Improving Feed Distribution in Flash Smelting: A CFD-DEM Approach

This chapter delves into the challenges of uneven feed distribution in flash smelting furnaces and how it affects smelting efficiency and heat loss. Through the use of Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD) models, the study evaluates the impact of non-uniform feed distribution in the reaction shaft. The conventional feeder design is analyzed, revealing issues such as feeder jamming, low smelting efficiency, and high build-up. The study then explores design modifications to the feeder, aiming for a more uniform distribution of feed material. The optimized feeder design, featuring a greater number of splitters at various angles and heights, is tested both in scaled-down physical models and in actual field trials. The results show a significant reduction in feeder jamming frequency, a substantial decrease in heat loss, and an improvement in matte grade. The chapter concludes with a detailed comparison of the conventional and modified feeder designs, highlighting the benefits of the optimized design in terms of operational stability and efficiency.