Modeling Centers

Computational Fluid Dynamics Modeling
(Pellet Induration Systems)

Induration modeling began at CMRL in 1997 when Computational Fluid Dynamics modeling capabilities were formally established, as an outgrowth of research initiated in the 1990s by the Minnesota Department of Natural Resources. Since then a number of projects involving design and analysis of induration systems have been completed for the taconite industry.

CFD simulations are used to design and investigate engineered systems as well as improve understanding of fluid physics and chemistry, as revealed through turbulence combustion and heat transfer. CFD process models are developed to analyze problems related to fluid flow turbulence, combustion and heat transfer. CMRL has focused on applications related to Grate-Kiln Cooler pellet induration systems; a model of a straight grate system is currently under development.

In addition to CFD models, CMRL has worked in close cooperation with the UMD Chemical Engineering Department to develop specialized computer subroutines defining pellet heat ansfer and chemical reaction kinetics for the CFD simulations. The Chemical Engineering Department has also developed the MEDUSA mass and energy balance model for pellet induration systems. CMRL and UMD Chemical Engineering have integrated CFD with the MEDUSA model to develop a highly accurate mass and energy balance simulator for Grate Kiln systems, including options such as coal combustion, and ported kilns.

For more information, please contact Dave Englund.

Concentrator Modeling Center

The goal of this center is to assist plant operators in improving their plant performance using simulation as a tool. It also develops improved models of unit operations common in processing plants to increase the predictive capabilities of simulators. Complete plant simulations—from crushing to final concentrate, including all processing steps—can be performed. Established simulation-based services employ conventional size-recovery type models with pseudo-liberation incorporated structures. Liberation-based modeling is now being developed as the next generation of mineral processing simulation software. The Concentrator Modeling Center already has the capability of predicting mineral content of individual particles and their fate in processing steps.

Most separations within a plant occur on the basis of liberation characteristics of individual particles. In 2005, the Center incorporated an integrated size reduction-liberation model developed by Ron Wiegel into the Usim Pac. A crucial step to move liberation-based simulations forward was incorporated into the Usim Pac in 2005 with an integrated size reduction-liberation model developed by Ron Wiegel. Since then, the Concentrator Modeling Center has been incorporating new models that are capable of processing liberation-based data, and now can carry out liberation-based simulations of taconite plants.

The Center is currently involved in several simulation-based projects, providing services to a wide-ranging mineral processing community.

Success Story: Mittal Steel, Minnesota

A throughput increase of 10% was achieved, as a result of simulation assisted modifications implemented at the plant. This study was jointly funded by the Department of Energy (DOE), Iron Ore Cooperative (MN DNR), Permanent University Trust Fund (UMD), and Mittal Steel. Our objective was to demonstrate that simulation could successfully be used as a tool to improve performance of taconite plants. This success resulted in simulation becoming a common tool for taconite plant engineers for testing their performance improvement ideas.

The Center is currently involved in several simulation-based projects, providing services to wide ranging mineral processing community.

For more information, please contact Salih Ersayin.

Liberation based simulation

One of our successes was at the Mittal Steel plant in Minnesota. As a result of simulation assisted modifications that are implemented at the plant, a throughput increase of 10% was achieved. This study was jointly funded by the DOE, Iron Ore Coop (MN DNR), Permanent University Trust Fund (UMD), and Mittal Steel. Our objective was to demonstrate that simulation could successfully be used as a tool to improve performance of taconite plants.