Copper reduction represents one of the steps in the process of fire refining of blister copper. Process of copper reduction with natural gas as performed in the anode furnace was modeled. Numerical analysis was conducted using the IPSA (Inter- Phase-Slip Algorithm) module of PHOENICS package and standard turbulent model k - ε. The model takes into account the liquid phase - slag and phase of natural gas which is supplied through the tuyere from the bottom of the charge. Calculations were made for two different diameters of tuyeres for supply of reducer. Based on the calculations and analysis, it was found out that the gas flow which causes strong movement in the bath guarantees homogeneous composition of the liquid copper in each process stage. Application of a tuyere with a larger diameter results in a greater intensity of the reduction process and better use of the reducer.

Process of heat exchange in a rotary furnace during converter slag reduction was modelled.Temperature distribution in the furnace and temperature of the charge (slag) only were examined. Influence of modification of the process gas supply method by changing the number of nozzles on the course of the reduction process was analyzed. It has been found out that application of a nozzle as a submerged flame burner provides possibilities to reach higher charge temperature. Application of more nozzles in the process of converter slag reduction can increase temperature of reduced slag and provide better uniformity of charge heating.

Purpose The purpose of this study is application of a numerical simulation for determination of the influence of geometric parameters of a furnace and hydrodynamics of the gas introduced by a vertical submerged lance on the process of feed mixing and temperature distribution. Design/methodology/approach A numerical simulation with Phoenics software was applied for modeling of liquid phase movement and heat exchange between the gas supplied through a lance and the slag feed in a top submerged lance (TSL) furnace. The simulation of a two-phase flow of a slag–gas mixture based on the inter phase slip algorithm module was conducted. The influence of selected parameters, such as depth of lance submergence, gas flow rate and change of furnace geometry, on the phenomena of movement was studied. Findings Growth of dynamics of mixing with the depth of lance submergence and with increase of gas velocity in the lance was observed. Formation of a recirculation zone in the liquid slag was registered. Movement of the slag caused by the gas flow brought homogenization of the temperature field. Originality/value The study applied the simulation of a two-phase flow in the liquid slag–gas system in steady state, taking into account heat transfer between phases. It provides possibilities for optimization and selection of process parameters within the scope of the developed new technology using a TSL furnace.

In this study influence of selected parameters on the process of reduction of converter slag from refining of Cu-Pb-Fe alloy was numerically examined. The process of the slag reduction is carried out in Q 80 converters of Hoboken type for copper removal. Converter slags show high concentration of lead therefore they can be seen as an important component for further processing in rotary-rocking furnaces together with other lead-bearing materials. Three-dimensional simulation was performed using the IPSA (Inter Phase Slip Algorithm) module of two-phase flow from PHOENICS package. Numerical simulations have forecasted influence of changes in the slag chemical composition and the process time on the process course.

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