Numerical modelling reduces engineering costs
The benefits of numerical modelling in quickly verifying design
improvements and optimisations, thus reducing the time from design
to installation, was again demonstrated in recent work by BATEMAN
on a new electrode pressure ring with an improved heat-dissipation
capacity. The ring is for application on Söderberg electrodes
in AC-arc furnaces.
Finite element analysis (FEA) and computational
fluid dynamics (CFD) are numerical-modelling techniques used by BATEMAN
in the design of furnace components. Such modelling is also offered
as a consultation service to the designers of a wide range of other
process and mechanical equipment. The service enables engineers to
simulate the response of structures to loads and the flow characteristics
of fluids and gases without the need to build and test costly prototypes
and conduct lengthy field trials. This is a cost-effective and rapid
method for the prototyping of proposed changes prior to re-tooling
and manufacture.
FEA and CFD were used to predict the stresses, cooling
fluid flow characteristics and heat transfer in the existing pressure
ring, quickly identifying the potential trouble spots and enabling
the improved design for the ring to be generated and intensively assessed
before building the new ring.
STAR-CD commercial CFD software was used to evaluate
the temperature and heat-flux distributions of different designs in
conjunction with mass-flow cooling so that hot spots corresponding
to regions of flow stagnation in the existing pressure-ring design
could be identified. The resulting changes made in the water-cooling-passage
configuration minimised the occurrence of these hot spots.
The ANSYS FEA software package was used to determine
the stresses and deflections resulting from the circumferential load
in the pressure ring. Areas showing high stress in the existing pressure
ring were identified and different geometries were analysed to optimise
the final geometry with respect to stress distribution.
To apply FEA and CFD in your design projects, or
for further information regarding these analysis capabilities please
contact:
FEA: Douglas Geekie, Structural Engineer, DC Furnaces
on +27-11-899-2504 or email dcfurnaces@batemanengineering.com.
CFD: Dr Bennie Henning, Mechanical Engineer, DC
Furnaces on +27-11-899-2505 or email dcfurnaces@batemanengineering.com.
