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Numerical Simulations in Metal Refining Process

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Mechanics of Materials".

Deadline for manuscript submissions: closed (10 November 2023) | Viewed by 5653

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Prof. Dr. Qiang Wang

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Guest Editor

The State Key Laboratory of Refractories and Metallurgy, Wuhan University of Science and Technology, Wuhan 430081, China
Interests: CFD modeling; fluid flow; heat transfer; secondary refining; electroslag remelting; continuous casting

Special Issue Information

Dear Colleagues,

With the increasing demand for high-quality metals, it is necessary to improve the refining process to improve its efficiency, stability, and lower its carbon to enhance smelter competitiveness. Due to the aggressive environment in the refining process, it is quite problematic to measure various physical quantities, such as the temperature, element concentration, and refractory lining thickness, with acceptable accuracy. With the development of numerical techniques and computational resources, the computational ﬂuid dynamics (CFD) method has become a powerful tool for understanding the metal refining process, able to solve the coupled mass, momentum, and heat transfer equations and allowing for a more realistic assessment of the ﬂow ﬁeld, temperature distribution, and component content map during the refining process. Therefore, the purpose of this Special Issue is to collect and display the latest research progress of the numerical simulation of the metal refining process, as well as identify any research gaps.

This Special Issue of Materials aims to advance the current knowledge in numerical studies concerning the multiphase flow, inclusion motion, bubble coalescence and breakup, and the chemical reaction in various metal refining processes, especially welcoming research papers addressing the innovative numerical approach. The journal accepts original research papers as well as review articles summarizing recent progress in the field.

Prof. Dr. Qiang Wang
Guest Editor

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Keywords

CFD modeling
heat transfer
mass transfer
multiphase flow
bubble
nonmetallic inclusion
refining reaction
refractory wear
molten slag
desulfurization
deoxidation

Published Papers (3 papers)

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Research

19 pages, 3948 KiB

Open AccessArticle

Modeling of Interfacial Tension and Inclusion Motion Behavior in Steelmaking Continuous Casting Mold

by Md Irfanul Haque Siddiqui, Latif Arifudin, Ibrahim Abdullah Alnaser, Masood Ashraf Ali and Khalid Alluhydan

Materials 2023, 16(3), 968; https://doi.org/10.3390/ma16030968 - 20 Jan 2023

Viewed by 1690

Abstract

The current work is an expansion of our previous numerical model in which we investigated the motion behavior of mold inclusions in the presence of interfacial tension effects. In this paper, we used computational fluid dynamic simulations to examine the influence of interfacial tension on inclusion motion behavior near to the solid–liquid interface (solidifying shell). We have used a multiphase model in which molten steel (SPFH590), sulfur, and alumina inclusions have been considered as different phases. In addition, we assume minimal to negligible velocity at the solid–liquid interface, and we restrict the numerical simulation to only include critical phenomena like heat transport and interfacial tension distribution in two-dimensional space. The two-phase simulation of molten steel mixed with sulfur and alumina was modeled on volume of fluid (VOF) method. Furthermore, the concentration of the surfactant (sulfur) in molten steel was defined using a species model. The surfactant concentration and temperature affect the Marangoni forces, and subsequently affects the interfacial tension applied on inclusion particles. It was found that the alteration in interfacial tension causes the inclusion particles to be pushed and swallowed near the solidifying boundaries. In addition, we have compared the computational results of interfacial tension, and it was found to be in good agreement with experimental correlations. Full article

(This article belongs to the Special Issue Numerical Simulations in Metal Refining Process)

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20 pages, 4197 KiB

Open AccessArticle

A Coupled CFD-DEM Study on the Effect of Basset Force Aimed at the Motion of a Single Bubble

by Huiting Chen, Weitian Ding, Han Wei, Henrik Saxén and Yaowei Yu

Materials 2022, 15(15), 5461; https://doi.org/10.3390/ma15155461 - 08 Aug 2022

Cited by 7 | Viewed by 1624

Abstract

The physical meaning of Basset force is first studied via polynomial approximation and the Fourier series representation method. After compiling the Basset force into the coupling interface with Visual C, a dynamic mathematical model is set up to describe the upward motion behavior of a single bubble by adopting the CFD-DEM method. Afterwards, the coupling interface with Basset force proposed in this study is verified experimentally and shows very good agreements. The initial velocity, releasing depth, bubble size, density ratio and viscosity ratio are studied qualitatively due to their great importance to Basset force. The ratio of Basset force to the sum of Basset force and drag force and to buoyancy,

{\vec{F}}_{B a}

{\vec{F}}_{D}

{\vec{F}}_{B a}

) and |

{\vec{F}}_{B a}

{\vec{F}}_{B}

|, are employed to quantify the contribution of Basset force quantitatively. In addition, some instructive outlooks and recommendations on a further development of appropriate and justifiable use of Basset force are highlighted at last. Full article

(This article belongs to the Special Issue Numerical Simulations in Metal Refining Process)

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15 pages, 9799 KiB

Open AccessArticle

A Three-Dimensional Comprehensive Numerical Model of Ion Transport during Electro-Refining Process for Scrap-Metal Recycling

by Chang Liu, Guangqiang Li, Lifeng Zhang, Qiang Wang and Qiang Wang

Materials 2022, 15(8), 2789; https://doi.org/10.3390/ma15082789 - 11 Apr 2022

Cited by 3 | Viewed by 1817

Abstract

A transient three-dimensional comprehensive numerical model was established to study ion transport caused by diffusion, convection, and electro-migration in the electro-refining process for scrap-metal recycling. The Poisson–Nernst–Planck equations were used to define ion transport within the electrolyte, while the Naiver–Stokes equations and the energy equation were employed to describe fluid flow and heat transfer. In addition, the Butler-Volmer formulation was used to represent the kinetics of the electrochemical reaction. The comparison between the measured and simulated data indicates the reliability of the model. Under the action of diffusion and electro-migration, the positive copper ion moves from the anode to the cathode, while the negative sulfate ion migrates in the opposite direction. The distribution of the ion concentration, however, greatly changes if the fluid flow is taken into account. The ion concentration around the anode and the rate of the electrochemical reaction that occurs at the anode surface are reduced by the fluid flow. The proposed computational framework offers a valuable basis for future research and development in the field of scrap-metal recycling technology. Full article

(This article belongs to the Special Issue Numerical Simulations in Metal Refining Process)

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