Isabella Mazza (Ergolines - IT)

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Enhancing Digital Transformation in Manufacturing SMEs

22nd of MayBrussels

2015

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Fortissimo Experiment 402

Isabella Mazza

Ergolines Lab s.r.l.

Cloud-based simulation of continuous casting

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INDEX1. WHAT WE ACHIEVED

2. HOW WE DID IT

3. HOW I4MS HELPED

4. HOW WE WILL TAKE IT FORWARD

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ERGOLINES PRESENTATION

I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels

Ergolines is based in Trieste, Italy

Technologies forSteel Continuous Casting:

• ELECTROMAGNETIC STIRRERS • SENSORS• INSTRUMENTATION

44 Countries

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WHAT WE ACHIEVED

1. THE CHALLENGE


INDUSTRIAL PROBLEM:

SLAG TRANSFER

LOWERS STEEL QUALITY

BREAKOUT AFFECTS:

SAFETY

PRODUCTIVITY

Continous Casting

LADLE

TUNDISH

CASTING STRAND

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WHAT WE ACHIEVED

1. THE CHALLENGE


INDUSTRIAL PROBLEM:

SLAG TRANSFER

LOWERS STEEL QUALITY

BREAKOUT AFFECTS:

SAFETY

PRODUCTIVITY

Continous Casting

OUR SOLUTION:

DESIGN OF

SLAG DETECTION SYSTEM

LADLE

TUNDISH

CASTING STRAND

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WHAT WE ACHIEVED

2. WHY HPC?


SLAG TRANSFER STEEL POURING INTERRUPTED BEFORE COMPLETE EMPTYING

STEEL WASTED = 1 TON/LADLE

COSTLY REMELTING NEEDED

DEMAND FOR SLAG DETECTION SYSTEM

NEW BUSINESS OPPORTUNITY

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WHAT WE ACHIEVED

2. WHY HPC?


SLAG TRANSFER STEEL POURING INTERRUPTED BEFORE COMPLETE EMPTYING

STEEL WASTED = 1 TON/LADLE

COSTLY REMELTING NEEDED

EXTREME CONDITIONS

LIQUID STEEL @ 1500 °C

FIELD EXPERIMENTS NOT FEASIBLE

DESIGN REQUIRES CFD SIMULATIONS

HUGE COMPUTATIONAL LOAD HPC

DEMAND FOR SLAG DETECTION SYSTEM

NEW BUSINESS OPPORTUNITY

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WHAT WE ACHIEVED 3. FORTISSIMO EXPERIMENT 402: “CLOUD-BASED SIMULATION OF CONTINUOUS CASTING”


• End User Ergolines Lab s.r.l. (Italy)

• HPC Resource Arctur d.o.o. (Slovenia)

• Objective Exploit HPC to solve an industrial challenge :

Prevent slag transfer

• Activities HPC based CFD simulation of slag transfer Experimental model validation

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HOW WE DID IT

4. Rationale


• Objectives

• Correlate vibrational signal with fluid dynamics

• Numerical Model

• Emptying mechanisms

• Experiments

• Single Phase Model (STEEL only)

• Double Phase Model (SLAG + STEEL)

• Performance Criterion

• Experimental validation of numerical models

Vortex

Drain Sink

Dedicated Laboratory System

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6. Software used & Simulations


HOW WE DID IT

• Simulation time = 322 s = 5 minutes

• Computation time = 183.5 days = more than 6 months

Successful experimental validationSoftware: OpenFOAM 2.2.0

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HOW I4MS HELPED

11. I4MS-enabled Achievements


• to achieve accurate results Transient simulations very fine geometrical discretization small time steps

ELEVATE COMPUTAIONAL TIME: 6 months to simulate 5 minutes

• High quality results: successful experimental validation MODEL RELIABILITY

• Complex phenomena, huge computational load CRUCIAL ROLE OF CLOUD HPC

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13. Economic Impact


Exploitable output: know-how for new product Slag Detection System

Target Market Segments: Steel Continuous Casting

Benefits for Ergolines: reduced time-to-market, new business opportunity, internationalization

Benefits for End-users = Mini Mills:

• Increased Steel Yield: save up to 60% of 1 t wasted steel /ladle= 0.6% of production

• +0.6% Increased Productivity: save 6000 tonnes of steel /year/ 1 Mt produced

• Reduced Remelting costs: 100 €/t X 6000 t/year = 600.000 €/year saved

• Reduced Energy costs of remelting: 500 kWh/t X 6000 t/year = 3 GWh/year saved

HOW WE WILL TAKE IT FORWARD

High Quality

High Velocity

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THANK YOUFOR YOUR ATTENTION

Isabella Mazza (Ergolines - IT)

Technology

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