Abstract
Three-dimensional magneto-hydrodynamic flow is numerically modeled in an industrial-scale electric furnace and the trajectories of nickel droplets are simulated. Calculations are carried out for varied droplet sizes and locations. The droplet settling ratio is introduced to describe the settling performance. Characteristic curve of the settling ratio with the droplet size is obtained. The droplet settling behavior is demonstrated by both the droplet volume fraction distribution and the droplet trajectories. Numerical predictions show that most of the droplets will settle into the matte in the central bottom region of the furnace. The fine droplets with a diameter less than 50 µm are unable to fall into the matte. The settling ratio increases with increasing the droplet size. The coagulation of droplets to form relatively large droplets may play an important role in the process of nickel matte droplet settling. The average residence time of droplets generally decreases with an increase in droplet size. The residence time for some droplets can be very long (over 5000 seconds). The turbulent droplet dispersion has a significant effect on the trajectories of the droplet and should be taken into account in simulation.
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