Modelling of fluid flow phenomena in Peirce-Smith copper converters and analysis of combined blowing concept
DK Chibwe, G Akdogan, P Taskinen, JJ Eksteen
This investigation consists of a numerical and physical modelling exercise
on flow patterns, mixing, solid-liquid mass transfer, and slag-matte phase
distribution in a 0.2-scale cold model of an industrial Peirce-Smith
converter (PSC). Water, kerosene, air, and sintered benzoic acid compacts
were used to simulate matte, slag, injected gas, and solid additions into the
PSC. The 2D and 3D numerical simulations were carried out using volume
of fluid (VOF) and realizable k-e (RKE) turbulence models to account for
the multiphase and turbulence nature of the flow respectively. These
models were implemented using the commercial computational fluid
dynamics numerical code FLUENT.
Numerical and physical simulations were able to predict, in agreement,
the mixing and dispersion characteristics of the system in relation to
various blowing conditions. Measurement of mass transfer indicated that
fluid flow in the PSC is stratified. Blowing configurations and slag volume
both had significant effects on mixing propagation, wave formation, and
splashing.
As a potential process alternative to increase conversion efficiency, we
propose a combined blowing configuration using top lance and lateral
nozzles. The numerical simulations were conducted on combined as well as
lateral blowing conditions, and the results of the combined concept are
encouraging.
Keywords: Peirce-Smith converter, combined blowing, CFD, mixing, splashing.