Approximately 80 industry collaborators and CIVS faculty, staff, and students met at CIVS for the SMSVC Semi-Annual Meeting on April 10 and 11, The events included 1) technical presentations by CIVS staff and students in 6 topics (safety, ironmaking, EAF, Continuous Casting, Ladel, and Reheating Furnace), 2) A Dinner Keynote, 3) CIVS student poster competitions, 4) Project Technical Committee meetings, and 5) 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 semi-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 dinner on April 10 by Barry Schneider, President and Chief Operating Officer of Steel Dynamics and President of AIST, entitled “Smart Use of Scrap and Other Alternatives in EAF Operation for Decarbonization.” The presentation highlighted Steel Dynamics’ history of sustainability efforts as well as an overview of various plants and their operations.

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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On April 9, 23 CIVS students, faculty, and staff attended the AIST Midwest Chapter Dinner at Avalon Manor in Merrillville, IN. Students were called to stand up and receive recognition by nearly 300 industrial attendees. This event is an excellent opportunity for students and staff to network with industry collaborators. 

U.S. Steel Senior Vice President and Chief Technology Officer Christian Gianni delivered the keynote presentation, highlighting the innovative philosophy that allows U.S. Steel to address the collective challenge of climate change by successfully reducing carbon emissions. Christian explained his approach to innovation and why innovation is critical to the steel industry’s future. Innovation is about generating impact, and that’s been his focus since joining the company in 2022.

The Association for Iron & Steel Technology (AIST) is a non-profit organization with 15,500 members from over 70 countries. With 30 Technology Committees and 22 Local Members Chapters, AIST represents an incomparable steel industry knowledge and expertise network. Their mission is to advance the technical development, production, processing, and application of iron and steel.

The Midwest Member Chapter is the largest AIST member chapter, with over 1,600 members. It includes North Dakota, South Dakota, Minnesota, Iowa, Nebraska, Wisconsin, Northern Indiana, and a small portion of Northwestern Illinois.

“In the symphony of steelmaking, the keynote dinner presentation from the U. S. Steel CTO orchestrates innovation and sustainability, conducting the industry towards a future where every shred of scrap becomes a pivotal part of decarbonization. This enlightening discourse not only unveils the pathways to cleaner production and substantial cost savings through resource optimization but also serves as a beacon of knowledge, illuminating my mind with a deeper understanding of the intricate dance between technology and environment in the modern world.”

Sowjanya Yelluripati, Graduate Research Assistant.

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Department of Energy Undersecretary Geri Richmond:

“That’s why it’s exactly the reason I am excited to be here, beyond the students, it’s also about the contact that you have with the steelmaking industries and the way that you guys are all really prototyping and leading in this area (to reduce energy use and greenhouse emissions), trying to make sure that we have steelmaking with much less environmental issues that we have”
“I have read about the things CIVS and this institution are doing, and now I am even more impressed. 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.”
“The fact that you are decarbonizing the steel industry by working with companies and students in areas such as using hydrogen, using electric arc furnaces, just to see the simulations of it is great. I am very proud to see what you are doing and particularly to think about how my brain could go right into a blast furnace and see what the flow of hydrogen would look like. This is great. I love projects like this. It shows that our taxpayer money is going to a good place and training more workforce in the meantime.”
“What Purdue Northwest is doing is an important contributor to why the MachH2 Hydrogen Hub was chosen. We want to make sure that you have workforce development, novel ideas and new ways of looking at things. CIVS fits that perfectly while also coupling with industry. Institutions like this are the kind we want to make sure are integrated into the hub.”

 

Congressman Frank Mrvan:

“When we talk about decarbonization, we talk about the ability of our steel industry to thrive. We talk about renewable energy or cleaner energy. We talk about the PNW students at the CIVS lab being able to be an example and a key component of that for the world to see, for the world and our nation to see right here in Hammond, Indiana. We’re creating jobs. We’re creating cleaner air and cleaner water. The students are able to access technologies that will lead for generations. “

“It all has to do with investment from the Infrastructure Bill, from this administration, and from the Department of Energy. This is what we have to offer. The world can see the CIVS lab. So when we bring resources back to Northwest Indiana, CIVS, and Purdue Northwest, they are well spent. We have the industry, the workforce, the education and everyone coming together to make a greater product and to show the world we can do it.”
“Northwest Indiana wins. Our steel industry wins throughout the country. A headline yesterday was we produce more steel in our region than anywhere else in the nation. We’re very proud of that. We welcome you to be able to show off how our educational institutions, our industry and our student body are working together for a thriving industry and for our workforce.”

At the conclusion of their tour, Rep. Mrvan thanked Dr. Richmond for “taking the time to see firsthand the incredible steelmaking and research capabilities of Purdue Northwest and Cleveland-Cliffs in Northwest Indiana.” The congressman then urged all parties to “continue working together to ensure that our region and incredible workforce drive innovation in the steelmaking process and support the strength of our economy and national security.”

 

PNW Chancellor Chris Holford:

 

“As an institution, one of the things that makes us so successful is how we are integrated into the industry around us, as evidenced by CIVS and the Steel Manufacturing Simulation and Visualization Consortium (SMSVC) which was established by CIVS. This close collaboration addresses issues that are important to those industries and helps facilitate economic and workforce development. Our goal is not only to train today’s workforce but also to train the future workforce ten years out. As we transition to hydrogen combustion at an industrial scale, you will also see the innovation and commercialization at a smaller scale. Industrial decarbonization and hydrogen consumption will fuel technological advancement that translates into other industries around us, and a lot of that work will be going on right around us in Northwest Indiana.”
“Our goal is to be training not only today’s workforce but the future workforce ten years out, because as we transition to more and more hydrogen combustion at an industrial scale, you’ll also see the innovation and commercialization at a smaller scale. “So industrial decarbonization and hydrogen consumption will fuel technological advancement, which will eventually translate into the automotive industry and other industries around us, and a lot of that work will be going on right here in Northwest Indiana.”
“We have a tight relationship with the companies and industries around us. We were designated as an innovation and economic prosperity institution and are the only non-R1 in the state of Indiana to accomplish that. I think it comes from the relationships we built over the last couple of decades with the industry around us. More than 90% of the projects we do on this campus are applied in nature. So it’s not just knowledge. It’s application and improvement from our activities. We have a strong commitment as an institution to making industry in the Region better and to providing opportunities for workforce development, providing our students who graduate the opportunity to be in a thriving economy in Northwest Indiana.”

 

Chenn Zhou (NIPSCO Distinguished Professor of Engineering Simulation and founding director of CIVS and SMSVC):

“CIVS is proud to collaborate on groundbreaking initiatives that research, test, and develop energy solutions in order to improve the quality of life for communities both here and around the country. At CIVS, we use cutting-edge technologies to solve real-world problems that can be implemented at large scales. We are grateful for the continued support of DOE and local industry partners, especially our SMSVC member companies, our academic and national lab collaborators, and local communities on these important initiatives.”

 

References – The quotes are from the following news articles:

PNW News: https://www.pnw.edu/federal-officials-tout-recent-multimillion-dollar-research-grants-for-civs-during-tour/
NWI Times: https://www.nwitimes.com/news/local/purdue-northwests-civs-lands-7-1-million-department-of-energy-grant-to-decarbonize-steel-industry/article_39b7ce52-ccea-11ee-8802-d362c955a7cf.html
Chicago Tribune: https://www.chicagotribune.com/2024/02/16/pnws-research-into-decarbonizing-steel-gets-the-spotlight/
DOE EERE News: https://www.energy.gov/eere/articles/solving-riddle-industrial-decarbonization

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On March 20, 2024, in celebration of Women’s History Month, the College of Engineering & Sciences and the College of Technology hosted a Women in STEM event held in the CIVS Immersive Theater.

The event featured a panel discussion with PNW alumna, industry partners, and friends, including long-time CIVS partner Kelly Dallas, who serves as Director of Engineering for the Flat Rolled plants from SMSVC member company Cleveland-Cliffs. Kelly served as the President of the Society of Engineering (SWE) when she studied for her B.S. in Mechanical Engineering at PNW. She has been a leader in the steel industry in promoting STEM education and Careers to K-16 students.

The panelists shared challenges unique to them in obtaining their degree and subsequent industry roles, as well as the barriers they had to overcome, such as Imposter phenomena and pay/equity gaps. Panelists also shared advice on supporting one another and finding a sponsor or mentor. Students had the opportunity to ask questions about key factors to success, such as time management, overcoming stereotypes, and combating burnout. A networking opportunity was provided after the panel discussion.

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On March 13, 2024, CIVS Director Chenn Zhou was invited to present “Saving Energy Using Simulation and Visualization” at the Energy Reduction Fundamentals in the Steel Industry program in Nashville, TN. The seminar is a joint effort between the AIST Energy & Utilities Technology Committee and individual subject experts in the steel industry.

In her presentation, Dr. Zhou gave an overview of industry 4.0 technologies. She specifically described simulation and visualization technologies and how to use them to save energy. She also demonstrated high-impact project examples in various ironmaking and steelmaking processes.

Advanced computer simulation and visualization technologies are increasingly playing a key role in saving energy in steel manufacturing. These technologies can provide coherent understandings of complex phenomena and processes, enabling faster and better decision-making for process design, optimization, troubleshooting, scale-up, and training. Energy saving is one of the primary focuses of SMSVC research.

To date, research outcomes include improved energy efficiencies and the identification of decarbonization and energy reduction opportunities.
Steelmaking is an energy-intensive process, with energy being the second-highest cost of conversion. Those working in the steel industry should pay close attention to how their energy is managed. Energy management and efficiency reduce costs and lower plant emissions, especially carbon dioxide. This seminar is designed to educate attendees on where to find energy-saving opportunities, what can be done to improve energy efficiency, and how to realize savings within their operations.

The Association for Iron & Steel Technology (AIST) is a non-profit organization with over 18,500 members from over 70 countries. AIST represents an extensive network of steel industry professionals with tremendous knowledge and expertise. The AIST Energy & Utilities Technology Committee was formed to promote safe, efficient, and environmentally responsible energy, utilities, and carbon capture & utilization technologies in the production and processing of iron and steel through the facilitation of training, technical presentations, and the exchange of information.

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On March 4th, 2024 CIVS Associate Directors Armin Silaen and Tyamo Okosun hosted international members of ArcelorMittal’s research and development team to showcase CIVS’s capabilities and the long-time collaboration efforts between CIVS and ArcelorMittal, as well as to explore further collaboration into the global industry.

Mark Atkinson, Head of Project Management Global R&D, Senior Director Head of Operations at ArcelorMittal East Chicago, visited CIVS with his colleagues:

Nicolas Bontems, Head of Process Development, Global R&D at ArcelorMittal Maizieres, France
Charles Martins, Head of Global R&D at ArcelorMittal Spain

They were welcomed into the CIVS Immersive Theater for an overview of the center’s history and the founding of the SMSVC. The presentation also included highlighted research and proposed projects that are being funded by recent Department of Energy grants. Associate Director for Research at CIVS, Tyamo Okosun explained the progression of the center’s applied research efforts and its role in the region’s push for industrial decarbonization. He also took a moment to recognize Purdue Northwest’s growth as a Hispanic serving institution and support of first-generation students.

After the presentation the group toured the Visualization Lab to see firsthand the innovative technology being applied to various projects such as work force development and hazard recognition. Two of the main projects showcased by CIVS Senior Research Scientist Jack Moreland were the crane simulator training, which creates a way for workers to train and prepare for live crane training in a risk free virtual environment, and the AIST Steel Wheel [https://apps.aist.org/steelwheel/index.html].
During the visit Mark expressed his gratitude for facilitating the visit and providing his international colleagues a tailored experience at the center as well as a thank you to Director Chenn Zhou for the university’s support to local industry.

ArcelorMittal is a charter member of the Steel Manufacturing Visualization and Simulation Consortium (SMSVC) and the Manager of Process Technologies and Digitalization, Global R&D at ArcelorMittal East Chicago, Bernard Chukwulebe, serves as the company’s representative on the SMSVC Board.

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On March 20, 2024, CIVS Director Chenn Zhou and CIVS research students Shiyu Wang and Abhishek Kolakotla were invited to showcase CIVS’ research achievements in the field of Computational Fluid Dynamics at the 9th bi-annual ArcelorMittal Global R&D CFD & Thermo-Mechanics Days. This virtual event took place March 18-21, 2024, to share information on cutting-edge CFD research in iron and steelmaking with expert research colleagues from Canada, Brazil, Belgium, France, the U.S., and worldwide.

Dr. Chenn Zhou, CIVS Director, presented “Smart Steel Manufacturing through Simulations: Overview of SMSVC Activities.”  She summarized the latest developments of the SMSVC projects in Blast Furnaces, Electric Arc Furnaces, Reheating Furnaces, Ladel, Continuous Casting, and Safety.  She also described nine recent multimillion-dollar DOE grants led or partnered by CIVS for cutting-edge collaborative efforts such as Hydrogen utilization in reheating furnaces and direct iron and steel reactors.  These projects will focus on research, development, and demonstration in industrial decarbonization, digitalization, and workforce development to achieve smarter and greener steel manufacturing by 2030.

Shiyu Wang, CIVS Research Assistant, presented “Integrated CFD Model for the EAF: Recent Progress” to give an overall introduction to the stage-by-stage approach to developing comprehensive and integrated EAF-CFD modeling. This series of models (Electric Arc Model, Coherent Jet Model, and Scrap Melting Model) has provided insights and practical guidance to SMSVC member companies for their EAF operations.

Abhishek Kolakotla, CIVS Research Assistant, presented “Modeling of Hydrogen Combustion in Reheating Furnace” which gave a deeper understanding and preliminary results of research into H2 as fuel in a Reheating Furnace.. The new DOE project on the Development and Demonstration of an Industrial Hydrogen-Fired Steel Reheating Furnace was also presented as it plans to lead the first-of-its-kind field demonstration at Gerdau Special Steel Monroe using H2 supply from Linde.

ArcelorMittal is a charter member of the Steel Manufacturing Simulation and Visualization Consortium (SMSVC), an industry-led sustainable consortium founded by CIVS in 2016.

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CIVS blast furnace research received another AIST Best Paper Award in addition to seven other best papers from AIST and AISI in the past. The newly awarded paper, “Investigating the Use of Shaft-Level Tuyere Injection With Computational Fluid Dynamics,” was presented at AISTech 2023 and selected by the AIST Ironmaking Technology Committee for the 2024 Josef S. Kapitan Ironmaking Best Paper Award.

The authors of this paper include Samuel E. Nielson, Tyamo Okosun, Orlando Ugarte, and Chenn Q. Zhou. The paper applies Computational Fluid Dynamics (CFD) models to explore the use of shaft-level tuyeres to deliver syngas, hydrogen, or recycled top gas into the furnace to enable lower carbon intensity in the blast furnace process. The results were validated against industrial conditions and provided insight into the impacts of shaft-level reducing gas supply on gas and burden temperatures, reduction rates, and coke consumption. The first author, Samuel Nielson, is a CIVS Graduate Assistant. He graduated with a B.S. and Master’s in Mechanical Engineering from Purdue Northwest and is currently studying at Purdue West Lafayette, pursuing a Ph.D. in Mechanical Engineering under the supervision of Professor Chenn Zhou.

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On March 1st, 2024, Joe Morey, Senior Technical Consultant at Morey Industrial Consulting, presented “A Possible Future for Blast Furnace Ironmaking” to CIVS research students, staff, and faculty in the Immersive Theater during the Friday student seminars held every semester.

“Mr. Morey’s presentation was quite an informative session for students like me who are from a non-mechanical background. I appreciated the interactive aspects of his presentation as well. It was clear that his extensive expertise led to his insightful look at the future of ironmaking.” – Gowtham Pentela

In his presentation, Joe gave valuable insight into the future of blast furnace ironmaking stemming from his almost three decades of experience in ironmaking, covering fundamental aspects of the blast furnace process and four potential solutions to reduce carbon emissions from the BF. Joe discussed the core elements of the blast furnace process, the history of blast furnace ironmaking, and changes that have been implemented to improve efficiency and increase productivity over time. He also provided a window into the future of ironmaking with an eye toward reducing and eliminating carbon emissions using methods like hydrogen injection, biofuels, and carbon capture and storage.

“Mr. Morey’s industrial experience has been immensely helpful as I have researched blast furnace ironmaking. His discussion of the energy requirements for iron reduction and potential future technologies to mitigate carbon emissions was insightful and relevant to my research. Additionally, his insight into the limitations of alternative ironmaking technologies reinforced the need to optimize the blast furnace process as much as possible to maintain the level of iron production needed to build an industrial society and reduce the levels of global poverty.” – Samuel Nielson

At Morey Industrial Consulting, the story begins with a passion for helping businesses succeed by unlocking the value buried within. Joe Morey has 20+ years of experience doing just this at one of the largest steel companies in North America and saw the need for personalized, results-driven consulting services for the metals industry, including those who service the metals industry by someone with iron and steelmaking experience.

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On February 13th, 2024, a new DOE-funded CIVS project, “Hydrogen Utilization in the Reheat Furnace,” was presented by Kevin Kondrat, Improvement Facilitator for Gerdau Special Steel, joined by CIVS Senior Research Engineer Nick Walla, at the AIST Detroit Chapter monthly dinner meeting.

The presentation highlighted the Development and Demonstration of an Industrial Hydrogen-fired Steel Reheating Furnace (H2RF) project, supported by a $10 million grant [link] from the U.S. Department of Energy (DOE)’s Industrial Efficiency and Decarbonization Office (IEDO). It was officially announced at a formal ceremony in October 2023. An essential aspect of this project was the H2 fuel research conducted at CIVS & SMSVC since 2018, which led to various phases of development that will expand into 2025.

During the presentation, Kevin introduced the Gerdau Special Steel Monroe mill, which will serve as the industrial site demonstration for the project assisted by Linde. He highlighted the mill’s economic footprint, automotive applications, and production capabilities.

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).

The Association for Iron & Steel Technology (AIST) is a non-profit organization with 15,500 members from over 70 countries. With 30 Technology Committees and 22 Local Members Chapters, AIST represents an incomparable steel industry knowledge and expertise network. Their mission is to advance the technical development, production, processing, and application of iron and steel. The Detroit Member Chapter includes Michigan and parts of Northwestern Ohio.

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