Since the introduction and use of converter technologies, e.g., TBRC (Top-Blown Rotary Converter) and TSL (Top Submerged Lance) bath smelting technology in the non-ferrous metals industry, top lance and/or injector systems have become a key component of such facilities. Depending on the process conditions (e.g., immersed or top blowing), the design of the lance and its component parts (e.g., nozzles) can be particularly complex and influence the hydrodynamics of the melt, which in turn affects important process parameters such as the reaction kinetics, heat transfer, splashing, surface area between gas and slag phase, and ultimately the efficiency of the metallurgical process. The BlueSmelter (BS), which features an advanced injector system, is the new bath smelting technology developed by SMS group for the non-ferrous metals industry. It is designed for e-waste recycling, fuming processes, and primary smelting. This paper presents the development of a novel pyrometallurgical bath smelting concept with a focus on the new advanced injector system. Sequential design, simulation, and pilot test phases were carried out to optimize the industrial BlueSmelter bath process. As regards the application of the injector system in the BlueSmelter, flow characteristics are discussed under various operational conditions covering bubble formation, gas penetration depth, melt splashing, and bath mixing. Computational fluid dynamics (CFD) is used extensively for this purpose to better understand the phenomena underlying the whole pyrometallurgical process. In addition, special attention is paid to a detailed description of the structure, mode of operation, and special features of the SMS group injector system.
