Computational Evaluation of Flow-Induced Abrasion of Blade and Ladle in Kanbara Reactors for Hot Metal Desulfurization

• Published in: JOM (1989) Vol. 74; no. 4; pp. 1588 - 1600
• Main Authors: Li, Qiang, Ma, Suwei, Shen, Xiaoyang, Li, Mingming, Zou, Zongshu
• Format: Journal Article
• Language: English
• Published: New York Springer US 01.04.2022; Springer Nature B.V
• Subjects: Abrasion; Chemistry/Food Science; Computational Modeling of Metallurgical Furnaces; Computer simulation; Continuous casting; Design optimization; Desulfurizing; Earth Sciences; Energy; Engineering; Environment; Evaluation; Impellers; Ladles; Mathematical models; Numerical models; Physics; Reactors; Service life; Shear stress; Stress analysis; Turbulence models; Velocity; Viscosity; Wear
• ISSN: 1047-4838; 1543-1851
• DOI: 10.1007/s11837-021-05120-z

The impeller blades in Kanbara reactors for hot metal desulfurization often fail due to extreme erosion induced by the hot metal. Computer simulation has made it possible to evaluate the degree of abrasion and predict wear locations. In this work, a numerical model coupled with the erosion formula was used to quantitatively assess the shear stress and abrasion rate. Based on the simulation results, nonuniform local erosive wear was identified, showing that the zones of high erosion concentrated at the lower part of the blade and along two rings of the ladle lining. The impeller immersion depth has a negligible influence on the blade abrasion but remarkably affects the ladle sidewall and bottom. The quantitative correlations of abrasion rate as a function of blade dimension and rotation speed were obtained. The results can be used to identify the erosion problems and optimize impeller design and operation to extend the service life of both the impeller and the ladle.