CFD Modeling of Swirl and Nonswirl Gas Injections into Liquid Baths Using Top Submerged Lances
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s are an integral part of many metallurgical processing operations. They affect the viability, effectiveness, and efficiency of many reactors regardless of whether they are physical or chemical in nature.[2] Gas injection methods are used frequently in modern pyrometallurgy because they allow for high-intensity and high-throughput processes in relatively small reactors.[3] Various methods to inject gas into molten baths include top submerged lance (TSL) technology, which uses a submerged vertical lance within an upright cylindrical furnace. Through the lance, oxygen-enriched air is injected into the molten bath, which creates an intense mixing of the bath and excellent contact between phases. Floyd[4] described the details of the TSL technology and its development since the 1970s. NAZMUL HUDA, PhD Student, J. NASER, Senior Lecturer, and G. BROOKS, Professor, are with the Swinburne University of Technology, Hawthorn 3122, Melbourne, Vic, Australia. Contact e-mail: [email protected] M.A. REUTER, Chief Executive Technologist, and R.W. MATUSEWICZ, Technical Development Manager, are with the Ausmelt Limited, 12 Kitchen Rd, Dandenong 3175, Melbourne, Vic, Australia. Manuscript submitted May 20, 2009. Article published online November 17, 2009. METALLURGICAL AND MATERIALS TRANSACTIONS B
Several experimental and numerical modeling studies have been performed on the injection of gas into liquid baths to understand the flow behavior inside furnaces. Mazumdar and Guthrie[5] carried out some experimental work on top-submerged gas injection on a 0.3-scale cold flow water model of a 150-ton steelmaking ladle with and without tapered side walls and surface baffles around the rising plume. They also developed a generalized two-dimensional (2D) steady-state computational scheme for predicting flows generated by fully submerged and partially submerged axisymmetric gas injection lances. Cold flow experiments also were carried out by Nilmani and Conochie,[6] Rankin et al.,[7] Neven et al.,[8] Iguchi et al.,[9] and Morsi et al.[1] Nilmani and Conochie[6] reported that the presence of swirl improves the radial dispersion of gas bubbles, produces finer bubbles, and minimizes bath slopping and splashing. The authors also investigated the effect of gas density and the gas rise mechanism through the bath. In contrast, Neven et al.[8] found no effect of swirl on bubbling frequency. Neven et al.[8] validated the Davidson-Schu¨ler[10] model for bubbling frequency. Dave and Gray[11] experimentally investigated the effect of constant and variable pitch swirled inserts into the liquid bath for submerged vertical lances. Their work mainly focused on the pressure drop across the VOLUME 41B, FEBRUARY 2010—35
lance because of fixed and variable pitch inserts. They concluded that the use of variable pitch swirlers could improve the lance flow dynamics substantially. Solnordal and Gray[12] carried out more experimental investigations on the fluid flow and heat transfer characteristics of decaying swirl flow in a TSL-heated annulus, and they reported that the entrance pr
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