2010 STAR European Conference: 22 & 23 March, London, UK
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1 EMULATING THE DIRECT BLISTER FURNACE (DBF) PROCESS WITH COAL COMBUSTION CAPABILITIES IN STAR-CCM+ V4.06 joint development venture between Bateman & Aerotherm 2010 STAR European Conference: 22 & 23 March, London, UK
2 CONTENTS Numerical Model Details - DBF. Boundary Conditions - DBF. Direct Blister Furnace Phase One. US / Throat / WHB Phase Two. Way Forward. Conclusions. Questions. 2
3 NUMERICAL MODEL DETAILS - DBF Chemical Reactions C12H26 (multi-component gas): {C12H O2 = 12CO2 + 13H20}. Fuel oil burners - C12H26 (liquid) - Lagrangian: {Quasi-Steady Evaporation to C12H26 vapor component}. Coal chute inlet coal combustion activates char oxidation by oxygen, devolatilisation & moisture evaporation. {Current approach to emulate concentrate / dust / flux process} Radiation (gas & particles) & Conjugate Heat Transfer (roof). Reports to monitor outlet gas temperature & heat transfer. Results shown at pseudo-steady state stage (minimum temp). 3
4 BOUNDARY CONDITIONS - DBF inlet boundaries (Table 2). inlet boundaries (Table 2). Fuel C. Raw Coal 0.2 kg/s, partially-premixed through the chute gas inlet 80 C (release same chemical energy as copper). Fixed Flux Wall Patches (Reaction Shaft only). Forced Convection Walls (copper & refractory). Adiabatic walls (settler region & slag bath). 4
5 Direct Blister Furnace Phase One Outotec Direct Blister Flash Smelting Process W N S E 5
6 Direct Blister Furnace Shaft & Settler Stopping criterion: Tmin = 1200 C Heat Flux = kw/m² W N S E 6
7 Direct Blister Furnace Composite Roof Local hot spots due to the combustion of the fuel, influenced by the 3D recirculation flow pattern in the reaction shaft. 7
8 Direct Blister Furnace Mass Fraction (CO2) N W E S 8
9 Direct Blister Furnace Velocity Contours N W E S 9
10 Direct Blister Furnace Sectional Contours Perpendicular plane temperature scale Symmetry plane temperature scale E S N W 10
11 Direct Blister Furnace Velocity Vectors W E 11
12 Direct Blister Furnace Fuel & Coal Results 12
13 Direct Blister Furnace Heat Transfer Results Boundary / Region Name Temperature ( C) Convection coeff (W/m².K) Heat Flux (W/m²) Heat Transfer Rate (MW) (Reports) Reaction Shaft CCM+ calculates CCM+ calculates (input) (-0.893) Roof (Copper) 40 (input) 143 & 180 (input) CCM+ calculates (-0.159) Roof (Refractory) 40 (input) 10 (input) CCM+ calculates Outlet (Excess) 1279 (1290) N/A N/A (-1.19) Total Heat (-2.24) Symmetrical Model Values 13
14 RESULTS SUMMARY PHASE ONE Pressure outlet: Area-weighted averaged CFD outlet temperature = 1279 C vs C obtained by 70 tons per hour of copper concentrate fed (excl. dust & flux additions) into DBF. Reaction Shaft Wall Heat Removal Rate: q = 0.78 MW vs MW calculated for plant operations (transition zone heat flux patch value 30 kw/m² less than that specified in CSIRO report). Composite Roof Heat Removal Rate: q = 0.45 MW vs MW calculated for plant operations (current CFD ambient heat transfer coefficients limited to ensure top maximum copper nestling block temperature = 500 C). 14
15 US / Throat / WHB Phase Two 15
16 US/Throat/WHB Modifications/Concepts
17 WAY FORWARD Incorporate copper sulphide concentrate / dust / flux reaction kinetics data & all properties for the DBF: obtaining necessary info from client (March 2010). Uptake Shaft, Throat & Waste Heat Boiler simulated separately - mapping CFD results Reaction Shaft outlet onto inlet of 2 nd CFD model (project started: February 2010 for coal combustion outlet results). STAR-CCM+ v4.06 enabled us to emulate the copper concentrate DBF process on the interim with pulverised coal combustion. Aim downstream: apply more accurate hot face temperatures and heat transfer coefficients to design better furnace containment equipment. 17
18 CONCLUSIONS Developed DBF numerical model for CFD purposes. Fluid Flow Initialised. Added Chemical Reactions, Fuel Injection & Radiation sequentially (numerical stability). COAL combustion capability applied to emulate copper concentrate / dust / flux energy release with calculated coal mass flow rate in DBF (fixed coal composition). STAR-CCM+ applied to emulate real process with latest pulverised coal combustion capability successfully. Transferred symmetrical DBF outlet data to full WHB model inlet to analyse fluid flow & improve possibly. 18
19 ACKNOWLEDGEMENTS AEROTHERM (SA): Martin van Staden, Julius Cloete & David Mentz. CD-adapco (USA): Piyush Thakre & Rajesh Rawat. 19
20 QUESTIONS? 20
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