Numerical investigation of sinusoidal pulsating gas intake to intensify the gas-slag momentum transfer in the top-blown smelting furnace

The variation characteristics of bubble morphology and the thermal-physical properties of bubble boundary in the top-blown smelting furnace were explored by means of the computational fluid dynamics method.The essential aspects of the fluid phase(e.g.,splashing volume,dead zone of copper slag,and gas penetration depth)were explored together with the effect of sinusoidal pulsating gas intake on the momentum-transfer performance between phases.The results illustrated that two relatively larger vortices and two smaller vortices appear in the bubble waist and below the lance,respectively.The expansion of larger ones as well as the shrinking of smaller ones combine to cause the contraction of the bubble waist.Compared to the results of the case with a fixed gas injection velocity(V_(g)=58 m/s),the splashing volume and dead zone volume of the slag under the V_(g)=58+10sin(2πt)condition are reduced by 24.9%and 23.5%,respectively,where t represents the instant time.Gas penetration depth and slag motion velocity of the latter are 1.03 and 1.31 times high-er than those of the former,respectively.

Production Practice of Solid Waste Desulfurizer Disposal in European Metallurgical Furnace

In order to realize the OY Smelting Furnace disposal of solid waste,municipal waste,form a model of steel enterprises and urban integration,through the production practice of smelting furnace,analyzes the mechanism of solid waste disposal,and proposed the disposal of solid waste desulfurization agent and disposal method:According to the theory to guide the actual production process,the test ton of iron with 10-15kg of desulfurizer in the production process does not affect the quality of molten iron and slag quality.

Numerical simulation analysis of Guixi copper flash smelting furnace

A numerical simulation analysis for reactions of chalcopyrite and pyriteparticles coupled with momentum, heat and mass transfer between the particle and gas in a flashsmelting furnace is presented. In the simulation, the equations governing the gas flow are solvednumerically by Eular method. The particle phase is introduced into the gas flow by theparti-cle-source-in-cell technique (PSIC). Predictions including the fluid flow field, temperaturefield, concentration field of gas phase and the tracks of particles have been obtained by thenumerical simulation. The visualized results show that the reaction of sulfide particles is almostcompleted in the upper zone of the shaft within 1.5 m far from the central jet distributor (CJD)type concentrate burner. The simulation results are in good agreement with data obtained from aseries of experiments and tests in the plant and the error is less than 2%.

Simulation of moving boundary of the reaction shaft in a flash smelting furnace

As to solve the online monitoring of the inner temperatur e and freezing profile of the reaction shaft of flash smelting furnace, simulation of the wall in the reaction shaft in a flash smelting furnace was made through numerical computation. The computational results are very near the data got in s ite. The error of the moving boundary is approximately 3%, and that of the tempe rature is less than 5%. It is proved that the simulation software is applicable for practice to monitor the temperature and moving boundary inside the hearth on line. Based on a large number of the data computed, the relation between the cha nge of the moving boundary and inner temperature is summarized, and the great in fluence of the cooling system on the forming and stability of the moving boundar y inside the hearth is emphasized, which provide the theoretical bases for optim izing the flash smelting operation.

Influence of operation parameters on flash smelting furnace based on CFD

The influence of three important operation parameters in Jinlong flashsmelting furnace, including the distributing blast speed, the oxygen enrichment rate of process airand the ratio of central oxygen to overall oxygen (O_c/O_o), has been investigated using a virtualsimulation system on copper flash smelting furnace. The core of this virtual simulation system is anumerical simulation of CFD (computational fluid dynamics), and this system incorporates couplingmomentum transport, heat transport, mass transport, reaction kinetics between gas and particles andchemical reactions between gas and gas. A set of numerical predicted data were obtained. The CFDsimulation shows that there is a sensitive zone of the distributing blast speed, and the dustcontent ascends when the speed exceeds 180 m centre dot s^(-1). Increasing the oxygen concentrationof processing air benefits the efficient production of the flash smelting furnace.

Numerical modeling of Jinlong CJD burner copper flash smelting furnace

Fluid flow, heat transfer and combustion in Jinlong CJD concentrate burnerflash smelting furnace have been investigated by numerical modeling and flow visualization. Themodeling is based on the Eulerian approach for the gas flow equations and the Lagrangian approachfor the particles. Interaction between the gas phase and particle phase, such as frictional forces,heat and mass transfer, are included by the addition of sources and sinks. The modeling resultsincluding the fluid flow field, temperature field, concentration field of gas phase and thetrajectories of particles have been obtained. The predicted results are in good agreement with thedata obtained from a series of experiments and tests in the Jinlong Copper Smelter and thetemperature error is less than 20 K.

Operation optimization of concentrate burner in copper flash smelting furnace

The software that simulates the flow, temperature, concentration and the heat generation field in the Outkumpu flash smelting furnace, was developed by a numerical method of the particle-gas flow together with some chemical reaction models. Many typical operating conditions were chosen for simulation in order to obtain the effect of the distribution air, process air, central oxygen and the oil-burner position etc. The concepts about optimum operation, 3C(concentration of high temperature, high oxygen and laden concentrate particles), are concluded from these simulated results, which have been checked primarily by operational experiments.

FUZZY ADAPTIVE CONTROL MODEL FOR PROCESS IN NICKEL MATTE SMELTING FURNACE

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Moisture effect on the combustion of a single copper concentrate particle in a flash smelting furnace

A mathematical model has been presented to study the combustion of a single copper concentrate particle with high moisture content. By using the presented model, the effect of particle moisture content on particle temperature, sulfur oxidation, and combustion heat generation has been evaluated. The mineralogical composition of the commonly used concentrate at Khatoonabad flash smelting furnace has been used in this study. It was found that the particle moisture content is removed in the sub-second time range and thus the moisture has marginal impact on the variation of particle temperature and on the reaction rate when the gas temperature is assumed to be constant in the reaction shaft. When a concentrate with high moisture content is charged, the particle size enlargement due to the agglomeration of concentrate particles causes an abrupt fall in the particle reaction rate.

Status and Progress of Refraetories for Aluminum Smelting Furnaces

Status and state-of-the-art progress on research,development and application of refractories for aluminum smelting furnaces and holding furnaces were reviewed and discussed in the present paper.The main types of aluminum smelting furnaces and smelting processes,and the service conditions of refractories and the requirements for refractory lining were also described and discussed.

Behavior of an indigenously fabricated transferred arc plasma furnace for smelting studies

The utilization of industrial solid waste for metal recovery requires high-temperature tools due to the presence of silica and alumina, which is reducible at high temperature. In a plasma arc furnace, transferred arc plasma furnace（TAP） can meet all requirements, but the disadvantage of this technology is the high cost. For performing experiments in the laboratory, the TAP was fabricated indigenously in a laboratory based on the different inputs provided in the literature for the furnace design and fabrication. The observed parameters such as arc length, energy consumption, graphite electrode consumption, noise level as well as lining erosion were characterized for this fabricated furnace. The nitrogen plasma increased by around 200 K（200 ℃） melt temperature and noise levels decreased by ~10 d B compared to a normal arc.Hydrogen plasma offered 100 K（100 ℃） higher melt temperature with ~5 d B higher sound level than nitrogen plasma. Nitrogen plasma arc melting showed lower electrode and energy consumption than normal arc melting, whereas hydrogen plasma showed lower energy consumption and higher electrode consumption in comparison to nitrogen plasma. The higher plasma arc temperature resulted in a shorter meltdown time than normal arc with smoother arcing. Hydrogen plasma permitted more heats, reduced meltdown time, and lower energy consumption, but with increased graphite consumption and crucible wear. The present study showed that the fabricated arc plasma is better than the normal arc furnace with respect to temperature generation, energy consumption, and environmental friendliness. Therefore, it could be used effectively for smelting-reduction studies.

Suggestions on Refractories in Nonferrous Metal Smelting Furnaces/Kilns

This paper introduces the refractories used in various nonferrous metal smelting equipment in China and the existing problems, and puts forward suggestions on the material of refractories, application of new technologies and production management of refractories, etc.

The Advancement in Intensified Smelting Technology of Baosteel Blast Furnace

Baosteel always aims at becoming one of the most profitable enterprises in the world, enjoying international competence, benchmarking with the world advanced level,pursuing innovation sustainable development. Recent years, Baosteel Iron-making Department has caught the opportunity of increasing steel demand; conquering disadvantages such as changeable up-stream market, fuel and raw material’s tight supplies and lower quality, etc. In our department, Major technical problems have been overcome, blast furnace intensified smelting technology improved, the cost of molten iron under control, blast furnace long-life span control technology made breakthrough, and Baosteel’s ironmaking capacity improved further.

Intelligent predictive model of ventilating capacity of imperial smelt furnace

In order to know the ventilating capacity of imperial smelt furnace(ISF), and increase the output of plumbum, an intelligent modeling method based on gray theory and artificial neural networks(ANN) is proposed, in which the weight values in the integrated model can be adjusted automatically. An intelligent predictive model of the ventilating capacity of the ISF is established and analyzed by the method. The simulation results and industrial applications demonstrate that the predictive model is close to the real plant, the relative predictive error is 0.72%, which is 50% less than the single model, leading to a notable increase of the output of plumbum.

CFD modeling of gas−liquid flow phenomenon in lead smelting oxygen-enriched side-blown furnace

A validated numerical model was established to simulate gas−liquid flow behaviors in the oxygen-enriched side-blown bath furnace.This model included the slip velocity between phases and the gas thermal expansion effect.Its modeling results were verified with theoretical correlations and experiments,and the nozzle-eroded states in practice were also involved in the analysis.Through comparison,it is confirmed that the thermal expansion effect influences the flow pattern significantly,which may lead to the backward motion of airflow and create a potential risk to production safety.Consequently,the influences of air injection velocity and furnace width on airflow behavior were investigated to provide operating and design guidance.It is found that the thin layer melt,which avoids high-rate oxygen airflow eroding nozzles,shrinks as the injection velocity increases,but safety can be guaranteed when the velocity ranges from 175 to 275 m/s.Moreover,the isoline patterns and heights of thin layers change slightly when the furnace width increases from 2.2 to 2.8 m,indicating that the furnace width shows a limited influence on production safety.

Mathematical model of multistage and multiphase chemical reactions in flash furnace

A mathematical model of multistage and multiphase reactions in flash smelting furnace, which based on the description of chemical reactions and reaction rate, is presented. In this model, main components of copper concentrate are represented as FeS 2 and CuFeS based on experiment, intermediate products are assumed to be S 2 and FeS, and the final products are assumed as FeS, FeO, SO 2, Cu 2S, FeO and FeO(SiO 2) 2. The model incorporates the transport of momentum, heat and mass, reaction kinetics between gas and particles, and reactions between gas and gas. The k-ε model is used to describe gas phase turbulence. The model uses the Eulerian approach for the gas flow equations and the Lagrangian approach for the particles. The coupling of gas and particle equations is performed through the particle source in cell(PSIC) method. Comparison between the model predictions and the plant measurements shows that the model has high reliability and accuracy.

Thermodynamic modeling of lead blast furnace

A thermodynamic model was developed to predict the distribution behavior of Cu, Fe, S, O, Pb, Zn, As, and the heat balance in a lead blast furnace. The modeling results are validated by the plant data of a lead smelter in Kazakhstan. The model can be used to predict any set of controllable process parameters such as feed composition, smelting temperature, degree of oxygen enrichment and volume of oxygen-enriched air. The effects of the blast air, industrial oxygen, and coke charge on the distribution of Cu, Fe, S, O, Pb, Zn, As, the heat balance, and the lead loss in slag, were presented and discussed.

Furnace bottom rise mechanism in preparation of Al Si alloys by electrothermal process

The experiments of preparation of Al Si alloys by electrothermal process were carried out respectively in 20 kW, 100 kW and 1 800 kW DC arc furnaces. The mechanism of furnace bottom rise was studied. It was found that the bottom rise can be divided into three types, including the low bottom temperature, abnormal reducing reaction and carbide deposition. The furnace bottom rise is related to the carbon ratio of the briquet, the heating speed of the briquet and the parameters and operation of furnace.

INFLUENCE OF MnO ON REDUCTION OF TiO_2 IN BLAST FURNACE TYPE SLAG

A study was carried out on the formation of Ti(C,N) during smelting vanadium-bearing titanomagnetite in blast furnace and the influence of MnO content on reduction of TiO_2 in the slag containing high titania. The reduction of TiO_2 is restricted by MnOpredominantly at the slag-metal interface and no more at the slag-coke one. The formation of Ti(C,N) is remarkably restricted by MnO in the slag when the MnO content is about 4% and the basicity from 0.6 to 1.2 in the slag. MnO may also retards the reduction of SiO_2 and accelerates the desulphidation under certain condition.

Reduction Mechanism of Chromite Ore in Blast Furnace

The structural changes and reduction degree of chromite ore in blast furnace were studied by optical micrograph analysis,scanning electron microscope(SEM)and energy dispersive X-ray analysis(EDXA).The smelting reduction mechanism of chromite in blast furnace was primarily discussed.