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<p>The top-submerged lance (TSL) technology is integral to non-ferrous metal smelting, particularly in the multi-stage reduction process of tin production, which includes smelting, weak reduction, and strong reduction to obtain crude tin. Nevertheless, the stirring behavior induced by injected gas in TSL furnace during smelting process has not been thoroughly explored. This study conducts numerical modeling of an industrial-scale TSL, taking into account of operational parameters such as lance position, lance diameter, and melt viscosity across various smelting stages. Key variables evaluated include the turbulent kinetic energy, gas-melt contact area, splashing behavior, stirring zone, impact cavity, and wall shear stress. The results indicate that the <i>Q</i>-criterion effectively isolates regions of strong turbulence, primarily concentrated in a conical region surrounding the lance. Central splashing dominated by large droplets by high axial penetration energy can reach the furnace top, while peripheral splashing is less pronounced. The impact cavity assumes a “V” shape, with its width increasing as the lance diameter enlarges. High shear stress is observed in annular regions both at the melt surface and near the furnace bottom. As melt viscosity increases, splashing is reduced; the gas-liquid contact area expands; but the stirring zone contracts, and mechanical stress on the furnace walls intensifies. Overall, a lance position of 0.8&#xa0;m and a diameter of 0.336&#xa0;m yield the largest stirring zone and effectively control splashing. The increase in melt viscosity, a critical factor during the smelting process, necessitates higher gas injection rate to maintain operational efficiency. This study provides insights into complex multiphase flow in TSL furnaces and offers practical recommendations for optimizing smelting operations.</p>

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Gas-Driven Melt Stirring and Multiphase Flow Mechanism in Top-Submerged Lance Furnace for Non-ferrous Metals

  • 期刊论文

  • 发表日期：

    2025年1月27日

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  • Zhongyu Du,
  • Shiliang Yang,
  • Guirong Bao,
  • Hua Wang

摘要

The top-submerged lance (TSL) technology is integral to non-ferrous metal smelting, particularly in the multi-stage reduction process of tin production, which includes smelting, weak reduction, and strong reduction to obtain crude tin. Nevertheless, the stirring behavior induced by injected gas in TSL furnace during smelting process has not been thoroughly explored. This study conducts numerical modeling of an industrial-scale TSL, taking into account of operational parameters such as lance position, lance diameter, and melt viscosity across various smelting stages. Key variables evaluated include the turbulent kinetic energy, gas-melt contact area, splashing behavior, stirring zone, impact cavity, and wall shear stress. The results indicate that the Q-criterion effectively isolates regions of strong turbulence, primarily concentrated in a conical region surrounding the lance. Central splashing dominated by large droplets by high axial penetration energy can reach the furnace top, while peripheral splashing is less pronounced. The impact cavity assumes a “V” shape, with its width increasing as the lance diameter enlarges. High shear stress is observed in annular regions both at the melt surface and near the furnace bottom. As melt viscosity increases, splashing is reduced; the gas-liquid contact area expands; but the stirring zone contracts, and mechanical stress on the furnace walls intensifies. Overall, a lance position of 0.8 m and a diameter of 0.336 m yield the largest stirring zone and effectively control splashing. The increase in melt viscosity, a critical factor during the smelting process, necessitates higher gas injection rate to maintain operational efficiency. This study provides insights into complex multiphase flow in TSL furnaces and offers practical recommendations for optimizing smelting operations.