blast furnace load simulation using edem - esss · blast furnace load simulation using edem...
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Blast furnace load simulation using EDEM
Guilherme Defendi – Vale
Anderson Baltazar – Vale
Paulo de Freitas Nogueira - Vale
Daniel Schiochet Nasato - ESSS
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SUMMARY
• Overview - Vale
• Introduction
• Objectives
• Conclusion
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Objectives
• Use EDEM to predict the material behavior when loading the
blast furnace;
• Analyze the voidage distribution in the blast furnace;
• Use EDEM to predict compressive forces;
• Show potential of EDEM to simulate blast furnaces.
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Geometry dynamics
• Geometry dynamics:
3 opening (batches)
• Linear translation z:
-75mm/s
• Total opening time:
10 s per batch
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Operating conditions
Informed by Vale:• Batch 1 (Coke):
– Coke: 31.2 ton
– Coke density (bulk): 500 kg/m³
• Batch 2 (Metal):
– Sinter: 70.59 ton
– Pellet: 26.91 ton
• Batch 3 (Metal):
– Sinter : 31.07 ton
– Pellet: 20.93 ton
– Metal density (bulk): 2300 kg/m³
Calculated by ESSS• Material density (absolute):
– Coke: 1250 kg/m³
• Considering a maximum
packing of 40%
• 500 kg/m³ /0.4 =1250 kg/m³
– Metal: 5750 kg/m³
Plate Position
(displacement):– Batch 1: 300mm
– Batch 2: 400mm
– Batch 3: 200mm
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Particle Size
• Informed by Vale:
• For pellet was used two fixed value from 8mm and 5mm
Pellet Size (mm) 18 8 5
Withheld (%) 0,0 97,96 2,04
Coke Size (mm) 40 37,5 30 25
Withheld (%) 69,2 12,47 14,87 3,46
Sinter Size (mm) 50 25 15 10 5
Withheld (%) 11,77 34,12 26,56 13,92 13,63
0
10
20
30
40
50
60
70
80
25 27 29 31 33 35 37 39
COKE
0,00
5,00
10,00
15,00
20,00
25,00
30,00
35,00
40,00
5 10 15 20 25 30 35 40 45 50
SINTER
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Data calibration – Coeff. of Restitution
• Experiments were performed at Vale, in order
to obtain correct materials data;
– Coefficient of restitution, static and rolling friction
were calibrated at ESSS.
• Restitution parameters calibrated based on
free fall test.
Initial Hight (cm) Return Hight (cm) Coeff of Restitution
40 0,400 0,100
40 1,270 0,178
40 1,200 0,173
40 1,000 0,158
40 1,140 0,169
40 1,300 0,180
pellet/pellet
sinter/pellet
sinter/coke
sinter/sinter
coke/pellet
coke/coke
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Data calibration – Static Friction
• Parameters were calibrated based on normal/shear force
test.
y = 0,6574x + 8,4531
y = 0,2222x + 10,054
y = 0,6484x + 43,417
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
0,00 5,00 10,00 15,00 20,00 25,00 30,00 35,00
Shear Force(N)
Normal Force (N)
Sinter Pellet Coke Sinter Pellet Coke
Coke Sinter Pellet Sinter Pellet Coke
9,81 14,24 36,92 12,90 12,54 49,38 13,17
19,62 22,68 45,37 20,46 13,79 56,94 16,28
29,43 27,13 56,50 25,36 16,90 62,10 18,68
Shear Force (N)Normal
Force (N)
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Data calibration – Rolling Friction
• Based on repose angle, simulations were
performed to reproduce the same angle on
EDEM;
• Friction coefficient were adjusted to
reproduce the repose angle.
Parameter coke/coke coke/pellet coke/sinter coke/steel pellet/pellet pellet/sinter pellet/steel sinter/sinter sinter/steel
Coeff. of Restitution 0.18 0.1 0.17 0.3 0.18 0.16 0.3 0.18 0.3
Coeff. of Static Friction 0.58 0.62 0.65 0.5 0.64 0.9 0.5 0.52 0.5
Coeff. of Rolling Friction 0.4 0.35 0.38 0.25 0.25 0.33 0.25 0.35 0.25
Material Repose angle (degree)
Coke 35 to 38
Sinter 29 to 33
Pellet 25 to 26
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Simplifications
• Due to real model size, it was simulated only a slice of the
real geometry;
• Batch 1 (Coke): – Coke: 174.2 Kg
• Batch 2 (Metal): – Sinter: 394 Kg
– Pellet: 150.2 Kg
• Batch 3 (Metal): – Sinter : 173.4 Kg
– Pellet: 116.8 Kg
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Initial conditions – particle creation
• It was defined a virtual area in the top of the blast furnace
to create particles.
• Particles were created in a dynamic way.
• Approximated 500 thousand particles simulated.
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Results
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Voidage Distribution
• Sample points in the material bed – voidage distribution
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Material Distribution
Coke distribution Metal distribution
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Material Distribution
Sinter distribution Pellet distribution
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Compressive Force
• Compressive force can be seen in the particle bed
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Compressive Force
• Compressive force profile similar to coke distribution profile
Coke distribution profileCompressive force profile
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Conclusions
• EDEM has demonstrated the ability to reproduce real
phenomena from a large and complex model;
• A furnace model was simulated in about 160 hours:
– More than 500.000 Particles Simulated;
– Physical results based on real Physics.
• EDEM is able to generate quantitative results for blast
furnaces;
– Particle size distribution, compressive force, total force, voidage.