Lechler, Inc., A leader in fluid application engineering, becomes the first in the steel industry to introduce a virtual-reality technology for optimizing the gas conditioning process.

The new technology, known as virtual-reality flow dynamics, is an integration of computational fluid dynamics and three-dimensional, real-time computer animations. Lechler introduces virtual-reality flow dynamics through an association with Fuel Tech of Naperville, IL., a manufacturer of gas conditioning systems.

The unique modeling process enables steel manufacturing engineers to 1) optimize the management of hot gases; 2) maximize the output of electric arc furnaces (EAF's) and basic oxygen furnaces (BOF's) to help the plant run at full capacity; and 3) minimize the cost of pollution control. Steel industry personnel are able to use the customized computer system to proactively improve the factory's existing operations or systematically set up a new gas handling equipment design. For example, the Lechler system can help the customer determine the optimum location for cooling or chemical-injection sprays and the most efficient nozzle types for the gas treatment process.

With this new technology the customer is taken on a virtual-reality tour inside the furnaces and ducts of the gas handling equipment to reveal important details on hot gas flow. More than just a simulation, the sophisticated flow dynamics tool provides a detailed, up-front view of the physical properties of hot gases, including temperatures, directional flows, speed of flow, turbulence, currents, eddies, and even hot and cold spots.

The customized model allows the engineer to then manipulate the positioning of Lechler nozzles and lances, and vary the parameters such as pattern, flow rate and droplet size, to maximize the effects of the gas conditioning system. With the nozzles in the correct position, the user can see first hand and monitor the optimum temperatures, as well as the hot gas emissions and, the particulate they carry.

"The Lechler virtual-reality flow dynamics program makes calculations required for describing gas flow dynamics and presents those results in the most visual format" explains Bernie Forster, Manager of the Primary Metals Group at Lechler. "The engineer can perform 'what if' analyses quickly and effectively and then actually see the results of the changed variables in a realistic, real-time output. Never before has there been such an accurate and visual modeling tool in the industry."

When working with a steel company, Lechler develops a model specific to its needs based on drawings of the manufacturer's gas vessels and input of gas system variables. The customized computer model is then presented to the customer within weeks, rather than the months required for traditional model building.

Before the introduction of this revolutionary gas modeling technology by Lechler, steel production engineers have had to use less-accurate, experimental procedures for identifying issues and potential problems with the process. Designs tended to be more costly or less effective than required - and in some cases, both.

"We understand our customer's need for increased operational efficiencies and improvements, " adds Forster, "and the Lechler virtual-reality flow dynamics system can benefit the steel manufacturer's daily operations with its focus on maximizing the plant's potential and minimizing the cost of environmental controls."

For more information and a videotape demonstration on the virtual-reality flow dynamics technology, please Email us, press the inquiry button below or contact our office.