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Huan Liu, Kejiang Li, Heng Zhou, Jianliang Zhang, Marco A. Ramírez-Argáez, and Alberto N. Conejo, Numerical simulation of slag-foaming dynamics in CaO–SiO2–Al2O3–FeO steelmaking slags, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-025-3348-7
Huan Liu, Kejiang Li, Heng Zhou, Jianliang Zhang, Marco A. Ramírez-Argáez, and Alberto N. Conejo, Numerical simulation of slag-foaming dynamics in CaO–SiO2–Al2O3–FeO steelmaking slags, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-025-3348-7
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CaO–SiO2–Al2O3–FeO炼钢渣发泡动力学数值模拟

摘要: 炉渣发泡是电弧炉炼钢中的重要操作,目前全球现代钢铁厂普遍采用这一工艺。然而,要实现高效的炉渣发泡,不仅需要在工业规模上控制工艺参数,还需对发泡现象有深入的理解,而这种理解可以通过建立数学模型来实现。但由于炉渣发泡过程极为复杂,该领域的研究仍较为不足。本研究采用欧拉–欧拉多相流模型耦合群体平衡模型,开发了一种计算发泡动力学的三维模型。该模型能够预测炉渣的泡沫高度和发泡指数,并在1773 K、恒定渣碱度条件下对含CaO–SiO2–Al2O3–FeO液态渣的泡沫高度和发泡指数进行了模拟验证,对比实验结果发现误差小于1.4%。说明该模型准确再现了炉渣的发泡行为。当模型被用于预测钢渣发泡行为时,其结果表明,在高温下向钢渣中注入惰性气体Ar时,泡沫形成具有较短的初始潜伏期,大约为4–5秒,且此时间与渣的成分无关。随后,渣的高度逐渐上升直至达到稳态。当将气体速度从1 cm/s增加至3 cm/s时,FeO含量为20wt%的渣中泡沫体积分数由0.33提高至0.46。模型还提供了预测发泡指数的信息。当FeO含量从3wt%增加到30wt%时,发泡指数从1.29下降至0.47 s,这一结果与现有的实验数据一致。发泡指数随FeO含量的增加而降低,可归因于渣黏度降低,从而加快了排水和气泡消亡速率。

 

Numerical simulation of slag-foaming dynamics in CaO–SiO2–Al2O3–FeO steelmaking slags

Abstract: Slag foaming is an important operation in electric arc furnace steelmaking, and modern steel shops worldwide currently apply this practice. However, an efficient slag-foaming practice requires not only control of the process variables at the industrial scale but also a fundamental understanding of the foaming phenomena, which can be achieved through the development of mathematical models. However, research in this field is lacking owing to the extreme complexity of slag foaming. In this work, a three-dimensional computational fluid dynamics model was developed based on the coupled Euler–Euler multiphase flow and population balance models. The model predicted the foam height and foaming index. It was validated against experimental data for batch smelting slags containing CaO–SiO2–Al2O3–FeO at 1773 K under a constant slag basicity, with the relative error in the foaming index being less than 1.4%. When applied to steelmaking slags, the model accurately reproduced slag foaming. The model predictions indicated that increasing the FeO content from 3wt% to 30wt% decreased the foaming index from approximately 1.3 to 0.5.

 

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