A Review of Computational Capabilities and Requirements in High-Resolution Simulation of Nonferrous Pyrometallurgical Furnaces

Alexandra Anderson; Vineet Kumar; Vivek M. Rao; Joseph Grogan

doi:10.1007/s11837-022-05169-4

A Review of Computational Capabilities and Requirements in High-Resolution Simulation of Nonferrous Pyrometallurgical Furnaces

Alexandra Anderson, Vineet Kumar, Vivek M. Rao, Joseph Grogan

Multiphysics CFD Applications

Research output: Contribution to journal › Review article › peer-review

8 Scopus citations

Abstract

Tremendous progress has been made over the last several decades in improving the pyrometallurgical processing routes of nonferrous metals, such as aluminum, copper, and lead. Advances in the numerical modeling of pyrometallurgical processes has aided in these improvements by providing a better understanding of the complex transport phenomena occurring in modern furnaces. However, there is a need for a comprehensive discussion of the numerical modeling of a primary and a secondary nonferrous pyrometallurgical furnaces. This review provides such a discussion by surveying recent attempts at capturing the physico-chemical phenomena occurring within these furnaces, including gas-phase combustion, melting/smelting, and multiphase heat- and mass-transfer with the molten phases.This work then identifies a complete set of approaches for simulating these types of furnaces and provides recommendations for applying high-resolution numerical tools towards full-furnace simulation. By identifying gaps in the current state of the art, this review offers suggestions for future developments in commercial codebases, outlining the path to fulfilling the promise of CFD-enabled pyrometallurgy.

Original language	English
Journal	JOM
DOIs	https://doi.org/10.1007/s11837-022-05169-4
State	Accepted/In press - 2022

Funding

This work was sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office, High Performance Computing for Energy Innovation Program (HPC4EI), under contract DE-AC05-00OR22725 with UT-Battelle, LLC., through a Cooperative Research and Development Agreement with Gopher Resource, LLC (NFE-19-07865). The HPC4EI Program is managed by Lawrence Livermore National Laboratory for the U.S. Department of Energy. The authors would also like to thank Gopher Resource for research support and H. Sceats for editorial contributions. This manuscript has been co-authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains, and the publisher, by accepting the article for publication, acknowledges, that the US government has a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

Funders	Funder number
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725, NFE-19-07865, HPC4EI
Office of Energy Efficiency and Renewable Energy

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title = "A Review of Computational Capabilities and Requirements in High-Resolution Simulation of Nonferrous Pyrometallurgical Furnaces",

abstract = "Tremendous progress has been made over the last several decades in improving the pyrometallurgical processing routes of nonferrous metals, such as aluminum, copper, and lead. Advances in the numerical modeling of pyrometallurgical processes has aided in these improvements by providing a better understanding of the complex transport phenomena occurring in modern furnaces. However, there is a need for a comprehensive discussion of the numerical modeling of a primary and a secondary nonferrous pyrometallurgical furnaces. This review provides such a discussion by surveying recent attempts at capturing the physico-chemical phenomena occurring within these furnaces, including gas-phase combustion, melting/smelting, and multiphase heat- and mass-transfer with the molten phases.This work then identifies a complete set of approaches for simulating these types of furnaces and provides recommendations for applying high-resolution numerical tools towards full-furnace simulation. By identifying gaps in the current state of the art, this review offers suggestions for future developments in commercial codebases, outlining the path to fulfilling the promise of CFD-enabled pyrometallurgy.",

author = "Alexandra Anderson and Vineet Kumar and Rao, {Vivek M.} and Joseph Grogan",

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Y1 - 2022

N2 - Tremendous progress has been made over the last several decades in improving the pyrometallurgical processing routes of nonferrous metals, such as aluminum, copper, and lead. Advances in the numerical modeling of pyrometallurgical processes has aided in these improvements by providing a better understanding of the complex transport phenomena occurring in modern furnaces. However, there is a need for a comprehensive discussion of the numerical modeling of a primary and a secondary nonferrous pyrometallurgical furnaces. This review provides such a discussion by surveying recent attempts at capturing the physico-chemical phenomena occurring within these furnaces, including gas-phase combustion, melting/smelting, and multiphase heat- and mass-transfer with the molten phases.This work then identifies a complete set of approaches for simulating these types of furnaces and provides recommendations for applying high-resolution numerical tools towards full-furnace simulation. By identifying gaps in the current state of the art, this review offers suggestions for future developments in commercial codebases, outlining the path to fulfilling the promise of CFD-enabled pyrometallurgy.

AB - Tremendous progress has been made over the last several decades in improving the pyrometallurgical processing routes of nonferrous metals, such as aluminum, copper, and lead. Advances in the numerical modeling of pyrometallurgical processes has aided in these improvements by providing a better understanding of the complex transport phenomena occurring in modern furnaces. However, there is a need for a comprehensive discussion of the numerical modeling of a primary and a secondary nonferrous pyrometallurgical furnaces. This review provides such a discussion by surveying recent attempts at capturing the physico-chemical phenomena occurring within these furnaces, including gas-phase combustion, melting/smelting, and multiphase heat- and mass-transfer with the molten phases.This work then identifies a complete set of approaches for simulating these types of furnaces and provides recommendations for applying high-resolution numerical tools towards full-furnace simulation. By identifying gaps in the current state of the art, this review offers suggestions for future developments in commercial codebases, outlining the path to fulfilling the promise of CFD-enabled pyrometallurgy.

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A Review of Computational Capabilities and Requirements in High-Resolution Simulation of Nonferrous Pyrometallurgical Furnaces

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