ANSYS Case Studies Optimizing Steel Production with IoT: A Case Study of BlueScope Steel Limited
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Optimizing Steel Production with IoT: A Case Study of BlueScope Steel Limited

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BlueScope Steel Limited, a division in New Zealand, produces 650,000 tons of steel annually from locally sourced iron sand and coal. A crucial part of this process involves the direct reduction of iron sand by char in four rotary kilns. These kilns, large structures with 65 meter-long revolving cylinders, are used to remove oxygen from iron sand to produce a partially reduced material containing the correct amount of carbon for feeding into downstream melters. However, the company faced challenges in understanding the flow patterns, temperature, and concentration contours inside these kilns. Accretion layers or rings, derived mainly from impurities, occasionally form on the inner face of the kiln shell, limiting the production rate. The company needed a solution to this complex problem involving highly turbulent flows, chemical reactions, heat transfer, and a very large geometry in a reasonable time. They also needed to test a range of operating conditions and geometries efficiently.
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BlueScope Steel Limited is a steel production company operating a division in New Zealand. The company produces 650,000 tons of steel per year from locally sourced iron sand and coal. A key component of their production process involves the direct reduction of iron sand by char in four rotary kilns. These kilns are large structures, about 4.2 meters in diameter with 65 meter-long revolving cylinders. The primary function of the kilns is to remove oxygen from iron sand to produce a partially reduced material containing the correct amount of carbon for feeding into downstream melters. The reduction process requires energy which is supplied by the combustion of carbon monoxide and char.
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BlueScope Steel Limited turned to ANSYS CFX and ANSYS DesignModeler software to provide a solution to their challenges. These software solutions were run on a 64-bit workstation to carry out the computations. The solution showed good stability and converged in less than 200 iterations. The computational fluid dynamics (CFD) results were qualitatively validated against available experimental data. The flexibility of both software packages allowed for quick implementation of changes in geometry and/or operating conditions. This provided full details of the predicted temperature, velocity, and concentration contours throughout the kiln in a relatively short time frame. The effects of air flow rates and other operating parameters were also examined readily, contributing to a better understanding of kiln operation and optimization of plant production.
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The implementation of ANSYS CFX and ANSYS DesignModeler software provided significant operational benefits to BlueScope Steel Limited. The software solutions allowed for a better understanding of the flow patterns, temperature, and concentration contours inside the kilns. This information was crucial in optimizing the operation of the kilns and potentially increasing the production rate. The software also allowed for quick changes in geometry and operating conditions, enhancing the flexibility and adaptability of the production process. Furthermore, the software solutions provided feedback in a relatively short time frame to personnel involved in operating the kilns, enabling them to make informed decisions and adjustments in a timely manner.
The solution converged in less than 200 iterations, indicating efficient computational performance.
The company produces 650,000 tons of steel annually, with the potential for increased production rates due to optimized kiln operation.
The solution was implemented on a 64-bit workstation, demonstrating the scalability of the solution.
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