ondemand webinar effizienzsteigerung durch
TRANSCRIPT
OnDemand WebinarEffizienzsteigerung durch multiphysikalische
Simulation in der Materialverarbeitung
Peter JeszencsakFrei verwendbar @ Siemens 2019 Realize innovation.
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Raw Material
• Operating Conditions
• Catalyst
Energy
• Steam
• Heat
• Fuel
Value Added
Product
• Waste
• Pollution
• By-products
Profitability in the Metallurgy and Glass Production
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Challenges
Energy Improve Efficiency
EnvironmentReduce, Reuse, Recycle
Source: https://www.nrcan.gc.ca/energy/efficiency/industry/technical-info/benchmarking/canadian-steel-industry/5183
Tremendous savings potentialOne of the most energy intensive industry
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2020 Vision for Energy Intensive Processes: Heat & Steam
Burners in process boiler systems
• NOx <2 ppm, CO < 5ppm
• Multi-fuel capability
Burners in furnaces
• 90% reduction of pollutants
• CO2 per international agreements
• 20%-50% reduction in fuel consumption
• Multi-fuel capability
Office of industrial technologies, DOE Report DOE/GO102001-1213, Feb 2001
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Aluminum Metals Glass Chemicals Steel Paper Petroleum
STEAM HEAT
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Louis Sullivan
Wainwright Building, St. Louis, MO ca.1891
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It is the pervading law of all things organic & inorganic,
of all things physical & metaphysical, human & superhuman,
of all true manifestations of the head, heart, & the soul,
that the life is recognizable in its expression,
that form ever follows function.
This is the law
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Form = Design
Function = Performance
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Base design or a “form” and performance indicator or a
“function”
•BUSINESS PROBLEM
Reduce
Emissions
Improve
Thermal
Performance Burner in a Ethylene Cracker Furnace
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Iteratively Evolve the Design
To
Solve Business Problem
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Genetic Algorithm
Smart Algorithm
Machine Learning
Artificial Intelligence
Natural Selection
Decision Tree
Evolution
Hybrid
Adaptive
Performance
Revolution
Design
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13% Lower
NOx
5% Lower
CO
Optimized
Flame
Shape &
Volume
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Simcenter STAR-CCM+
An integrated multiphysics solution for process efficiency
Realism with multiphysics
Fluid dynamics
Multiphase flows
Reacting flows
Solid mechanics
Particle flows
Rheology
Electrochemistry
Electromagnetics
Fluid-structure
interaction
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• Optimum material distribution (coke and ore)
required for efficient use of fuel
• Siemens Simcenter STAR-CCM+ is
CAE (computer aided engineering) software that
can analyze performance using fundamental physics
• Phenomenon such burden structure, cohesive zone.
• Algorithms can be used to find optimum operating
conditions or design alternatives that can balance
complex parameters
Use Case: Reduce blast furnace operating costs
Blast Furnace Burden Structure
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Customer benefits
Reduce fuel costs
Energy savings (>100 K)
Increase operating efficiency
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• Characterize of gas-liquid flow to optimize the mixing
efficiency of the Basic Oxygen Furnace (BOF)
• Siemens Simcenter STAR-CCM+ is
CAE (computer aided engineering) software that
can analyze performance using fundamental physics
• Phenomenon such burden structure, cohesive zone.
• Algorithms can be used to find optimum operating
conditions or design alternatives that can balance
complex parameters
Use Case: Improve mixing performance
Basic Oxygen Furnace Mixing
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Customer benefits
45% decrease in mixing time
Improve steel quality
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• Evaluate stirring and mixing efficiency in ladle
• Siemens Simcenter STAR-CCM+ is
CAE (computer aided engineering) software that
can analyze performance using fundamental physics
• Phenomenon such gas injection or magnetic stirring
can be ealuated
• Algorithms can be used to find optimum operating
conditions or design alternatives that can balance
complex parameters
Use Case: Gas or Magnetic Stirring
Ladle Furnace
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Customer benefits
Improve stirring efficiency
Reduce cost of trial and error with a safer
method
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• Effective method to evaluate and mitigate the risk
connected to confined hazardous releases
• Siemens Simcenter STAR-CCM+ is
CAE (computer aided engineering) software that
can analyze performance using fundamental physics
• Phenomenon such gas dispersion, explosive limits,
mean age of gas can be evaluated.
• Algorithms can be used to find optimum operating
conditions or design alternatives that can balance
complex parameters
Use Case: Gas dispersion and explosion limit evaluation
Coke Oven
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Customer benefits
Low Cost Safety and Risk Analysis
Accurate sizing of ventilation area & rate
Prevent human hazards and accidents
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ArcelorMittal
Cutting plant maintenance costs with Simcenter STAR-CCM+
ArcelorMittal uses simulation
to troubleshoot excessive
equipment wear due to
erosion and extends plant
life
30%reduction in erosion
achieved in best design
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Key Requirements
• Ability to import CAD from a variety of sources, including
directly from external CAD packages
• Tools to create, modify or repair complex geometry
Workflow Automation
Speed and Performance
Multiphysics Modelling
Flexible and Robust Meshing
Powerful Data Analysis
Intelligent Design Exploration
Complex Geometry Handling
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Key Requirements
• Robust meshing to capture complex geometry features
• Adequate resolution of fluid and solid regions for accurate
conjugate heat transfer simulations
Workflow Automation
Speed and Performance
Multiphysics Modeling
Flexible and Robust Meshing
Powerful Data Analysis
Intelligent Design Exploration
Complex Geometry Handling
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Key Requirements
• Ability to model liquid as well as gaseous fuels
• Conjugate heat transfer analysis for component durability
• Accurate prediction of emissions such as NOx and Soot
Workflow Automation
Speed and Performance
Multiphysics Modeling
Flexible and Robust Meshing
Powerful Data Analysis
Intelligent Design Exploration
Complex Geometry Handling
NOx in Flameless combustor (LES)
Green areas: NOx > 50 ppm
Blue: Fuel
Orange: Flame front
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Engineer Innovation with Simcenter STAR-CCM+
Operational excellence for high temperature processes
FV Flow FE Flow DEM particle FE Stress
Comprehensive multiphysics
Multiple solvers in a single environment
• Choose the right numerical scheme for the physics
• Perform multidisciplinary analyses using one tool
Wide range of physics models in a single environment
• Use the right physics for the engineering problem
• Includes: multiphase, reactions, electromagnetics
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Key Requirements
• Robust solvers for combustion simulations
• Excellent scalability for multiphysics simulations
Workflow Automation
Speed and Performance
Multiphysics Modeling
Flexible and Robust Meshing
Powerful Data Analysis
Intelligent Design Exploration
Complex Geometry Handling
0%
25%
50%
75%
100%
0
12.288
24.576
36.864
49.152
0 6.144 12.288 18.432 24.576 30.720 36.864 43.008 49.152S
PE
ED
UP
CORES
ColdHotIdeal (100% scaling)
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Key Requirements
• Powerful, integrated post processing and visualization
• Tools to understand complex interdependencies
Workflow Automation
Speed and Performance
Multiphysics Modeling
Flexible and Robust Meshing
Powerful Data Analysis
Intelligent Design Exploration
Complex Geometry Handling
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Key Requirements
• End-to-end pipelined workflow in one environment
• Workflow easily repeated with a few clicks enabling design
space exploration
Workflow Automation
Speed and Performance
Multiphysics Modeling
Flexible and Robust Meshing
Powerful Data Analysis
Intelligent Design Exploration
Complex Geometry Handling
CAD Solution AnalysisMesh
R1
R2
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Key Requirements
• Intelligent search and design space exploration to improve
combustor performance
• Explore designs that help maximize fuel-air mixing, minimize
emissions, or maximize exit temperature uniformity
Workflow Automation
Speed and Performance
Multiphysics Modeling
Flexible and Robust Meshing
Powerful Data Analysis
Intelligent Design Exploration
Complex Geometry Handling
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Simcenter STAR-CCM+ simulation of a generic flat flame burner
Burner Operation Requirements
• Flame Stability
• Acceptable flame pattern / length
• Flue gas patterns
• Avoid Flame impingement
• Avoid Flame-Flame interaction
• Maximize combustion efficiency
• Meet stringent emission standards
Design and Performance Objectives of Burners
CFD modeling of burners operating in their actual environment can
provide useful and detailed information that can be used to asses,
improve and optimize their performance
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Design Space Exploration Case Study
Geometry Details:
• 4 Fuel ports
• Fuel and oxidizer at STP – Natural Gas burning in air
• Burner Heat Release = 0.88 MW
• Excess Air Supplied = 10%
Fuel flow rate
Air flow rate
D
Objective : Minimization of CO and NOx from
Baseline Flat Flame Burner Geometry
• Multi-objective optimization
• CO and NOx are competing objectives
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Burner Design Variables
Primary injector Spacing
(range: 25mm – 250mm)
Side nozzle angle
(range: 1 to 30 deg, 10 steps)
Primary ports angle spacing
(range: 5 to 45 deg, 11 steps)
Primary nozzle angle
(range: 1 to 20 deg, 10 steps)
Burner tile angle
(range: 1 to 35 deg, 10 steps)
Side nozzle angle spacing
(range: -120 to 60 deg, 50 steps)
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Burner Optimization Results
Fuel jet resolution using table
based refinement
14 million cells
Sym
me
try
pla
ne
Volume rendering of the flames
4,50E-05
4,51E-05
4,52E-05
4,53E-05
4,54E-05
4,55E-05
1,50E-04 1,90E-04 2,30E-04 2,70E-04 3,10E-04 3,50E-04
To
tal C
O a
t th
e E
xit (
kg
/s)
Total NOx at the Exit (kg/s)
Pareto Front and BaselineOptimization
Baseline
Best Design
Baseline
Lowest NOx and CO
• A total of 85 designs were run
• 13 designs did not meet the following constraints and were rejected:
• Constraint 1: Meet Flame Height Requirement
• Constraint 2: Meet average fire box temperature
• Best design minimizes CO by 0.5% and NOx by 13% from baseline