# 618-0812/01 – Modelling of Metallurgical Processes (MoMePr)

 Gurantor department Department of Metallurgy and Foundry Credits 5 Subject guarantor prof. Ing. Karel Michalek, CSc. Subject version guarantor prof. Ing. Karel Michalek, CSc. Study level undergraduate or graduate Requirement Compulsory Year 2 Semester winter Study language Czech Year of introduction 2004/2005 Year of cancellation 2015/2016 Intended for the faculties FMT Intended for study types Follow-up Master
Instruction secured by
LoginNameTuitorTeacher giving lectures
GRY04 doc. Ing. Karel Gryc, Ph.D.
MIH50 prof. Ing. Karel Michalek, CSc.
SAW002 prof. Ing. Markéta Tkadlečková, Ph.D.
Extent of instruction for forms of study
Form of studyWay of compl.Extent
Full-time Credit and Examination 2+3
Part-time Credit and Examination 16+0

### Subject aims expressed by acquired skills and competences

- student will be able to characterise importance, methods and utilisation of modelling methods in technical practice - student will be able to formulate basic regularities of physical and numerical process modelling - student will be able to describe similarity of processes, derivation of similarity criterion and modelling application in metallurgy of steel production, treatment and casting - student will be able fundamentals of 3D modelling of geometry and numerical modelling in CFD programme FLUENT

### Teaching methods

Lectures
Seminars
Individual consultations
Tutorials
Experimental work in labs
Project work

### Summary

The subject is focused on general methods of process modelling, as mathematical methods, so physical methods of modelling. The subject is focused on principle of process algorithm with particular applications directed to the domain of steel making, secondary metallurgy and steel casting.

### Compulsory literature:

[1] Ilegbusi, O., J., Iguchi, M., Wahnsiedler, W.: Mathematical and Physical modeling of Materials Processing Operation. 2000. ISBN 1-58488_017_1. [2] Cockcroft S.L., M. Maijer D.M.: Modeling of Casting, Welding, and Advanced Solidification Processes XII. Vancouver, British Columbia, 2009, 728 p. ISBN 978-0-87339-742-1. [3] Stefanescu, D.M.: Science and Engineering of Casting Solidification, 2nd ed. 2009, 402 p. ISBN 978-0-387-74609-8

### Recommended literature:

[1]User's Guide MS Word, MS Excel [2]Magazines: Ironmaking & Steelmaking, Steel Research International etc. [3]Articles in professional journals, papers from conferences, research reports, theses. [4]Mazumdar, D., Evans, J., W.: Modeling of Steelmaking Processes. CRC Press, 1 edition, 2009. 493 pages. ISBN-13: 978-1420062434 [5]Ghosh, A., Chatterjee, A.: Ironmaking and Steelmaking. Prentice-Hall of India Pvt.Ltd, 2008. 472 pages. ISBN-13 978-8120332898 [6]Lee, H.-H.: Finite Element Simulations with ANSYS Workbench 13. SDC Publications, Pap/DVD editions, 2011. 608 pages. ISBN-13: 978-1585036530

### Way of continuous check of knowledge in the course of semester

Two scored semester works and its presentation in relevant seminars during exercises. Two scored progress tests.

### E-learning

Only study support in Czech language is available now: http://www.fmmi.vsb.cz/cs/okruhy/studium-a-vyuka/podklady-ke-studiu For electronic communication with the teachers enjoy the university e-mail addresses those can be found here: http://staff.vsb.cz/ Integration of e-learning elements into the subject is in progress.

### Other requirements

There are not additional requirements on students in the field of this subject.

### Prerequisities

Subject has no prerequisities.

### Co-requisities

Subject has no co-requisities.

### Subject syllabus:

Lectures 1.Basic terms of process modelling, classification of models according to different criteria. Physical modelling and its importance in various fields of science. System Similarity, the similarity constants. The geometric, kinematic and dynamic similarity. Dynamic similarity of hydrodynamic systems. Basic types of forces in hydrodynamics. Thermal similarity. 2.Dimensionless parameters (similarity criteria), the distribution and properties of similarity criteria. A complete physical equations, the basic equations, the criterial equations. Determination of dimensionless parameters using dimensional analysis, practical examples of using of dimensional analysis. 3. Determination of dimensionless parameters using method of similarity transformation of the basic equations. Similarity transformation of the Navier-Stokes equations. 4.Approximate physical modelling. Automodelling. Physical meaning of some similarity criteria, the issue of respecting of the identity of Fr and Re criteria. Determination of volumetric flow scales. 5. The experimental nature of physical modelling. Methods for determination of retention times, the impulse-response method, the RTD curves, flow visualization. The principles of construction of physical models. Basic experimental techniques in physical modelling of flow of liquid metals. 6. Fundamentals of flow reactors - hypothetical models of flow, plug flow, perfect mixing. Real reactor. Theoretical retention time. Curve C, curve F. A combined flow model, mean retention time, short-flow, dead volume. Dispersion flow model. 7. Theoretical principles of mathematical modelling of fluid flow phenomena. Flow of real fluids. Laminar and turbulent flow. Navier-Stokes equations and continuity equation. Mathematical models of turbulence. Computational mesh. Discretization technique. 8. CFD software systems. The procedure of numerical simulation in CFD programme ANSYS FLUENT. Preprocessing - geometry creation and generation of computational mesh, the definition of a physical model, the choice of turbulence model, setting of the operational conditions, determination of material properties and boundary conditions. Processing - Solving: the actual implementation of the calculation (stationary, nonstationary), convergence of the solution. Postprocessing - evaluation of results. Examples of using CFD programmes in practice. 9. The selection of suitable mathematical models to describe transient metallurgical processes. Empirical - mathematical and physical (adequate) - mathematical approach a solution. Theoretical foundations of the mathematical description of the transient processes. Approaches and methods for solving of approximation and regression. Parametric identification. 10. The method of planned experiment - DOE. Basic terms, objectives, utilization of planned experiment. Develop a plan of the experiment. Calculation of the effects of factors and interactions. Development of the model experiment. Software support of DOE methodology. Practical use of DOE methods. 11. Static and dynamic model of heat management in the oxygen converter. Basic management level, superior management level. The essence of a dynamic model of management, monitoring of the heat, the relevant data to manage the heat, the methods of measurement. The main features of calculating the charge for heat in oxygen converter. Innovation of melting process. Excise (only for full-time study form) 1. Problems of steel alloying, the basic method of calculation. Build a simple balance equation. Calculating of amount of alloying elements using MS Excel, matrix methods for solving of equation system. 2. Material balance of the charge in preparing the production of high-alloy steels. Software support (P27), the calculation procedure. Solutions for specific conditions specified steel production. Material balance of oxygen converter - calculation, software support (bilance.exe), the function of the program, values setting, processing of the results in MS Excel. Metallurgical justification of the curves. 3. Steel desulfurization at different ways of slag application - theoretical foundations of steel desulfurization, sulfur partition coefficient, desulphurization with synthetic slag using multiple doses of slag, algorithm, calculation in MS Excel. 4. Test No.1. Projection of videos created by the Department of Metallurgy about the physical modelling of metallurgical processes. Excursion to the Modelling Laboratory of Department of Metallurgy. 5. Calculation of characteristic volume of the reactor from the measured values of the impulse response. 6. Analytical derivation of the F-shaped curve. Simulation for the specified boundary conditions. 7. Introduction to working with the CFD software ANSYS FLUENT. Entering the practical problems to practice the solving of the flow in a simple flow system using numerical modelling in the programme ANSYS FLUENT. Basics of geometry drawing, computational mesh generation and specification of input, output, and the walls of the modelled area. Export to CFD code ANSYS FLUENT. 8. Preparation of input values for the solution of flow in the environment of the ANSYS FLUENT CFD computational model and definitions - determining the laminar or turbulent flow in flow systems based on the award, the specification of the physical properties of flowing media, specifications of boundary and operational conditions. Solving. 9. Convergence and termination of the calculation, graphical evaluation of results - the methods of visualization of computational mesh, production profiles and current vectors of temperature, velocity and concentration fields. Sample of data results and their import into MS Excel. 10. Practical utilization of DOE methods to determine the relevant variables of lifetime of springs steel. Aproximative modelling of metallurgical processes - the practical application of Klán identification methods, utilization of solver in MS Excel. 11. Excurse to the CCM in Trinecke zelezarny - Control system of casting. 12. Compensatory exercise, the test No.2, submission programs. To obtain credit in the combined study form is needed to develop a session project.

### Conditions for subject completion

Full-time form (validity from: 1960/1961 Summer semester)
Task nameType of taskMax. number of points
(act. for subtasks)
Min. number of pointsMax. počet pokusů
Exercises evaluation and Examination Credit and Examination 100 (100) 51 3
Exercises evaluation Credit 30 (30) 0 3
Other task type Other task type 30  0 3
Examination Examination 70 (70) 0 3
Written examination Written examination 20  0 3
Oral Oral examination 50  0 3
Mandatory attendence participation:

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Conditions for subject completion and attendance at the exercises within ISP:

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### Occurrence in study plans

Academic yearProgrammeBranch/spec.Spec.ZaměřeníFormStudy language Tut. centreYearWSType of duty
2015/2016 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2015/2016 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production K Czech Ostrava 2 Compulsory study plan
2014/2015 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production K Czech Ostrava 2 Compulsory study plan
2014/2015 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2013/2014 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2013/2014 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production K Czech Ostrava 2 Compulsory study plan
2012/2013 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2012/2013 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production K Czech Ostrava 2 Compulsory study plan
2011/2012 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2011/2012 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production K Czech Ostrava 2 Compulsory study plan
2010/2011 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2009/2010 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2008/2009 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2007/2008 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2006/2007 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan
2005/2006 (N2109) Metallurgical Engineering (2109T035) Technologies of Metal Production P Czech Ostrava 2 Compulsory study plan

### Occurrence in special blocks

Block nameAcademic yearForm of studyStudy language YearWSType of blockBlock owner
FMMI 2013/2014 Full-time Czech Compulsory 601 - Study Office stu. block
FMMI 2012/2013 Full-time Czech Compulsory 601 - Study Office stu. block
FMMI_ECTS 2011/2012 Full-time Czech Compulsory 600 - Faculty of Materials Science and Technology - Dean's Office stu. block