Physical and mathematical modeling of pyrometallurgical channel reactors with bottom gas injection: Residence time distribution analysis and ideal- reactor- network model

Abstract

An ideal-reactor-network model has been developed to describe the fluid flow and mixing observed in pyrometallurgical channel reactors with countercurrent liquid flow and high-strength bottom gas injection. Experiments were performed in a cold model under various operating conditions to determine the effects of liquid density, viscosity, flow rate, gas injection rates, injector diameter, and injector spacing on the residence time distribution (RTD) behavior of the channel reactor. The ideal-reactor-network model was used to represent the experimentally observed RTD behavior in both heavy- and light-liquid phases in the channel reactor. The model requires one parameter for each liquid, and all other model parameters are determined on the basis of this parameter. Correlations were developed for the parameters using dimensionless variables. There is excellent agreement between model predictions and experimental measurements for a wide range of experimental conditions. Scale-up calculations and RTD predictions have been made for a QSL leadmaking reactor as well as for proposed channel reactors for coppermaking and steelmaking.