A Simulator for Educating the Digital Technologies Skills in Industry. Part One. Dynamic Simulation of Technological Processes

Monitoring of the Behaviour and State of Nanoscale Particles in a Gas Cleaning System of an Ore-Thermal Furnace

The aim of this paper is to define and select stable zones in the off-gas duct of an ore-thermal furnace using a mathematical model. This is needed to increase the effectiveness of exhaust gas composition control in metallurgical silicon production. Methods. The goals of this study were achieved by means of computational fluid dynamics. A model with a water-cooled furnace roof as well as a model comprising steel gas passes with a sliding shutter was developed using ANSYS Fluent software. Both models were symmetrical to ensure a uniform gas-dust distribution, which allowed us to test the adequacy of the obtained models. The models were based on the Navier–Stokes equations system as well as on a discrete phase model (DPM) that was developed using the Euler–Lagrange method. Results. As a result of the modelling, a transition flow mode (Re 0-7437) was revealed behind the sliding shutter. As such, it can be assumed that the most suitable place for measuring equipment to be installed is directly behind the closed part of the sliding shutter.

Modeling of Non-Ferrous Metallurgy Waste Disposal with the Production of Iron Silicides and Zinc Distillation

This paper presents studies on the possibility of utilization of technogenic waste from the metallurgical industry by the method of complex processing in order to reduce the anthropogenic load on the environment of the region with the example of the zinc silicate-magnetite-carbon system. The selected sample of clinker dump from welting was subjected to chemical and scanning electron microscopic analyses and thermodynamic modeling. Thermodynamic studies were carried out in the temperature range 1600–2200 K and pressure p = 0.1 MPa, modeling the process of electric melting of clinker from welting in an arc furnace using the software application Astra 4 developed at the Bauman Moscow State Technical University (Moscow, Russian Federation). As a result of the thermodynamic modeling, the optimal temperature range was established, which was 1800–1900 K. Thermodynamic studies established that it is possible to drive away zinc from the system under study by 99–100% in the entire temperature range under study. The maximum degree of silicon extraction (α_Si) in the alloy is up to 69.44% at T = 1900 K, and the degree of iron extraction (α_Fe) in the alloy is up to 99.996%. In particular, it was determined and proved that clinker waste from welting can act as a secondary technogenic raw material when it is processed as a mono mixture to produce iron silicides with a silicon content of 18 to 28%.

The Choice of Optical Flame Detectors for Automatic Explosion Containment Systems Based on the Results of Explosion Radiation Analysis of Methane- and Dust-Air Mixtures

A review of the existing optoelectron monitoring devices revealed that the design of optoelectron detectors of the mine atmosphere does not sufficiently take into account the factor of external optical interference. This includes any extraneous source of thermal emission: a source of artificial lighting or enterprises. As a consequence, the optoelectron detectors -based safety systems currently installed at mining sites are not able to ensure properly the detection of the ignition source in the presence of optical interference. Thus, it is necessary to determine the working spectral wavelength ranges from methane and coal dust explosions. The article presents the results of experimental research devoted to the methane-air mixture and coal dust explosion spectral analysis by means of the photoelectric method. The ignition of a methane-air mixture of stoichiometric concentration (9.5%) and coal dust of size characterized by the dispersion of 63–94 microns and concentration of 200 g/m3 was carried out in a 20 L spherical chamber with an initial temperature in the setup of 18–22 °C at atmospheric pressure. Then, photometry of the explosion light flux was conducted on a photoelectric unit. Operating spectral wavelength ranges from methane and coal dust explosions were determined. For the methane-air mixture, it is advisable to use the spectral regions at the maximum emission of 390 and 900 nm. The spectrum section at the maximum emission of 620 nm was sufficient for dust-air mixture. It enabled us to select the wavelength ranges for automatic explosion suppression systems’ launching references. This will exclude false triggering of the explosion suppression system from other radiation sources. The research results will help to improve the decision-making credibility of the device in its direct design. The results will be used in further research to design noise-resistant optical flame detection sensors with a high response rate.

Investigation of the Effectiveness of an Augmented Reality and a Dynamic Simulation System Collaboration in Oil Pump Maintenance

The maintenance of oil pumps is a complex task for any operating organization, and for an industrial enterprise in the oil and gas sector of the economy, this issue has a high degree of urgency. One of the reasons for this is a wide spread of pumping equipment in all areas of oil and gas enterprises. At the same time, an aggressive environment, uneven load, remote facilities, and harsh climatic zones (especially in the areas of the Arctic region or production platforms) are factors that make it relevant to develop special systems that help or simplify the maintenance of pumping equipment. Dynamic modeling is one of the modern technologies which allows for solving the urgent issue of assessing the technical condition of equipment. It is the basis of systems that carry out diagnostics and prognostic calculations and allow for assessing the dynamic state of objects under various conditions of their operation, among other functions. Augmented reality technology is a technology that allows for reducing the time for equipment maintenance by reducing the time for searching and processing various information required in the maintenance process. This paper presents an investigation of the effectiveness of an augmented reality and a dynamic simulation system collaboration in oil pump maintenance. Since there is insufficient research on the joint application of these two technologies, the urgent issue is to prove the effectiveness of such collaboration. For this purpose, this paper provides a description of the system structure, gives a description of the development process of the augmented reality system application and tests the application using Microsoft HoloLens 2.