| Abstract Scope |
Electric Smelting Furnaces (ESFs) are emerging as a promising technology for processing Direct Reduced Iron (DRI) produced from low-carbon reduction routes. However, the elevated operating temperatures and aggressive slag chemistry can accelerate refractory wear and increase energy losses. Freeze-lining formation provides an effective protective barrier between molten slag and furnace walls, enhancing campaign life and thermal efficiency. In this study, a three-dimensional computational fluid dynamics (CFD) model was developed to investigate multiphase flow, heat transfer, and freeze-lining evolution in an industrial ESF processing high-gangue DRI. A Volume of Fluid (VOF) approach was coupled with a solidification model to capture slag motion, thermal gradients, and freeze-lining growth under different operating conditions. The simulations reveal the influence of bath temperature, slag circulation, and cooling intensity on freeze-lining stability and thickness distribution. The results provide insights for optimizing furnace operation, reducing refractory consumption, and improving energy efficiency in future green steelmaking processes. |