CFD-Based studies and model development for top-blown rotary converters (TBRC).
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Date
2025
Journal Title
Journal ISSN
Volume Title
Publisher
Universidad de Concepción
Abstract
Las simulaciones computacionales son una herramienta efectiva que permite estudiar fenómenos complejos con precisión, es especialmente útil en la investigación y creación de prototipos por su bajo costo económico y alta precisión. En el presente estudio se creó un modelo computacional de un reactor metalúrgico TBRC a partir de un modelo TSL, ambos reactores son ampliamente utilizados en la industria de metales no ferrosos y asoman como opciones viables para el camino a la sostenibilidad. El objetivo del modelo computacional es estudiar el efecto de variables operacionales, como la velocidad de rotación y la inclinación, en el comportamiento hidrodinámico del sistema. En este tipo de reactores la interacción gas-líquido domina la velocidad de reacción y como consecuencia la eficiencia del proceso.
El modelo computacional es creado utilizando el software comercial Ansys FLUENT, para el seguimiento de la interfaz gas-liquido se utiliza el modelo "Volume of fluid (VOF)" el cual es acoplado con el modelo de turbulencia k-ω SST. Para estudiar el comportamiento hidrodinámico del sistema se analizan definiciones de informe, tales como el área total de la interfase gas-líquido, la frecuencia de burbujeo y la altura alcanzada por las gotas de líquido dentro del reactor junto con imágenes instantáneas y promediadas en el tiempo.
Los resultados revelan que la penetración de la lanza aumenta de gran manera la frecuencia de burbujas, además, se observa un aumento notable en el área total de interfase gas-liquido. Contrariamente a lo esperado, los patrones de recirculación tienden a ser más débiles a medida que aumenta la penetración, aumentando la probabilidad de zonas de estancamiento, sin embargo, la velocidad de rotación ayuda a mejorar la recirculación de los fluidos, en especial en la zona baja del reactor. La inclinación del reactor, una característica única de los reactores TBRC, disminuye la frecuencia de burbujas, el splashing y el área total de interfase gas-líquido, lo que resulta en una disminución en la interacción gas-líquido. Remover las zonas de estancamiento a través del aumento en la velocidad de rotación y aumentar la penetración de la lanza para aumentar el área total de la inferface asegura que los reactivos estén en constante contacto con las superficies activas donde ocurren las reacciones, además, se facilitaría la transferencia de masa desde la fase gaseosa a la fase liquida, impactando directamente la conversión y la eficiencia del sistema.
Computational simulations are an effective tool that allows for the precise study of complex phenom ena; they are especially useful in research and prototype creation due to their low economic cost and high accuracy. In the present study, a computational model of a TBRC metallurgical reactor was cre ated from a TSL model; both reactors are widely used in the non-ferrous metal industry and appear as viable options on the path to sustainability. The objective of the computational model is to study the effect of operational variables, such as rotation speed and inclination, on the hydrodynamic behav ior of the system. In this type of reactors, the gas-liquid interaction dominates the reaction rate and consequently the process efficiency. The computational model is created using the commercial software Ansys FLUENT. For tracking the gas-liquid interface, the "Volume of Fluid (VOF)" model is used, which is coupled with the k-ω SST turbulence model. To study the hydrodynamic behavior of the system, report definitions such as the total area of the gas-liquid interface, the bubbling frequency, and the height reached by the liquid droplets inside the reactor are analyzed, along with instantaneous and time-averaged images. The results reveal that the lance penetration greatly increases the bubble frequency, and a notable increase in the total gas-liquid interfacial area is also observed. Contrary to expectations, the re circulation patterns tend to be weaker as penetration increases, increasing the likelihood of stagnant zones; however, the rotation speed helps improve fluid recirculation, especially in the lower zone of the reactor. The inclination of the reactor, a unique feature of TBRC reactors, decreases the frequency of bubbles, splashing, and the total gas-liquid interfacial area, resulting in a reduction in gas-liquid interaction. Removing stagnant zones through increased rotation speed and increasing the lance pen etration to increase the total interface area ensures that the reactants are in constant contact with the active surfaces where the reactions occur. Additionally, it would facilitate mass transfer from the gaseous phase to the liquid phase, directly impacting the conversion and efficiency of the system.
Computational simulations are an effective tool that allows for the precise study of complex phenom ena; they are especially useful in research and prototype creation due to their low economic cost and high accuracy. In the present study, a computational model of a TBRC metallurgical reactor was cre ated from a TSL model; both reactors are widely used in the non-ferrous metal industry and appear as viable options on the path to sustainability. The objective of the computational model is to study the effect of operational variables, such as rotation speed and inclination, on the hydrodynamic behav ior of the system. In this type of reactors, the gas-liquid interaction dominates the reaction rate and consequently the process efficiency. The computational model is created using the commercial software Ansys FLUENT. For tracking the gas-liquid interface, the "Volume of Fluid (VOF)" model is used, which is coupled with the k-ω SST turbulence model. To study the hydrodynamic behavior of the system, report definitions such as the total area of the gas-liquid interface, the bubbling frequency, and the height reached by the liquid droplets inside the reactor are analyzed, along with instantaneous and time-averaged images. The results reveal that the lance penetration greatly increases the bubble frequency, and a notable increase in the total gas-liquid interfacial area is also observed. Contrary to expectations, the re circulation patterns tend to be weaker as penetration increases, increasing the likelihood of stagnant zones; however, the rotation speed helps improve fluid recirculation, especially in the lower zone of the reactor. The inclination of the reactor, a unique feature of TBRC reactors, decreases the frequency of bubbles, splashing, and the total gas-liquid interfacial area, resulting in a reduction in gas-liquid interaction. Removing stagnant zones through increased rotation speed and increasing the lance pen etration to increase the total interface area ensures that the reactants are in constant contact with the active surfaces where the reactions occur. Additionally, it would facilitate mass transfer from the gaseous phase to the liquid phase, directly impacting the conversion and efficiency of the system.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Químico/a.
Keywords
Industria de metales no ferrosos, Dinámica de fluidos, Convertidores rotatorios