Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace

Vivek M. Rao; Vineet Kumar; Alexandra Anderson; Joseph Grogan; Prashant K. Jain

doi:10.1007/978-3-030-92563-5_53

Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace

Vivek M. Rao, Vineet Kumar, Alexandra Anderson, Joseph Grogan, Prashant K. Jain

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

Pyrometallurgical recovery of nonferrous metals involves a combination of thermally intensive transformations during exothermic gas-phase reactions, endothermic decomposition of solid charge, and melting of simpler solids. In the recovery of secondary lead, simultaneous thermal effects in a reverberatory-style furnace cause a melt pool to accumulate at the bottom, with lighter solids (slag) floating above and gaseous products from decomposition of the charge diffusing through the gas–slag interface. Species from oxy-fuel combustion of natural gas, species profiles from smelting reactions, and the formation of a melt pool consisting primarily of lead are simulated via a time-averaged formulation. Predictions of outflow are compared with preset inflow profiles to ensure conservation of mass. Thermal profiles for solid, liquid, and gas phases are presented by species. A novel method is implemented to model the latent heat of fusion using a heterogeneous chemical reaction. The simulation is conducted in Simcenter STAR-CCM+ v. 16.02.009-R8.

Original language	English
Title of host publication	REWAS 2022
Subtitle of host publication	Developing Tomorrow’s Technical Cycles
Editors	Adamantia Lazou, Katrin Daehn, Camille Fleuriault, Mertol Gökelma, Elsa Olivetti, Christina Meskers
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	503-513
Number of pages	11
ISBN (Print)	9783030925628
DOIs	https://doi.org/10.1007/978-3-030-92563-5_53
State	Published - 2022
Event	7th Installment of the REWAS conference series held at the TMS Annual Meeting and Exhibition focuses on developing tomorrow’s technical cycles, 2022 - Anaheim, United States Duration: Feb 27 2022 → Mar 3 2022

Publication series

Name	Minerals, Metals and Materials Series
ISSN (Print)	2367-1181
ISSN (Electronic)	2367-1696

Conference

Conference	7th Installment of the REWAS conference series held at the TMS Annual Meeting and Exhibition focuses on developing tomorrow’s technical cycles, 2022
Country/Territory	United States
City	Anaheim
Period	02/27/22 → 03/3/22

Bibliographical note

Publisher Copyright:
© 2022, The Minerals, Metals & Materials Society.

Funding

This work was sponsored by the US 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. The HPC4EI Program is managed by Lawrence Livermore National Laboratory for the US Department of Energy.

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

Keywords

CFD
DEM
Lead
Melting
Oxy-fuel combustion
Smelting

Access to Document

10.1007/978-3-030-92563-5_53

Cite this

Rao, V. M., Kumar, V., Anderson, A., Grogan, J., & Jain, P. K. (2022). Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace. In A. Lazou, K. Daehn, C. Fleuriault, M. Gökelma, E. Olivetti, & C. Meskers (Eds.), REWAS 2022: Developing Tomorrow’s Technical Cycles (pp. 503-513). (Minerals, Metals and Materials Series). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-030-92563-5_53

Rao, Vivek M. ; Kumar, Vineet ; Anderson, Alexandra et al. / Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace. REWAS 2022: Developing Tomorrow’s Technical Cycles. editor / Adamantia Lazou ; Katrin Daehn ; Camille Fleuriault ; Mertol Gökelma ; Elsa Olivetti ; Christina Meskers. Springer Science and Business Media Deutschland GmbH, 2022. pp. 503-513 (Minerals, Metals and Materials Series).

@inproceedings{0747c6495c754567aa144f1c77fd8868,

title = "Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace",

abstract = "Pyrometallurgical recovery of nonferrous metals involves a combination of thermally intensive transformations during exothermic gas-phase reactions, endothermic decomposition of solid charge, and melting of simpler solids. In the recovery of secondary lead, simultaneous thermal effects in a reverberatory-style furnace cause a melt pool to accumulate at the bottom, with lighter solids (slag) floating above and gaseous products from decomposition of the charge diffusing through the gas–slag interface. Species from oxy-fuel combustion of natural gas, species profiles from smelting reactions, and the formation of a melt pool consisting primarily of lead are simulated via a time-averaged formulation. Predictions of outflow are compared with preset inflow profiles to ensure conservation of mass. Thermal profiles for solid, liquid, and gas phases are presented by species. A novel method is implemented to model the latent heat of fusion using a heterogeneous chemical reaction. The simulation is conducted in Simcenter STAR-CCM+ v. 16.02.009-R8.",

keywords = "CFD, DEM, Lead, Melting, Oxy-fuel combustion, Smelting",

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

note = "Publisher Copyright: {\textcopyright} 2022, The Minerals, Metals & Materials Society.; 7th Installment of the REWAS conference series held at the TMS Annual Meeting and Exhibition focuses on developing tomorrow{\textquoteright}s technical cycles, 2022 ; Conference date: 27-02-2022 Through 03-03-2022",

year = "2022",

doi = "10.1007/978-3-030-92563-5_53",

language = "English",

isbn = "9783030925628",

series = "Minerals, Metals and Materials Series",

publisher = "Springer Science and Business Media Deutschland GmbH",

pages = "503--513",

editor = "Adamantia Lazou and Katrin Daehn and Camille Fleuriault and Mertol G{\"o}kelma and Elsa Olivetti and Christina Meskers",

booktitle = "REWAS 2022",

}

Rao, VM, Kumar, V, Anderson, A, Grogan, J & Jain, PK 2022, Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace. in A Lazou, K Daehn, C Fleuriault, M Gökelma, E Olivetti & C Meskers (eds), REWAS 2022: Developing Tomorrow’s Technical Cycles. Minerals, Metals and Materials Series, Springer Science and Business Media Deutschland GmbH, pp. 503-513, 7th Installment of the REWAS conference series held at the TMS Annual Meeting and Exhibition focuses on developing tomorrow’s technical cycles, 2022, Anaheim, United States, 02/27/22. https://doi.org/10.1007/978-3-030-92563-5_53

Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace. / Rao, Vivek M.; Kumar, Vineet; Anderson, Alexandra et al.
REWAS 2022: Developing Tomorrow’s Technical Cycles. ed. / Adamantia Lazou; Katrin Daehn; Camille Fleuriault; Mertol Gökelma; Elsa Olivetti; Christina Meskers. Springer Science and Business Media Deutschland GmbH, 2022. p. 503-513 (Minerals, Metals and Materials Series).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace

AU - Rao, Vivek M.

AU - Kumar, Vineet

AU - Anderson, Alexandra

AU - Grogan, Joseph

AU - Jain, Prashant K.

PY - 2022

Y1 - 2022

N2 - Pyrometallurgical recovery of nonferrous metals involves a combination of thermally intensive transformations during exothermic gas-phase reactions, endothermic decomposition of solid charge, and melting of simpler solids. In the recovery of secondary lead, simultaneous thermal effects in a reverberatory-style furnace cause a melt pool to accumulate at the bottom, with lighter solids (slag) floating above and gaseous products from decomposition of the charge diffusing through the gas–slag interface. Species from oxy-fuel combustion of natural gas, species profiles from smelting reactions, and the formation of a melt pool consisting primarily of lead are simulated via a time-averaged formulation. Predictions of outflow are compared with preset inflow profiles to ensure conservation of mass. Thermal profiles for solid, liquid, and gas phases are presented by species. A novel method is implemented to model the latent heat of fusion using a heterogeneous chemical reaction. The simulation is conducted in Simcenter STAR-CCM+ v. 16.02.009-R8.

AB - Pyrometallurgical recovery of nonferrous metals involves a combination of thermally intensive transformations during exothermic gas-phase reactions, endothermic decomposition of solid charge, and melting of simpler solids. In the recovery of secondary lead, simultaneous thermal effects in a reverberatory-style furnace cause a melt pool to accumulate at the bottom, with lighter solids (slag) floating above and gaseous products from decomposition of the charge diffusing through the gas–slag interface. Species from oxy-fuel combustion of natural gas, species profiles from smelting reactions, and the formation of a melt pool consisting primarily of lead are simulated via a time-averaged formulation. Predictions of outflow are compared with preset inflow profiles to ensure conservation of mass. Thermal profiles for solid, liquid, and gas phases are presented by species. A novel method is implemented to model the latent heat of fusion using a heterogeneous chemical reaction. The simulation is conducted in Simcenter STAR-CCM+ v. 16.02.009-R8.

KW - CFD

KW - DEM

KW - Lead

KW - Melting

KW - Oxy-fuel combustion

KW - Smelting

UR - http://www.scopus.com/inward/record.url?scp=85125270569&partnerID=8YFLogxK

U2 - 10.1007/978-3-030-92563-5_53

DO - 10.1007/978-3-030-92563-5_53

M3 - Conference contribution

AN - SCOPUS:85125270569

SN - 9783030925628

T3 - Minerals, Metals and Materials Series

SP - 503

EP - 513

BT - REWAS 2022

A2 - Lazou, Adamantia

A2 - Daehn, Katrin

A2 - Fleuriault, Camille

A2 - Gökelma, Mertol

A2 - Olivetti, Elsa

A2 - Meskers, Christina

PB - Springer Science and Business Media Deutschland GmbH

T2 - 7th Installment of the REWAS conference series held at the TMS Annual Meeting and Exhibition focuses on developing tomorrow’s technical cycles, 2022

Y2 - 27 February 2022 through 3 March 2022

ER -

Rao VM, Kumar V, Anderson A, Grogan J, Jain PK. Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace. In Lazou A, Daehn K, Fleuriault C, Gökelma M, Olivetti E, Meskers C, editors, REWAS 2022: Developing Tomorrow’s Technical Cycles. Springer Science and Business Media Deutschland GmbH. 2022. p. 503-513. (Minerals, Metals and Materials Series). doi: 10.1007/978-3-030-92563-5_53

Computational Methodology to Simulate Pyrometallurgical Processes in a Secondary Lead Furnace

Abstract

Publication series

Conference

Bibliographical note

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this