8th International Symposium on High Temperature Metallurgical Processing: Simulation of High Temperature Process
Sponsored by: TMS Extraction and Processing Division, TMS: Pyrometallurgy Committee
Program Organizers: Jiann-Yang Hwang, Michigan Technological University; Tao Jiang, Central South University; Mark Kennedy, Proval Partners SA; Onuralp Yücel, ITU; P. Chris Pistorius, Carnegie Mellon University; Varadarajan Seshadri, Universidade Federal de Minas Gerais; Baojun Zhao, The University of Queensland; Dean Gregurek, RHI AG; Ender Keskinkilic, Atilim University

Monday 2:00 PM
February 27, 2017
Room: 18
Location: San Diego Convention Ctr

Session Chair: Varadarajan Seshadri, Universidade Federal de Minas Gerais; Yousef Mohassab, University of Utah

2:00 PM Introductory Comments

2:05 PM  
A CFD Based Algorithm for Kinetics Analysis of the Reduction of Hematite Concentrate by H₂+CO Mixtures in a Drop Tube Reactor: De Qiu Fan1; Mohamed Elzohiery1; Yousef Mohassab1; H.Y. Sohn1; 1University of Utah
    A novel flash ironmaking process is under development at the University of Utah. A computational fluid dynamics (CFD) approach, coupled with experimental results, was developed for the analysis of the kinetics of reduction of hematite concentrate by H₂+CO mixtures at 1150-1350 °C in a drop tube reactor. Rate expressions of hematite concentrate reduction by single gases (H₂ or CO) were used in the analysis of the experimental data under H₂+CO mixtures. Synergistic effects, which were found in the H₂+CO mixture experiments compared with simple summation of contributions of component gases, was considered in this paper. The gas phase was treated as a continuum in the Eulerian frame of reference, and the particles are tracked using a Lagrangian approach in the evaluation of the particle residence time and temperature profile inside the reactor. The calculated reduction degrees based on this approach are in good agreement with the experimental values.

2:25 PM  
A Continuous Dynamic Process Model to Design a Carbon Profile toward Yield Improvement: Mohammed Tayeb1; Narottam Behera1; Raja Mathu2; 1SABIC Metals SBU; 2HADEED
    With the steel market nowadays, steelmakers are in extensive demand to reduce their operational cost. Optimization in the melt shops therefore become not only preferable but mandatory. This work is a continuous work at HADEED. A continuous dynamic process model for scrap-DRI EAF process was recently developed. This model was used to propose a new carbon profile which was used successfully to decrease (%FeO) in the slag and improve the yield. This paper will review the basics of the model and present the industrial results.

2:45 PM  
Alloy Yield Prediction Model Based on the Data Analysis in EAF Steelmaking Process: Lingzhi Yang1; 1Central South University
    In this paper, based on the big data in steelmaking process, formula about the relationship between steel composition (especially the oxygen content) and the element yield is established by using mathematical analysis method to analyze the factors influencing yield. Meanwhile, combining the alloy yield dynamic libraries that were established based on self-learning of historical data and computer technology in steelmaking process, a method of yield prediction of alloy elements is studied. To provide support for this method, alloying elements yield prediction software is developed to realize the rapid and intuitive site operation guidance, and to realize the precise control of dosage of alloy material.

3:05 PM  
Analysis of Jet Behavior and Surface Fluctuations in the Meniscus of Fluid in a Physical Model of a Beam Blank Mold and CFD Modelling: Johne Peixoto1; Weslei Gabriel2; Ciro Silva2; Leticia Ribeiro2; Carlos Silva2; Itavahn Silva2; Varadarajan Seshadri3; 1Federal University of Brazil, Ouro Preto ; 2Federal University of Brazil, Ouro Preto; 3Universidade Federal de Minas Gerais
     In this study, the influence of the immersion depth, casting speed on the flow characteristics in a beam blank mold with two tubular nozzles have been investigated using a physical model as well as CFD simulations. The results of CFD simulations were found to be consistent with the results of experiments in the physical model. The liquid jet spreads faster the flange region compared to the web region. This can lead to a non-uniform shell thickness along the cross section resulting in uneven solidification of the skin.The jet penetration depth ranged between 66cm and 77cm. The average intensity of meniscus fluctuation was 0.22mm, and the maximum fluctuation was found to be 0.85mm. Based on these results, the suggested optimum operating parameters for immersion depth and casting speed were 75 mm and maximum casting speed of 1m/min.

3:25 PM  
CFD Study of Gas-liquid Phase Interaction Inside a Submerged Lance Smelting Furnace for Copper Smelting: Guangwu Tang1; Armin Silaen1; Hongjie Yan2; Zhixiang Cui3; Zhi Wang3; Haibin Wang3; Kaile Tang2; Ping Zhou2; Chenn Zhou1; 1Purdue University Northwest; 2Central South University; 3Dongying Fangyuan Nonferrous Metals
    Bath smelting technology, such as polynary furnace, is used in modern copper making industry. The first polynary furnace developed by Dongying Fangyuan Nonferrous Metals Co., Ltd has shown potential for high productivity and energy saving. In this study, computational fluid dynamics (CFD) has been applied to investigate the current design of the furnace. A three-dimensional multiphase CFD model has been developed to study the interaction between injected gas and liquid bath. The multiphase Eulerian model was used for simulating gas/liquid two-phase flow. The flow pattern in the polynary furnace indicates a fast flow development and strong turbulence interaction between gas and liquid. The model has been validated based on a water model experiment with mixing process. The simulation result of mixing time shows agreement with the experiment. The gas residence time and liquid copper matte splashing under different gas flow rate were investigated.

3:45 PM Break

4:05 PM  
Debottlenecking High Temperature Metallurgical Plants through Modeling and Simulation: Kamal Adham1; Daan Sauter1; 1Hatch Ltd.
    Debottlenecking of high temperature processes within an existing metallurgical plant can significantly increase the throughput, to meet new production demands. Modeling and simulation can help to fulfil that aim through incremental changes and operational improvements, rather than the more expensive option of building new plants and facing new environmental and infrastructure challenges. This paper describes a methodology of how modeling tools can be used to simulate the processing steps, how to estimate their existing and ultimate capacities, and how to determine the minimum cost points for a plant capacity expansion. This technique is presented through a generic description that can be applied to different metallurgical processing studies. We start with heat-and-mass balances, draw a bottleneck diagram, brainstorm capacity increase options, and prepare a cost-capacity curve. Hatch has successfully applied this technique to a number of plant capacity studies, with great benefits to our industrial clients.

4:25 PM  
Assessment of Slag Entrainment in a RH Degasser through Physical Modelling Using Circulating Fluids of Different Densities/Oil Systems for Simulating Steel Melt/Slag: Johne Peixoto1; Natalia Barony1; Weslei Gabriel1; Carlos Silva1; Itavahn Silva1; Varadarajan Seshadri2; 1Federal University of Ouro Preto; 2Universidade Federal de Minas Gerais
     In this work the circulation rates have been determined in a 1:7.5 scale physical model of RH reactor and using oil/water and oil/zinc chloride solution to simulate steel melt/slag in the prototype with the objective of evaluating the influence of density and viscosity on the entrainment of oil simulating slag.A technique based on strain gages bridge and particle image velocimetry was developed, as the usual tracer method is not feasible due to the presence of chloride ions. The critical velocity and critical diameter of oil drops for slag (oil) entrainment in water / oil and ZnCl2/oil systems were estimated using equations from the literature. Due to the difference in density, the ZnCl2/oil system, showed a critical velocity that is 28% higher than the silicone oil/water system while the maximum size of the entrained droplets was about 65% lower than that for water/oil system.