The purpose of this work is to focus on the hydrodynamics of a Top-Submerged-Lance (TSL) smelting furnace, understanding how liquid properties and operational parameters act on key factors of a TSL process, such as splashing, mixing, mass transfer area, and bubble development. A deep knowledge of all those aspects is needed since they all influence the smelting reaction rates; hence the efficiency of the reactor. The characterization and scaling of the TSL gas injection are commonly based on the modified Froude number, the ratio of dynamic and gravitational forces. Detailed literature research reveals a potential weakness of this approach, since it does not consider the effects of viscosity and surface tension. To investigate this question an extensive parametric study was performed applying computational fluid dynamics to cold and non-reactive flows, which provided a broad overview of the physics of the flow. The analysis was performed on fluid dynamic properties (liquid density, liquid viscosity, surface tension) and operational variables (gas volume flow, lance immersion depth). The coupled Level Set-Volume of Fluid model, available in the commercial solver ANSYS Fluent Ò , was used to resolve the gas-liquid interface in the multiphase flow. The results of the work underscore the significance of the viscous and interfacial forces for gas injection in smelting slags, confirming the incompleteness of applying only the Froude number to describe such flows.

In the present work, the dynamics of a downward gas injection into a liquid metal bath is studied using a numerical modeling approach, and validated with experimental data. As in a top-submerged-lance (TSL) smelter, gas is injected through the lance into the melt. By this means, the properties of the liquid are closer to the actual industrial process than the typically used water/glycerol–air/helium systems. The experimental activity was carried out in a quasi-2D vessel $$(144\times 144\times 12\,{\hbox {mm}}^{3})$$ ( 144 × 144 × 12 mm 3 ) filled with GaInSn, a metal alloy with eutectic at room temperature. Ar was used as the inert gas. The structure and behavior of the gas phase were visualized and quantitatively analyzed by X-ray radiography and high-speed imaging. Computational Fluid Dynamics (CFD) was applied to simulate the multiphase flow in the vessel and the Volume Of Fluid (VOF) model chosen to track the interface using a geometric reconstruction of the interface. Three different vertical lance positions were investigated, applying a gas flow rate of $$Q_{\text {gas}}=6850\,{\hbox {cm}}^{3}/{\hbox {min}}.$$ Q gas = 6850 cm 3 / min . The CFD model is able to predict the bubble detachment frequency, the average void fraction distributions, and the bubble size and hydrodynamic behavior, demonstrating its applicability to simulate such complex multiphase systems. The use of numerical models also provides a deep insight into fluid dynamics to study particular phenomena such as bubble break-up and free surface oscillations.

The motion of bubbles in a liquid slag bath with temperature gradients is investigated by means of 3D fluid dynamic computations. The goal of the work is to describe the dynamics of the rising bubbles, taking into account the temperature dependency of the thermo-physical properties of the slag. Attention is paid to the modeling approach used for the slag properties and how this affects the simulation of the bubble motion. In particular, the usage of constant values is compared to the usage of temperature-dependent data, taken from models available in the literature and from in-house experimental measurements. Although the present study focuses on temperature gradients, the consideration of varying thermo-physical properties is greatly relevant for the fluid dynamic modeling of reactive slag baths, since the same effect is given by heterogeneous species and solid fraction distributions. CFD is applied to evaluate the bubble dynamics in terms of the rising path, terminal bubble shape, and velocity, the gas–liquid interface area, and the appearance of break-up phenomena. It is shown that the presence of a thermal gradient strongly acts on the gas–liquid interaction when the temperature-dependent properties are considered. Furthermore, the use of literature models and experimental data produces different results, demonstrating the importance of correctly modeling the slag’s thermo-physical properties.

Computational fluid dynamics (CFD) is applied to investigate rotational sloshing waves in a top-submerged-lance (TSL) cylindrical metal bath. The study is an extension of a recent work of the authors, where the top injection of Ar into a metallic bath was examined in a quasi-2D flat setup, allowing the numerical model to be extensively validated against experimental data based on x-ray radiography. The new analysis of top gas injection in a cylindrical vessel reveals the appearance of rotational sloshing in the bath, which is maintained by a condition of synchronism between the gas bubbles and the free surface of the bath. A numerical quantification is achieved with specific post-processing of the simulation results, showing the effect of control parameters such as the lance immersion depth and the gas flow rate. This fundamental research study demonstrates the capability of CFD modeling to predict bath dynamics known from literature and practice, the understanding of which is essential for the design of TSL furnaces.

The hydrodynamics of a Top Submerged Lance (TSL) slag bath are investigated here by means of Computational Fluid Dynamics (CFD) simulation. The object of the study is the pilot-scale furnace located at TU Bergakademie Freiberg, where air is injected beneath the slag bath with a top lance. The fluid dynamics system is evaluated at operating conditions, with experimentally measured slag physical properties and real flow rates. The numerical approach is based on the Volume Of Fluid (VOF) model, a front-tracking method that allows the interface to be geometrically reconstructed. Using a fine computational grid, the multiphase interactions are calculated with a high level of detail, revealing the mechanisms of bubble formation and bath dynamics. Two lance configurations are compared, with and without a swirler, and the effect on the hydrodynamics is discussed with regards to key features of the process, such as bubble dynamics, slag splashing, the interface area, rotational sloshing, and bath mixing. The model predicts bubble frequencies in the range of 2.5 to 3 Hz and captures rotational sloshing waves with half the frequencies of the bubble detachment. These results agree with real furnace data from the literature, proving the reliability of the computing model and adding value to the empirical understanding of the process, thanks to the direct observation of the resolved multiphase flow features. The comparative study indicates that the air swirler has an overall positive effect in addition to the proposed enhancement of lance cooling, with an increase in the bath mixing and a reduction in the splashing.