Optimization of aerodynamic characteristics of a flash smelting furnace using CFD modeling

Modern metallurgical enterprises, seeking to improve the efficiency of smelting units, face a number of technological challenges. One of the most common units in non-ferrous metallurgy is a flash smelting furnace. Currently, the analysis of the aerodynamic characteristics of the furnace, temperature distribution in different zones of the unit, gas flow velocity and movement of charge particles remains an urgent task. These studies are necessary to ensure optimal smelting conditions and improve the thermal mode. A numerical simulation of the aerodynamic characteristics of the flash smelting furnace was performed using CFD methods to analyze the influence of its design and process parameters on gas-dynamic processes. Model calculations were performed for two design options for the charge sprayer element – the spray ring, as well as four burner operating modes. This made it possible to determine the patterns of temperature distribution and gas flow rates. It was found that the main parameters of the dust-gas flow in the furnace settler are determined by the number of active burners and the flow rate of the oxygen-air mixture for combustion per the charge sprayer. It was determined that a decrease in the flow rate of the oxygenair mixture contributes to a more uniform distribution of the charge in the reaction shaft, and the operation of the burners in the settler increases the efficiency of particle afterburning. As a result of the studies, it was recommended to make changes to the burner operating mode to reduce dust emission and increase the efficiency of smelting.