Numerical Simulation of Multiphase Flow in Ironmaking Process for Oxygen-Rich Side-Blown Bath Smelting Furnace

The smelting reduction of vanadium–titanium magnetite (VTM) with oxygen-rich side-blown bath smelting furnace (OSBF) is a promising process. However, the study on the behavior of gas–liquid multiphase flow in the OSBF in ironmaking process is deficient. In present work, a 3D simulation model of the OSBF is established to investigate the multiphase flow of gas–slag–metal in the furnace during the VTM smelting process. The bubbles motion, slag phase distribution, flow field distribution, and the flow status in the bath during the smelting process are obtained by combining the Coupled Level Set Volume of Fluid (CLSVOF) method and the Realizable k-ε model. The analysis of the characteristics of gas–slag–metal multiphase flow in the horizontal and vertical directions in the bath indicates that the gas and slag in the bath are evenly mixed, the fluctuation of the slag iron interface is subtle, and the turbulence of the molten iron layer is weak, which is conductive to the smelting process. In addition, the effects of primary air flow, slag layer thickness, and slag viscosity on the smelting process are also studied, and the appropriate operation conditions were recommended. This provides a theoretical basis for the operation and optimization design of the OSBF.