Mathematical modeling and computer simulation of the rotating impeller particle flotation process: Part I. Fluid flow

Removal of unwanted particles from molten metal by flotation is one of the most useful melt cleansing techniques used by the foundry industry. An effective way of flotation of particles in a melt relies on purging a gas into the molten metal through holes in a rotating impeller. Impeller rotation creates turbulence inside the melt, which helps agglomerate the impurity particles and, thereby, enhances their removal from the melt. In addition, turbulence increases the probability of particles attaching to the rising gas bubbles and, therefore, enhances the chance of their removal from the molten metal. A mathematical model has been developed to simulate the turbulent multiphase flow field inside the flotation treatment furnace. Simulations based on the model were used to demonstrate the effect of the various process parameters on the performance of a batch-type rotating impeller particle flotation process.