CFD Modeling of Copper Smelting - Peru 2012

7/27/2019 CFD Modeling of Copper Smelting - Peru 2012

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Computational Fluid Dynamic

(CFD) modeling of copper flash

smelting and converting

Hong Yong Sohn

Department of Metal lurgical Engineer ing

University of Utah, Salt Lake City, Utah, U.S.A.


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Outokumpu Flash Furnace


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Process Design andMathematical Modeling


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Process Modeling

Earlierpyrometallurgical processes: Batch, equil.

conditionsNewer processes: Higher productivity, higher

intensity (Rate processesare inportant.)

Need for transport property data, more reliable

thermochemical data

Improved tools have become available:

Computers, analytical instruments, electronic

apparatusesCFD: Flash smelting processes

Thermochemistry of minor element behavior

Gas injection into melts


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x

y

z

OXYGEN-ENRICHED AIR

MOLTEN BATH

SURFACE

TO UPTAKE

SHAFT

O2

SO2

I

REACTION SHAFT

COPPER MATTE

PARTICLES

PARTICLE CLOUDS

Computational Fluid Dynamics Modeling

of Flash Smelting and Converting Furnaces


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Components of Computer Modeling


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Turbulent Flow Phenomena


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Gas-Phase Equations


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Particle-Phase Equations


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Apparatus for Particle-Dispersion Analysis


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Digitized Image of Particles in Gas Jet


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Experimental vs. Computed Particle Distribution


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Schematics of Pilot Flash Furnace Facility


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Results for Flash Smelting Experiment


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6-Jet Entry Pilot Burner


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Gas Velocity Vectors in Laboratory Furnace(6-Jet Entry System)

The largest vector

represents 1.32 m/s.


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(a) single axial entry burner (b)85-distributor cone burner

(Numbers indicate velocity in m/s)

Gas velocity fields in an industrial

flash converting furnace


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(a) single axial entry burner (b)85-distributor cone burnerNumbers indicate logarithm of number of particles per cubic meter

Particle number density in an industrial



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(a) single axial entry burner (b) 85-distributor cone burner

Gas temperature in an industrial



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(a)single axial entry burner (b)85-distributor cone burner

Oxygen concentration in an industrial



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Results for Flash Converting Experiment


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Results for Flash Converting Experiment


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Results for Flash Converting Experimen


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Nippon Mining and Metals Co. (Nikko)

Modified operating conditions to double their

feed rate (production rate) without changing

their furnace based on modeling results.

[Y. Yasuda did graduate work on CFD of flash furnaces at Utah.]

Suzuki, Y., Suenaga, C., Ogasawara, M., and Yasuda, Y., 1998, Productivity increase in flash smelting furnace operation atSaganoseki Smelter & Refinery, in Sulfide Smelting 98, Current and Future Practices, J.A. Asteljoki and R.L. Stephens, eds., TMS,Warrendale, PA, pp. 587-595.

Y. B. Hahn and H. Y. Sohn, Mathematical Modeling of Sulfide Flash Smelting Process: Part I. Model Development and Verificationwith Laboratory and PilotPlant Measurements for Chalcopyrite Concentrate Smelting, Metall. Trans. B, 21B, 945958 (1990).

An Example of Application


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Ready availability of CFD capabilityPowerful yet inexpensive computers

Commercial softwareNeed to learn how to use it

Like driving a car

Benefits:Optimal designImproved control and operationCan perform many test runs at low costs

Concluding Remarks


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End of Presentation

Documents

CFD Modeling of Copper Smelting - Peru 2012