A three-dimensional mathematical model was developed to simulate the distributions of electrical potential, heat release, temperature, and velocity in the slag and matte in a six-in-line 36 MVA capacity furnace for smelting nickel calcine. From Part I of this series, it was found that there was a substantial electrical potential drop at the electrode surface, likely due to arcing through evolved carbon monoxide. The incorporation of this phenomenon into the model permitted accurate calculation of the current, power, and temperature distributions in the slag and matte. The slag was found to be thermally homogenized due to the evolved gas, and to a lesser extent by natural convection. In contrast, the matte was thermally stratified; this finding was attributed to poor momentum transfer across the slag/matte interface. Ninety percent of the electrical energy was used in smelting reactions in the calcine; to simulate the heat transfer from the slag to the calcine, a heat transfer coefficient was deduced from plant data. The implications of these findings for stable furnace operation are discussed.
An electric potential probe was constructed so that simultaneous, multiple measurements of electric potential could be made in a six-in-line electric furnace for smelting nickel calcine having a maximum transformer capacity of 36 MVA. When the electric potential distributions were compared with those calculated from the solution of the Laplace equation, it was evident that there was significant electric potential drop at the electrode surface, 100 to 120 V for an applied potential of 180 to 230 V and currents of 20 to 30 kA. The Soderberg electrodes were continuously oxidized in the slag, likely creating carbon monoxide. The electric potential drop at the surface was attributed to arcing through the carbon monoxide. Thus, heat was released in the immediate vicinity of the electrode due to arcing, as well as in the bulk of the slag by Joule heating. The proper distribution of heat dissipation is required for the transport model, developed in Part II of this series.
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