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CFD Modeling of Swirl and Nonswirl Gas Injections into Liquid Baths Using Top Submerged Lances

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Abstract

Fluid flow phenomena in a cylindrical bath stirred by a top submerged lance (TSL) gas injection was investigated by using the computational fluid dynamic (CFD) modeling technique for an isothermal air–water system. The multiphase flow simulation, based on the Euler–Euler approach, elucidated the effect of swirl and nonswirl flow inside the bath. The effects of the lance submergence level and the air flow rate also were investigated. The simulation results for the velocity fields and the generation of turbulence in the bath were validated against existing experimental data from the previous water model experimental study by Morsi et al.[1] The model was extended to measure the degree of the splash generation for different liquid densities at certain heights above the free surface. The simulation results showed that the two-thirds lance submergence level provided better mixing and high liquid velocities for the generation of turbulence inside the water bath. However, it is also responsible for generating more splashes in the bath compared with the one-third lance submergence level. An approach generally used by heating, ventilation, and air conditioning (HVAC) system simulations was applied to predict the convective mixing phenomena. The simulation results for the air–water system showed that mean convective mixing for swirl flow is more than twice than that of nonswirl in close proximity to the lance. A semiempirical equation was proposed from the results of the present simulation to measure the vertical penetration distance of the air jet injected through the annulus of the lance in the cylindrical vessel of the model, which can be expressed as \( L_{va} = 0.275\left( {d_{o} - d_{i} } \right)Fr_{m}^{0.4745} . \) More work still needs to be done to predict the detail process kinetics in a real furnace by considering nonisothermal high-temperature systems with chemical reactions.

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Abbreviations

C D :

Drag coefficient

D :

Cylinder diameter

D o :

Outlet diameter of the cylinder

D b :

Bubble diameter

d o :

Outer diameter of the lance

d i :

Inner diameter of the lance

Fr m :

Modified Froude number

f :

Body force vector

g :

Gravitational body force

H :

Lance submergence Level

K :

Turbulent kinetic energy

L :

Liquid level in the cylinder

L va :

Vertical penetration distance for air jet injected through annulus

N :

Number of phases

Q :

Air flow rate through lance

Re b :

Bubble Reynolds number

R :

Radius of the cylindrical vessel

r :

Radial distance from the centre point

\( T_{k}^{t} \) :

Phase k reynolds stress

v :

Velocity vector

X :

Radial coordinate

Y :

Tangential coordinate

Z :

Axial coordinate

μ k :

Molecular viscosity

\( \mu_{k}^{t} \) :

Turbulent viscosity for phase k

\( \mu_{c}^{t,SI} \) :

Shear induced turbulent viscosity for continuous phase

\( \mu_{c}^{t,BI} \) :

Bubble induced turbulent viscosity for continuous phase

α k :

Volume fraction of phase k

ρ k :

Density for phase k

τ k :

Phase k shear stress

δ k :

Kronecker delta function

ε k :

Dissipation rate

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Acknowledgment

The authors would like to express their gratitude to the Faculty of Engineering and Industrial Science, Swinburne University of Technology, and Ausmelt Limited for their financial and technical support.

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Authors and Affiliations

  1. Swinburne University of Technology, Hawthorn, 3122, Melbourne, Vic, Australia

    Nazmul Huda (PhD Student), J. Naser (Senior Lecturer) & G. Brooks (Professor)

  2. Ausmelt Limited, 12 Kitchen Rd, Dandenong, 3175, Melbourne, Vic, Australia

    M.A. Reuter (Chief Executive Technologist) & R.W. Matusewicz (Technical Development Manager)

Authors
  1. Nazmul Huda
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  2. J. Naser
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  3. G. Brooks
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  4. M.A. Reuter
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  5. R.W. Matusewicz
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Correspondence to Nazmul Huda.

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Manuscript submitted May 20, 2009.

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Huda, N., Naser, J., Brooks, G. et al. CFD Modeling of Swirl and Nonswirl Gas Injections into Liquid Baths Using Top Submerged Lances. Metall Mater Trans B 41, 35–50 (2010). https://doi.org/10.1007/s11663-009-9316-1

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