Bubble-assisted matte transportation into slag phase: A numerical investigation

Copper loss into the slag phase during the smelting process can be minimized by controlling gas bubble size and hydrodynamics. Here, bubble rising characteristics from copper matte to slag phase were investigated using the volume-of-fluid modelling approach, in which the continuous surface force model was adopted to define the surface tension parameters. The simulated results for bubble terminal velocities in bulk water and the literature data showed relative errors up to 4.51 %. The obtained qualitative and quantitative data from simulation at the liquid-liquid interface agreed well with the literature experimental results. The simulation setup was applied to investigate three different sizes of bubble rising dynamics from matte to slag phase with the bubble Reynolds number (Re) up to 1734 and the Eotvos number (Eo) up to 3.2. For low Re and Eo, the bubble rising velocity decreased before the matte film rupture and the bubble required a long time to complete that film drainage due to the balance of interfacial tension force and bubble buoyancy. No matte residue associated with the bubble rise in the slag phase was obtained because of restoring initial, non-deformed shape of bubbles. For the higher Re and Eo, quicker matte film drainage was obtained around the upper bubble surface while the entrained matte contribution to the slag phase was strongly dependent on the bubble-shape deformation, which was discussed with the well-known Grace diagram. The decreasing viscosity and increasing surface tension of the slag phase significantly affected the matte film height more than the film rupture time. The film height and rupture time increased and decreased with increasing Eo, respectively. The outcomes of our studies are useful for the design and operation of smetling furnaces in pyrometallurgical purification of metal concentrates.