Computational Fluid Dynamic Modeling of Zinc Slag Fuming Process in Top-Submerged Lance Smelting Furnace |
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Authors: | Nazmul Huda Jamal Naser Geoffrey Brooks Markus A Reuter Robert W Matusewicz |
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Affiliation: | (1) Faculty of Engineering and Industrial Science, Swinburne University of Technology, Hawthorn, Melbourne, VIC, 3122, Australia;(2) Outotec Limited, Dandenong, Melbourne, VIC, 3175, Australia |
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Abstract: | Slag fuming is a reductive treatment process for molten zinciferous slags for extracting zinc in the form of metal vapor by
injecting or adding a reductant source such as pulverized coal or lump coal and natural gas. A computational fluid dynamic
(CFD) model was developed to study the zinc slag fuming process from imperial smelting furnace (ISF) slag in a top-submerged
lance furnace and to investigate the details of fluid flow, reaction kinetics, and heat transfer in the furnace. The model
integrates combustion phenomena and chemical reactions with the heat, mass, and momentum interfacial interaction between the
phases present in the system. A commercial CFD package AVL Fire 2009.2 (AVL, Graz, Austria) coupled with a number of user-defined
subroutines in FORTRAN programming language were used to develop the model. The model is based on three-dimensional (3-D)
Eulerian multiphase flow approach, and it predicts the velocity and temperature field of the molten slag bath, generated turbulence,
and vortex and plume shape at the lance tip. The model also predicts the mass fractions of slag and gaseous components inside
the furnace. The model predicted that the percent of ZnO in the slag bath decreases linearly with time and is consistent broadly
with the experimental data. The zinc fuming rate from the slag bath predicted by the model was validated through macrostep
validation process against the experimental study of Waladan et al. The model results predicted that the rate of ZnO reduction is controlled by the mass transfer of ZnO from the bulk slag
to slag–gas interface and rate of gas-carbon reaction for the specified simulation time studied. Although the model is based
on zinc slag fuming, the basic approach could be expanded or applied for the CFD analysis of analogous systems. |
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