Kinetic Simulation of Gas-Particle Injection into the Molten Lead
Year: 2025
Type: article
Abstract: Powder addition onto a molten-lead surface followed by stirring is widely used for desilvering during lead bullion refining operations. We model submerged zinc particle injection by coupling (i) a transient particle–metal reaction following Ohguchi with a time-dependent reaction efficiency E, (ii) a Stefan-type estimate of the zinc melting time Tf, and (iii) hydrodynamic descriptors of residence (τres) and mixing (τmix) times. The model is validated against experiments under a benchmark condition (gas velocity U = 3.32 m/s, 70% submergence), achieving a mean absolute percentage error of 1.13% for the experimental desilvering curve. A parametric study over lance submergence (30–90% of bath depth), injection velocity (3.32–9.79 m/s), and geometric scalings of lance and kettle identifies conditions where the hydrodynamic residence time τres approaches the Stefan melting time, maximizing liquid-Zn contact with molten Pb. Specifically, the proposed optimum balances the competing effects of plume buoyancy at high velocities—which tends to reduce residence time—against the deeper injection depth, ensuring that particles remain submerged long enough to fully melt and react. Within 16 simulated scenarios, the pair “90% submergence + U = 9.79 m/s” provides the best multi-criteria performance (desilvering fraction, E, and residence time) under realistic constraints. A parametric sensitivity analysis ranks injection velocity and submergence as the dominant levers, with geometry playing a secondary role over the tested ranges. The coupled hydrodynamic–kinetic framework provides quantitative guidance for optimizing industrial desilvering by particle injection and is extensible to other powder-injection refining operations.
Source: Metals
DOI: 10.3390/met15121334
Authors: Victor Hugo Gutiérrez Pérez, Seydy Lizbeth Olvera Vázquez, Alejandro Cruz Ramírez, Ricardo Gerardo Sánchez Alvarado, Jorge Enrique Rivera Salinas, Mario Cesar Ordoñez Gutiérrez, Mercedes Paulina Chávez Diaz
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,137
OpenAlex ID: W4416953733