Computational Fluid Dynamics Simulation of Gas–Matte–Slag Three-Phase Flow in an ISASMELT Furnace

A mathematical model was developed to simulate gas–matte–slag three-phase flow in ISASMELT furnace with a top-submerged lance. An experimentally verified simulation model was established by adopting a VOF multiphase model coupled with a realizable k−e turbulence model. The flow field in ISASMELT furnace during the top-blowing process can be divided into 5 parts including injection, splashing, strong-loop, weak-loop, and sedimentation zones. The optimal lance diameter of 0.4 m and lance immersion depth of 0.4 m which have been applied in industry were obtained by investigating the mean velocity, phase volume fraction, splashing quantity, and wall shear stress distributions. Compared to the original operating conditions, a higher concentrate feeding rate of 140 t/h, a longer lance life of > 15 days, and a longer furnace life of 56 months were achieved for an industrial ISASMELT furnace operation under the improved lance diameter and immersion depth.