Tuyere Design for Blast Furnace
Engineering Challenges
- Combustion characteristics of coal across different tuyere & lance configurations
Ansys Solutions
- Porous media capability
- Reaction & species transport modeling
- Discrete Element Method (DEM)
Simulation
Transforming product and process development for metal industry using Engineering.
Ansys Solutions for the Steel Industry
In the steel industry, processes operate under extreme temperatures and demanding conditions where precision, safety, and efficiency are critical. Ansys simulation solutions enable engineers to model and analyse every stage of steel production — from casting and rolling to forming and thermal management. By predicting material behaviour, optimizing equipment design, and improving process efficiency, Ansys helps manufacturers reduce downtime, minimize energy consumption, and ensure safer, more cost-effective production.
Engineering Challenges in Steel Industry
- Campaign life of Blast Furnace
- Stratification in Ladles
- Low quality of coal
- Coal upgrading using Dense Medium Cyclone
- Erosion of refractories in vessels and furnaces
- Air and Water Treatment
- Grade Mixing in Tundish
- Optimization of casting velocities in SEN
- Decarburization of vacuum degassers
- MHD for higher quality continuous casting
- Metal splashing in ladle
- Optimal metal quenching
- Optimization of parameters for higher energy economy in BOF Components
- Uniform heating of billets in furnace
- Thermal cracking of liquid metal containers
Ansys Solutions
- Raceway Modeling, Burner Design
- Flow field modeling due to gas injection
- Flow field prediction inside Dense Media Cyclone to improve separation
- Flow and Thermal field prediction in vessels and furnaces to prediction erosion
- Ash separation based on size, shape, and density
- Canopy Hood and ESP filter modeling
- De-dusters, hoods, blowers, etc., and basic mixing pattern in vessel
- Transient imbalance and free surface flow modeling
- Stabilization of Turbulence in Continuous Casting
- Flow field modeling under EM field
- Free surface modeling under various conditions
- Flow field prediction inside quench tanks
- Burner and Furnace design based on flame shape, flame length and flame-wall interactions
- RTD analysis for optimal tank design
- Fluid-Thermal interaction to solve for structural failure due to high temperature transients
Primary Steel Making Process
Key engineering challenges across stages and the corresponding Ansys capabilities to solve them.
Multiphase Melt Flow in 335t Converter
Engineering Challenges
- No comprehensive CFD model to predict melt flow, cavity depth/diameter, penetration depth
- Jet interactions, slag splashing, mixing times & blowing configurations
Ansys Solutions
- Compressible flow
- Multiphase models
Ladle Drainage & Pouring
Engineering Challenges
- Drain-induced vortices pulling floating slag/inclusions into the outlet stream, contaminating cast product
Ansys Solutions
- Multiphase models
Tundish Flow
Engineering Challenges
- Tundish is critical for meeting steel product grades
- Predicting inclusion–flow interaction
- Mixing time determination during grade changes
Ansys Solutions
- Multiphase (free-surface / Eulerian multifluid) & DPM
- Reacting flow
Ladle Purging
Engineering Challenges
- Optimize gas purging to eliminate temperature gradients
- Predict metal-flow-induced shear stress on refractory lining
Ansys Solutions
- Multiphase (free-surface / Eulerian multifluid) & DPM
Ansys Solutions for Metal Shaping
Processes
- Rolling
- Forging
- Extrusion
- Machining
- Stamping
- Welding
HFSS Solution
Our HFSS Solution provides a comprehensive suite of electromagnetic simulation capabilities designed to support research, design, and development across various industries. This includes expertise in antenna design, RF and microwave components, signal integrity analysis, and electromagnetic compatibility, leveraging advanced simulation technologies to accelerate innovation, optimize performance, and ensure reliable, high-quality products.
