dr. Chris Holford & New Provost Dr. Maria Mora, Hydrogen Hub leader Dr. Elizabeth Koch, Stelco, CN, and other international and local industry leaders, as well as PNW new students.

 

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On August 7, CIVS staff and students visited NIPSCO’s Michigan City Generating Station. This included visits to the boiler, bag house, and FGD systems, among others. PNW attendees included three undergraduate Mechanical Engineering students working with CIVS on related projects, and two graduate research assistants working on combustion modeling. The tour was organized and supported by Aerielle Kackos (Strategy & Risk Consultant Lead) and Bin Wu (Manager, R&D and Partnerships, Corporate Strategy & Risk, and former CIVS Research Engineer) to provide students with a better understanding of industrial power generation facilities. NIPCSO is a long-time collaborator with PNW and CIVS and has been a Charter member of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC) since its inception in 2016.

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On August 12, new and returning CIVS research assistants gathered in the Immersive Theater for the Fall 2024 student orientation.

CIVS Director Dr. Chenn Zhou and Associate Director for Operations Dr. Armin Silaen opened the meeting by welcoming back and sharing successful student stories over the summer.  Students were encouraged to fully utilize the research opportunities at CIVS to learn and grow for their future careers.

This event fosters belonging between students as well as staff. Staff outlined expectations for CIVS students with the goal of setting them up for success.  Discussions were had to practice this year’s CIVS core value, “Creative, Consistency, Culture”.

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On June 13, CIVS Associate Director for Research Tyamo Okosun attended the ARPA-e Revolutionizing Ore to Steel to Impact Emissions (ROSIE) Kick-off meeting in Chicago, IL. CIVS will be collaborating with Argonne National Laboratory, the University of Illinois Urbana-Champagne, Starfire Industries, and ArcelorMittal on a newly awarded project to explore methods of using microwave-generated hydrogen plasma for ironmaking without generating CO2 emissions.

The project, led by Argonne National Laboratory, will further develop a microwave-powered hydrogen plasma rotary kiln process for reducing iron ore that would eliminate carbon dioxide emissions from the ironmaking process. Argonne’s method has the potential to reduce carbon dioxide emissions arising from ironmaking by 35% compared to the blast furnace process when using today’s grid and by 88% when using a future low-carbon grid, while also reducing the cost of making hot rolled steel. CIVS’s role is to use CFD simulation and visualization for the research and development of the technology.

The iron and steel industry accounts for around 7% of global greenhouse gas (GHG) emissions and 11% of global carbon dioxide (CO2) emissions. By 2050, global iron and steel demand is projected to rise as much as 40%. Already, between 2000 and 2022, global steel production more than doubled to 1,840 million tonnes (Mt). ROSIE aims to develop new technology pathways to enable zero direct process emissions in ironmaking (i.e., zero-process-emission ironmaking) and ultra-low life cycle emissions for steelmaking at scale. All ROSIE projects must account for the impact a given technology will have on supply chain, production of a final steel product, and overall emissions.

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On July 24, CIVS welcomed SMSVC member company Stelco from Canada.  Their visit included 1) overview of CIVS & SMSVC latest development, 2) review of past and current collaborated projects, 3) In-depth discussions on expansion of Stelco-PNW partnership and potential future projects in digitalization, decarbonization, and safety training in blast furnace, DRI, Casting, Ladle, Reheating Furnace, and other iron/steelmaking processes, and 4) a tour and hands-on demonstrations in the newly renovated CIVS Immersive Theater and AR/VR Visualization Lab.

Representatives from Stelco included Director (Operating Technology & Innovation) John D’Alessio, Manager (Operating Technology & Innovation, Steelmaking & Casting) Fernando Guerra, Process Engineering Consultant (Operating Technology & Innovation) Shamik Ray, Student Employee (Strategic Planning) Zachary Burley and Manager (Operations Shift) Victoria Golebiowski.

Stelco has collaborated with CIVS for more than 15 years.  They have closely worked with CIVS faculty, staff, and students to use CFD simulations and visualization for process troubleshooting and optimization, which has generated cost-savings and down-time reductions.

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Congratulations to the 7 teachers who completed the six-week NSF Research Experience for Teachers summer program at CIVS. At the end of the summer program, the teachers presented their research projects and how their research will be implemented in their course curriculum over the school year.

In addition to carrying out their research, teachers developed lesson plans to use with their students during the school year that tie their research experiences to academic standards and introduce them to potential careers in research and industry.

RET facilitator and CIVS Senior Research Scientist John “Jack” Moreland concluded the session by presenting the teachers with their certificates of achievement during the RET Teacher Ceremony. This event celebrates their achievement and a chance to showcase their future goals for enhancing STEM education and students’ STEM interest.

Congratulations to the following area teachers who joined CIVS for this summer’s RET program:

Kevin Kaluf, Kankakee Valley High School
Abigail Kraupner, Highland High School
Aaron Longacre, Merrillville High School
Michelle Moreland, Hobart Middle School
Erin Rawls, Crown Point High School
Rami Salahieh, Ivy Tech Community College
Tiffany White, Homewood Flossmoor High School

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CIVS staff, CIVS graduate research assistants, along with industry collaborators were highlighted in the July and August issues of Iron & Steel Technology. 3 technical papers were published in categories of Ladle Refining & Refractories, Safety & Environment, and Decarbonization Technologies (and Energy & Utilities and Environmental).

July 2024 Vol. 21, No. 7

“A CFD Study of Alloy Dissolution and Homogenization in Ladle Metallurgy Furnace”

The addition of microalloying elements in steel production is essential to improve steel properties, as they have a strengthening effect even in small amounts. The dissolution process of copper in the ladle metallurgy furnace was studied using parametric tests on the number of plugs and argon gas flowrates for stirring. To understand the particle movement in the molten bath, numerical simulations were performed using a three-dimensional computational fluid dynamics method. The results show that the mixing time is affected by the number of plugs and the gas flowrate, with the shortest mixing time achieved with a single-plug ladle with a flowrate of 0.85 m3/minute and a dual-plug ladle with a total flowrate of 1.13 m3/minute, both taking 5.6 minutes.

Authors:

Ogochukwu Q. Duruiheme, CIVS Graduate Research Assistant
Xipeng Guo, CIVS Graduate Research Assistant
Nicholas Walla, CIVS Senior Research Engineer
John Lowry, Nucor Steel
Chenn Zhou, CIVS Director

August 2024 Vol. 21, No.8

“Hazard Recognition Scenario Builder for On-Site Customizable Virtual Training”

Hazards are ever-present in the steel plant environment, and a heightened awareness and emphasis on safety is a necessary priority for our industry. This monthly column, coordinated by members of the AIST Safety & Health Technology Committee, focuses on procedures and practices to promote a safe working environment for everyone.

Authors:

Sai Laya Mallineni, CIVS Graduate Research Assistant
Kyle Toth, CIVS Senior Research Engineer
John (Jack) Moreland, CIVS Senior Research Scientist
Xibin Zhou, CIVS Graduate Research Assistant
Chenn Zhou, CIVS Director
Michael Schwentor, U.S. Steel
Garrett Page, Steel Dynamics, Inc.

“Decarbonization and Increased Productivity in the Reheating Furnace Using Hydrogen Fuel”

In the last decade, decarbonization of the steel industry has motivated comprehensive investigation on the use of hydrogen fuel in steelmaking. However, the increased heat output of hydrogen-fueled burners also creates opportunities for furnace throughput improvements. The primary factors that affect steel quality and productivity are the uniform distribution of heat, followed by slab residence time in the reheating furnace. Using computational fluid dynamics to model hydrogen utilization and comparing the results to traditional natural gas combustion, opportunities for increased furnace throughput were found due to the higher relative heat output of hydrogen as a fuel. One approach covered in this study is the use of regenerative burners in a reheating furnace using hydrogen as fuel. Apart from the decarbonization achieved while using hydrogen as fuel, the additional effect of using regenerative burners in such a furnace is studied with respect to thermal efficiency and productivity increase.

Authors:

Anurag Karambelkar, CIVS Graduate Research Assistant
Chukwunedum Uzor, CIVS Graduate Research Assistant
Nicholas Walla, CIVS Senior Research Engineer
Armin Silaen, CIVS Associate Research Professor
Lawrence Fabina, Cleveland-Cliffs
Kurt Johnson, Cleveland-Cliffs
Chenn Zhou, CIVS Director

 

Iron & Steel Technology is the premier technical journal for metallurgical, engineering, operating and maintenance personnel in the iron and steel industry. For more information, visit AIST.org.

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On July 22-23, the 7 teachers participating in the NSF RET program at CIVS presented at the 2024 National Science Foundation (NSF) Research Experience for Teachers (RET) Virtual Poster Session. The session is an opportunity for RET Site Participants from the BIO, CISE, and ENG Directorates to present the culmination of their research to one another in an open and accessible format that fosters the building of cross-directorate relationships among Site Participants and PIs. With sessions for poster presentation and networking, the 2024 NSF RET Virtual Poster Session will increase the impact of the RET program for K-12 and community college teachers by leveraging the networks and making available the research of RET sites across the country.

Kevin Kaluf, Kankakee Valley High School: “The Effects of Charging Temperatures on Transient Thermal & Structural Stress Analyses of Steel Billets in a Walking-Beam Reheat Furnace.”
Abigail Kraupner, Highland High School: “FEA of Thermal Stress in Reheat Furnaces for Various Steel Grades.”
Michelle Moreland, Hobart Middle School: “Investigating the Impact of Teaching Using Virtual Models vs. Traditional Paper/Pencil.”
Tiffany White, Homewood Flossmoor High School: “Enhancing Learning: Designing a Virtual Simulation of a School Emergency Drill.”
Erin Rawls, Crown Point High School: “Enhancing Learning: Technology and Piecewise Functions.”
Aaron Longacre, Merrillville Community School Corporation: “Investigating the Material Properties & Characteristics of 3D Filament. Crane Simulator Controller Redesign.”
Rami Salahieh, Ivy Tech Community College: “Investigating Virtual Training to Mitigate SCADA/ICS Cyber Attack Using AI Expert System.”

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