Numerical Study of Bath Dynamics in the Industrial-Scale Top Submerge Lance Furnaces

• Published in: Metallurgical and materials transactions. B, Process metallurgy and materials processing science Vol. 54; no. 4; pp. 2159 - 2173
• Main Authors: Wan, Zhanghao, Yang, Shiliang, Kong, Desong, Li, Dongbo, Hu, Jianhang, Wang, Hua
• Format: Journal Article
• Language: English
• Published: New York Springer US 01.08.2023; Springer Nature B.V
• Subjects: Characterization and Evaluation of Materials; Chemistry and Materials Science; Elliptical cylinders; Furnaces; Materials Science; Metallic Materials; Nanotechnology; Nonferrous metals; Original Research Article; Penetration depth; Shear stress; Slag; Stirring; Strain rate; Structural Materials; Surfaces and Interfaces; Thin Films; Vorticity; Wall shear stresses
• ISSN: 1073-5615; 1543-1916
• DOI: 10.1007/s11663-023-02823-3

Top submerged lance technology (TSL) is a potentially promising process for the extraction of non-ferrous metals. In this work, the characteristics and performance of three industrial-scale TSL furnaces ( i.e ., cylindrical furnace, rectangular furnace, and elliptical cylinder furnace) are evaluated in terms of the effects expected to be achieved in engineering applications, including reduced splash volume, enhanced penetration depth, suppressed the stirring dead zone, and reduced wall shear stress. The results illustrate that the chaotic turbulent flow in the gas-phase region is governed by both vorticity and strain rate. Splashing occurs primarily in the core region of the furnaces. The stirring region presents a “V” pattern, with greater axial stirring intensity than radial stirring intensity. The slag phase with a velocity less than 0.1 m/s accounts for 85 pct of the total volume of slag phase, while the percentage of slag phase in the velocity range 0.1 m/s ≤  U slag  ≤  U slag,max  × 5 pct is about 10 pct. It is evident that the lance experiences higher shear stress than the furnace sidewalls. Overall, the cylindrical TSL furnace demonstrates the largest penetration depth and slag volume-averaged velocity, while exhibiting the lowest shear stresses in the furnace sidewalls overall.