Process Modeling and Optimization of a Submerged Arc Furnace for Phosphorus Production
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A phosphorus-producing, submerged arc furnace (SAF) is a complex system in both physical and chemical aspects. It involves multiphase, high-temperature reduction reactions, energy conversion, and distribution from electric power through arcs and conduction. Although the underlying chemical reactions and, to a lesser extent, the kinetics driving the main reactions in the submerged arc furnace are well documented, it is the complex interaction between these phenomena and the intricate burden characteristics that cause the specific power consumption (the energy consumed for every ton of P4 produced) to be a largely uncontrollable, dependent variable. The most complex electric powered furnace is the SAF, and over the years, it has proven difficult to model. Larsen et al.[1] developed a numerical two-dimensional EMILE SCHEEPERS, formerly Ph.D. Student, Delft University of Technology, Delft 2628, The Netherlands, is now Plant Performance Analyst, Corus RD&T, IJmuiden 2628 CD, The Netherlands. YONGXIANG YANG, Assistant Professor and Deputy Group Leader for Metals Production, Refining, and Recycling, Delft University of Technology, is also concurrent Professor at Northeastern University, Shenyang, P.R. China and Anhui University of Technology, Anhui, P.R. China. Contact e-mail: [email protected]. ALLERT T. ADEMA, Ph.D. Student, and ROB BOOM, Professor, Group Leader for Metals Production, Refining and Recycling, M2i Chair in Primary Metals Production, and M2i Senior Scientific Advisor, are with Delft University of Technology. MARKUS A. REUTER, Chief Technologist, Outotec Ausmelt, 12 Kitchen Road, Dandenong VIC 3175, Australia, is also Professorial Fellow, University of Melbourne, Melbourne, Australia. Manuscript submitted October 31, 2009. Article published online July 30, 2010. 990—VOLUME 41B, OCTOBER 2010
(2D) model for an alternating current (AC) arc in a silicon metal SAF using Fluent. The arc is the main energy source in the furnace (90 pct). The conservation equations for mass, momentum, and energy together with time-dependent Maxwell’s equations were solved. The model assumes symmetric furnace conditions and takes only one phase in consideration for a three-phase SAF. Therefore, the significant interactions among phases cannot be reflected by the model. Andresen and Tuset[2] simulated fluid flow, heat transfer, and heterogeneous chemical reactions above 2123 K (1850 C) in the arc region of a silicon furnace with a 2D Fluent model. The AC arc in the gas-filled cavity is simplified with a direct current (DC) arc. Saearsdottir et al.[3] investigated arc behavior in silicon and ferrosilicon furnaces using a 2D model. The behavior of the solid bed region and overall furnace thermal performance was not included. Sridhar and Lahiri[4] developed a 2D single electrode model for the current and temperature distribution in a SAF for ferromanganese production. The current distribution is calculated by solving Maxwell equations for the magnetic field. Joule heating and heat conduction are modeled in the slag and solid zones, and the arc and
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