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<p>Side-blown bath smelting technology has been extensively employed in the extraction of non-ferrous metals such as copper, nickel, and lead due to its high productivity and efficient utilization of resources. In this study, the multi-scale dynamics of bubbles and the associated hydrodynamic characteristics in an industrial-scale side-blown bath were investigated numerically. A volume of fluid multiphase model coupled with the realizable <i>k–ε</i> turbulence model was developed and validated against experimental measurements of penetration depth. The model was subsequently applied to examine bubble growth, breakup, coalescence, trajectories, and velocity distributions. The results elucidate the coupled influences of inertial, buoyancy, and surface tension forces on bubble deformation and motion. In low-viscosity slags, inertial forces dominate bubble motion, whereas viscous damping becomes increasingly significant in high-viscosity systems. In low-viscosity slag, inertial forces predominantly govern bubble motion, whereas viscous damping effects become significant under high-viscosity conditions. In the side-blown bath, the Weber number is positively correlated with the bubble Froude number, which satisfies the following relationship: (ln<i>Fr</i><sub><i>b</i></sub>+5.25)&#xa0;&lt;&#xa0;ln<i>We</i>&#xa0;&lt;&#xa0;1.45&#xa0;×&#xa0;(ln<i>Fr</i><sub><i>b</i></sub>&#xa0;+&#xa0;6.7). Studies have shown that a blowing angle of 16 deg and a slag viscosity of 0.3–0.4&#xa0;kg/(m·s) represent the optimal operating conditions. This structural configuration enhances the gas–liquid interfacial area and promotes uniform gas holdup. Overall, the study provides theoretical guidance for optimizing side-blown smelting furnaces, thereby improving smelting efficiency and metal quality.</p>

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Numerical Study of Slag Hydrodynamics and Multi-scale Bubble Dynamics in an Industrial-scale Side-blown Molten Bath

  • 期刊论文

  • 发表日期：

    2025年11月24日

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  • Yinghua Li,
  • Shiliang Yang,
  • Junyi Hu,
  • Hua Wang

摘要

Side-blown bath smelting technology has been extensively employed in the extraction of non-ferrous metals such as copper, nickel, and lead due to its high productivity and efficient utilization of resources. In this study, the multi-scale dynamics of bubbles and the associated hydrodynamic characteristics in an industrial-scale side-blown bath were investigated numerically. A volume of fluid multiphase model coupled with the realizable k–ε turbulence model was developed and validated against experimental measurements of penetration depth. The model was subsequently applied to examine bubble growth, breakup, coalescence, trajectories, and velocity distributions. The results elucidate the coupled influences of inertial, buoyancy, and surface tension forces on bubble deformation and motion. In low-viscosity slags, inertial forces dominate bubble motion, whereas viscous damping becomes increasingly significant in high-viscosity systems. In low-viscosity slag, inertial forces predominantly govern bubble motion, whereas viscous damping effects become significant under high-viscosity conditions. In the side-blown bath, the Weber number is positively correlated with the bubble Froude number, which satisfies the following relationship: (lnFrb+5.25) < lnWe < 1.45 × (lnFrb + 6.7). Studies have shown that a blowing angle of 16 deg and a slag viscosity of 0.3–0.4 kg/(m·s) represent the optimal operating conditions. This structural configuration enhances the gas–liquid interfacial area and promotes uniform gas holdup. Overall, the study provides theoretical guidance for optimizing side-blown smelting furnaces, thereby improving smelting efficiency and metal quality.