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<p>Improving the longevity of submerged injectors is a critical challenge in Oxygen-Rich Bottom-blown Bath Smelting (OBBS) furnaces, where severe erosion curtails campaign life. This work introduces a novel protective shield designed not only to extend the injector durability but also to enhance process hydrodynamics. A high-fidelity computational fluid dynamics (CFD) model, which addresses the limitations of prior studies by employing a key-field coupling method for the inlet boundary, revealed that the erosion of an injector is driven by the intense wall shear stress from a large-scale melt recirculation loop, exacerbated by gas back-attack phenomena. An optimized arched shroud effectively redirects this erosive flow into a protective swirling pattern. This hydrodynamic reorganization yields a dual benefit: a substantial 80 pct reduction in the time-averaged wall shear stress on the injector and a 15 pct increase in the volume-averaged melt velocity, promoting more vigorous bath mixing. This study provides a simulation-driven pathway for designing multifunctional components that improve both the reliability and performance of high-temperature metallurgical reactors.</p>

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Hydrodynamic Design of a Protective Injector Shield for Bottom-Blown Smelting Furnaces Using Key-Field Coupling CFD

  • 期刊论文

  • 发表日期：

    2026年4月29日

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  • Wei Wang,
  • Jie Wang,
  • Xin Liu,
  • Ke Ding,
  • Liangjun Huang,
  • Hongliang Zhao,
  • Yongqiang Chen,
  • Fengqin Liu,
  • Hong Yong Sohn

摘要

Improving the longevity of submerged injectors is a critical challenge in Oxygen-Rich Bottom-blown Bath Smelting (OBBS) furnaces, where severe erosion curtails campaign life. This work introduces a novel protective shield designed not only to extend the injector durability but also to enhance process hydrodynamics. A high-fidelity computational fluid dynamics (CFD) model, which addresses the limitations of prior studies by employing a key-field coupling method for the inlet boundary, revealed that the erosion of an injector is driven by the intense wall shear stress from a large-scale melt recirculation loop, exacerbated by gas back-attack phenomena. An optimized arched shroud effectively redirects this erosive flow into a protective swirling pattern. This hydrodynamic reorganization yields a dual benefit: a substantial 80 pct reduction in the time-averaged wall shear stress on the injector and a 15 pct increase in the volume-averaged melt velocity, promoting more vigorous bath mixing. This study provides a simulation-driven pathway for designing multifunctional components that improve both the reliability and performance of high-temperature metallurgical reactors.