Numerical Simulation of Pre-Reduction for a New Process of Acid Production from Phosphogypsum by Gas Sulfur Reduction

Abstract

The gas sulfur reduction of phosphogypsum in the acid co-production of sulfoaluminate cement clinker is a new process for treating phosphogypsum. The reduction furnace of this system was studied and analyzed by combining computational fluid dynamics (CFD) and experimental validation. The effects of n(CaSO4)/n(S2), particle residence time, and kiln tail flue gas temperature on the performance of the reduction furnace were obtained. A second-order response model based on the response surface methodology was developed using a three-factor Box–Behnken design (BBD). The results show that the comparison error between the simulation and test data of the reduction furnace is acceptable. The above three conditions arranged in order of significance in terms of their effect on the performance of the reduction furnace is n(CaSO4)/n(S2) > particle residence time > kiln tail gas temperature. Finally, by optimizing the response surface model, the predicted optimal operation parameter combination is n(CaSO4)/n(S2) = 3.04, with the particle residence time and flue gas temperature at the kiln end given as 8.90 s and 1265.39 K, respectively.