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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TROF-Converter Operation Optimization Using Cold and Numerical Simulation
Nikifor Ageev1; Vikenty Menshikov1;1URAL FEDERAL UNIVERSITY, Yekaterinburg, Russian Federation;
Type of Paper: Regular
Id Paper: 278
Topic: 6
Abstract:
Rotary bevel drum-type furnace, mainly represented by Kaldo furnace and TROF-converter, are not widely distributed in Russia. There are only two units, one of them located in Kishtim, and another one in Velikiy Novgorod. TROF-converter as Kaldo furnace is not an autogenous smelting process; it may process either molten or solid materials. Particularly in Kishtim, it is being used for slag reduction. The main advantage of this type of furnace is strap slag processing possibility, while recycling copper containing materials such slag is formed and because of high zinc and tin containment such slags have high viscosity. The ability to mix producing slag allows to receive waste slag with low copper containment. It may be used as converter unit, with use of unsubmerged blowing. Due to unsubmerged blowing and rotating smelting chamber, the material flow trajectory is very difficult to predict. For the better understanding of TROF-converter operation and to find possible ways for hydrodynamics improvement, cold and numerical simulation had been carried out. The obtained results permitted to calculate energy balance. By means of it, we revealed that only 43% of the energy provided by blowing uses for mass transfer process. Moreover, we determined the relationship between air flow penetration depth and air flow rate. We also detected a number of dead zones in furnace molten bath. TROF-converter cold model was constructed of plexiglass in scale of 1:10 to real furnace and equipped with steel lance. Model construction may simulate furnace rotation and has an ability to set angel of furnace drum and lance independently. Blowing was performed by compressed air with rate 145 l/min. The results were obtained by means of video recording using two 100 fps cams. The liquids used were water and different oils. Series of experiments were conducted. The obtained data had been used for CFD modeling of the process. During the experiments, we varied angle of model body, lance angel and position, volume of liquid in model and air blow rate. We measured pressure at the inlet and outlet of lance. By means of video recording, we determined torch size, its penetration depth and volume of displaced liquid, calculated Reynolds. Among valuable statistical data to use in future detailed modeling, the following facts were noted:
1. Potential and kinetic energies were calculated for different blowing conditions. Blowing intensity varied from 30 to 249 l/m. The potential energy varied from 0.002 to 0.246 N, while the kinetic energy varied from 1.7 to 223 N;
2. The relationship between air pressure and distance from lance tip to bath surface was measured. It showed that small (from 0 to 5 mm) change in distance does not have any significant effect on pressure at the state flow rate;
3. Flow trajectories in liquid bath were found using solid indicators and video capture. They will be used for computational modelling of bath mixing later;
Our next step is the examination of slag composition influence on its physical properties in conditions of TROF-converter slag treatment. Then, this data will be combined with modeling results and will provide us with prediction model for industrial process optimization.