2015-Sustainable Industrial Processing Summit
SIPS 2015 Volume 5: Vanyukov Intl. Symp. / Non-ferrous & KIVCET
| Editors: | Kongoli F, Kozlov P, Tsymbulov L, Fedorov A, Shumskiy V |
| Publisher: | Flogen Star OUTREACH |
| Publication Year: | 2015 |
| Pages: | 310 pages |
| ISBN: | 978-1-987820-28-7 |
| ISSN: | 2291-1227 (Metals and Materials Processing in a Clean Environment Series) |
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Cold Modeling and Hydrodynamic Analysis of Top-Submerged Lance Furnace Operation
Boris Kolmachikhin1; Vladimir Zhukov1;1URAL FEDERAL UNIVERSITY, RUSSIA, Ekaterinburg, Russian Federation;
Type of Paper: Regular
Id Paper: 272
Topic: 6
Abstract:
Top submerged lance furnaces are new for Russian metallurgy. The first metallurgical plant to use such furnace was "Karabashmed" at Karabash. It uses a single TSL-type furnace as their main smelting unit since 2007. Two more plants - Mednogorskiy Mednoserniy Combinat (at Mednogorsk) and Svyatogor (at Krasnouralsk) are planning to switch from reverberatory furnace (Svyatogor) and shaft furnace (Mernogorsk) to TSL furnaces too in the near future.
Due to this trend, understanding the TSL furnace operation is becoming vital for scientific groups working with the mentioned plants and, therefore, we started our investigation on these process properties to find possible fields for improvement and optimization.
Cold model of TSL furnace was built using plexiglass and plastic tubes in a scale of 1:12 to real furnace. It features several lance options, including single, two-tube, three-tube and different swirl solutions. Blowing was performed using 300 l/min compressor, video was captured using two 100 fps cams. The liquids used were water and different oils.
Series of experiments were conducted using this model to obtain data for future CFD modeling of the process. The parameters that varied during experiments included lance height, lance size, swirl form and amount of air blown.
We measured pressure at the lance tip, torch size, calculated Reynolds criteria and torch penetration depth.
Among valuable statistical data to use in future detailed modeling, the following facts were noted:
1. At high blowing intensity (130-160 l/m, pressure 10-15 kg/cm2) there is a plateau at torch size graph, which means that from 130 to 160 liter per minute there is some kind of equilibrium point, after which pressure becomes high enough for further development of blowing torch;
2. Swirls form (angle, length) have little effect on torch geometry or mixing efficiency. However, positioning swirls too high inside the lance (higher than at 1/3 of total lance height) results in great reduction of their effectiveness. Therefore, swirls should be positioned closer to the lance tip;
3. Air velocity (m/s) varied from 32 to 211 during air blown amount changes from 62 to 272 liter per minute respectively. This range gives us an opportunity to run experiments in conditions either close to real plant furnace conditions or extremely low or high modes.
The next stage of our work is computer modelling based on cold modelling results and then prediction model based on real plant data combined with modelling to find optimal conditions for smelting furnace operation to minimize copper loses with slag.