Isabella Mazza (Ergolines - IT)
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Transcript of Isabella Mazza (Ergolines - IT)
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Fortissimo Experiment 402
Isabella Mazza
Ergolines Lab s.r.l.
Cloud-based simulation of continuous casting
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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
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
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
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
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?
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
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?
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
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”
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
• 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
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
• 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
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
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
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
• 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
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels
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