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<p>A fundamental challenge in optimizing gas-stirred reactors lies in reconciling the conflicting needs of intense turbulence for efficient mixing and quiescent conditions for effective phase separation. This study addresses this conflict through an integrated strategy combining reactor geometry and operational parameters. A three-dimensional transient computational fluid dynamics (CFD) model, integrating the volume of fluid (VOF) method with the realizable <i>k</i>–<i>ε</i> model, was developed and validated against water-model experiments to simulate gas–liquid flow in a dual-side-blown furnace. Increasing the gas injection velocity to 300&#xa0;m/s enhanced mixing, raising the maximum melt velocity by over 25% and reducing the dead zone volume ratio from 10.68 to 3.40%. However, this also caused significant interface instability, elevating slag splash rates and operational risks. To mitigate this, an internal baffle configuration was designed, symmetrically positioned 6.48&#xa0;m from the centerline with a 0.82&#xa0;m immersion depth. This design effectively decoupled the flow fields, reducing the volumetric average turbulent kinetic energy (TKE) in the settling zone by 84.4% while increasing TKE in the melting zone by 33%. Statistical evaluation confirmed that this arrangement optimally balances mixing intensity and separation stability. The results demonstrate that strategic internal baffles offer a effective method for intensifying performance in multiphase reactors facing similar phase-disengagement challenges.</p> Graphical Abstract <p></p>

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Turbulence Modulation via Internal Baffles for Intensified Slag-Matte Separation in Gas-Stirred Reactors

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • Peipei Zhang,
  • Hao Zhang,
  • Ge Deng,
  • Dongbo Li,
  • Jianhang Hu,
  • Cheng Tan,
  • Yong Yu,
  • Ruijin Fan,
  • Hua Wang

摘要

A fundamental challenge in optimizing gas-stirred reactors lies in reconciling the conflicting needs of intense turbulence for efficient mixing and quiescent conditions for effective phase separation. This study addresses this conflict through an integrated strategy combining reactor geometry and operational parameters. A three-dimensional transient computational fluid dynamics (CFD) model, integrating the volume of fluid (VOF) method with the realizable k–ε model, was developed and validated against water-model experiments to simulate gas–liquid flow in a dual-side-blown furnace. Increasing the gas injection velocity to 300 m/s enhanced mixing, raising the maximum melt velocity by over 25% and reducing the dead zone volume ratio from 10.68 to 3.40%. However, this also caused significant interface instability, elevating slag splash rates and operational risks. To mitigate this, an internal baffle configuration was designed, symmetrically positioned 6.48 m from the centerline with a 0.82 m immersion depth. This design effectively decoupled the flow fields, reducing the volumetric average turbulent kinetic energy (TKE) in the settling zone by 84.4% while increasing TKE in the melting zone by 33%. Statistical evaluation confirmed that this arrangement optimally balances mixing intensity and separation stability. The results demonstrate that strategic internal baffles offer a effective method for intensifying performance in multiphase reactors facing similar phase-disengagement challenges.

Graphical Abstract