TY - JOUR

T1 - Modeling Freeze-Lining Formation

T2 - A Case Study in the Slag Fuming Process

AU - Gomes Rodrigues, Christian

AU - Wu, Menghuai

AU - Chintinne, Mathias

AU - Ishmurzin, Anton

AU - Hackl, Gernot

AU - Lind, Clemens

AU - Kharicha, Abdellah

N1 - Publisher Copyright: © 2024 The Author(s). Steel Research International published by Wiley-VCH GmbH.

PY - 2024/10/27

Y1 - 2024/10/27

N2 - Slag fuming (SF) is a metallurgical process designed to recycle Zn-containing slagsderived from various industrial residues. To protect the reactor from corrosivemolten slag, a deliberate as-solidified slag layer, known as a freeze lining (FL), isformed on the reactor walls using intense water-cooled jackets. In this article, acomputational-fluid-dynamics-based model capable of simulating FL formation in aSF furnace is presented. To capture the complex multiphase flow dynamics, heattransfer, and FL formation during SF, a volume-of-fluid model is coupled with amixture continuum solidification model. Three phases are considered: gas, liquidbulk slag, and solid slag (FL). Moreover, two types of FL are distinguished: one thatsolidifies on the reactor wall in the bulk slag region and another that solidifies onthe reactor wall in the freeboard region owing to slag splashing. Comparisonsbetween calculated FL thickness and heat fluxes and corresponding industrial datademonstrate satisfactory agreement. In this outcome, the robustness of the modelis underscored and confidence in its accuracy is instilled. In the simulation results,valuable insights are provided into the evolution of the fuming process, particularlyregarding the slag bath temperature, slag splashing dynamics, FL formation, localheat fluxes through the reactor wall, and global net energy balance.

AB - Slag fuming (SF) is a metallurgical process designed to recycle Zn-containing slagsderived from various industrial residues. To protect the reactor from corrosivemolten slag, a deliberate as-solidified slag layer, known as a freeze lining (FL), isformed on the reactor walls using intense water-cooled jackets. In this article, acomputational-fluid-dynamics-based model capable of simulating FL formation in aSF furnace is presented. To capture the complex multiphase flow dynamics, heattransfer, and FL formation during SF, a volume-of-fluid model is coupled with amixture continuum solidification model. Three phases are considered: gas, liquidbulk slag, and solid slag (FL). Moreover, two types of FL are distinguished: one thatsolidifies on the reactor wall in the bulk slag region and another that solidifies onthe reactor wall in the freeboard region owing to slag splashing. Comparisonsbetween calculated FL thickness and heat fluxes and corresponding industrial datademonstrate satisfactory agreement. In this outcome, the robustness of the modelis underscored and confidence in its accuracy is instilled. In the simulation results,valuable insights are provided into the evolution of the fuming process, particularlyregarding the slag bath temperature, slag splashing dynamics, FL formation, localheat fluxes through the reactor wall, and global net energy balance.

KW - computational fluid dynamics simulations

KW - freeze-linings

KW - fuming furnaces

KW - mixture continuum model

KW - slag solidifications

KW - olume-of- fluid model

KW - mixture continuum models

KW - volume-of-fluid model

UR - http://www.scopus.com/inward/record.url?scp=85207367156&partnerID=8YFLogxK

U2 - 10.1002/srin.202400618

DO - 10.1002/srin.202400618

M3 - Article

VL - 2025

JO - Steel research international

JF - Steel research international

SN - 0177-4832

IS - ??? Stand: 17. Februar 2025

M1 - 2400618

ER -