Jeremy Fu

Electric Arc Furnace Test Bench

Role
  • Prototyping
  • 3D Print 
  • Laser Cut

Brief

Create a small-scale model and test bench to evaluate the design of ventilation systems for EAFs. The test bench can test different ventilation system designs and determine their performance by measuring key parameters including flow rate, temperature, and capture efficiency. The model will maintain a similar Reynolds number to the full-scale system so that the systems are comparable, both in time scale and flow properties, and will allow for the placement of varying types and sizes of dampers at different locations. 

Opportunity Space
Electric arc furnaces (EAFs) account for about 25 percent of worldwide steel production. Electric-arc steelmaking heats to temperatures upwards of 3,000 degrees Fahrenheit via massive electric current. During the melting process, the EAF produces many gas emissions and toxic metallic particulates, which are referred to as “off-gas”. Off-gas is responsible for large losses in energy efficiency, poses numerous environmental concerns, and compromises the health of steelmaking workers.
 
Currently, the user struggles because existing computer models lack modularity and robustness. A physical model is the next logical step in advancing their understanding of the nuances in the metallurgy process. In addition, the EAFs that our client works with are highly dangerous facilities and the companies they work for are very risk averse, meaning they are not willing to run tests on their equipment to increase efficiency.
Technical Requirements
  • The test bench accurately reflects the behavior of off-gas in the full-scale system

  • Multiple sensors must gather and display temperature and velocity data at the same time

  • The test bench reliably simulates and tests the temperature change inside the system, the flow velocity through the system, and the response time of the system

  • The test bench allows a user to easily add pieces to it, remove pieces from it, and take it apart

  • The test bench measures the effects of a damper opening and closing on flow velocity

  • The test bench accommodates the placement of a damper at multiple location and accommodates the placement of multiple types of dampers

  • The test bench accurately measures the capture efficiency of the system
3D Printed Damper
Damper Adapter

Low fidelity minimum viable prototypes to test brainstorm concepts

Damper Screen
Reflection

By developing the solution over four design sprints, we were able to adapt to changes and user feedback quickly.

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