blast furnace simulation using dem

8/11/2019 Blast Furnace Simulation using DEM

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Blast furnace load simulation using EDEM

Guilherme Defendi Vale

Anderson Baltazar

ValePaulo 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/m

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/m

Calculated by ESSS Material density (absolute):

Coke: 1250 kg/m

Considering a maximum

packing of 40% 500 kg/m /0.4 =1250 kg/m

Metal: 5750 kg/m

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 toreproduce 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.

blast furnace simulation using dem

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