Computational Fluid Dynamics for Slag Splashing in Electric Arc Furnaces
Numerical simulation of multi-phase supersonic oxygen lance jets and slag coating dynamics to double refractory lining campaign life in modern steel mini-mills.
Slag splashing in electric arc furnaces (EAF) and basic oxygen furnaces (BOF) utilizes high-pressure nitrogen jets to blow molten slag against refractory wall linings, forming a protective sacrificial layer.
1. Multi-Phase Supersonic CFD Simulation MacProtec modeled supersonic nitrogen gas jets interacting with high-temperature molten slag: - Predicting slag droplet ejection trajectories, velocity vectors, and wall impingement angles. - Calculating slag solidifying rates as a function of MgO saturation and furnace wall thermal boundary conditions.
2. Furnace Campaign Extension Results - Achieved uniform slag coating thickness of 25-40mm across high-wear furnace knuckle zones. - Doubled refractory campaign duration, significantly decreasing specific gunning mix consumption.
Pyroprocessing Optimization & Alternative Fuel Combustion in Cement Kilns
Discover how CFD flow modeling, flame aerodynamics, and thermal heat balances increase alternative fuel substitution rates up to 65% while preserving kiln shell integrity.
3D Laser Scanning & Reverse Engineering for Brownfield Plant Revamps
Capturing high-density point cloud spatial data eliminates clash errors during brownfield equipment replacements, preheater tower upgrades, and pipe rack retrofits.
Predictive Telemetry & AI Digital Twins for Heavy Industrial Equipment
Connecting real-time SCADA sensor streams to virtual digital twin replicas enables early detection of bearing micro-fractures, vibration spikes, and thermal anomalies.
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