Experimental Study on Bubble Distribution and Splashing in a Peirce–Smith Copper Converter

More than 80 pct of copper matte in the world is refined by a Peirce–Smith converter (PSC), but there still exist a number of problems restricting the productivity of PSC. A novel view for improving the copper PSC process was proposed by investigating the bubble distribution and surface splashing through water model experiments. The operating parameters of tuyere diameter (d), liquid height (H), and gas flow rate (Q) were determined, and dimensionless equations were developed that calculate the bubble surface area per unit bath volume, A_b/(HL); bubble number, N_b; and vertical and horizontal splashing distances, x/y, with errors less than 5 pct. From the application of the similarity principles on the results of the water model experiments, the optimal industrial parameters were determined as d = 0.03 m, H = 1.8 m, and Q = 30,000 to 35,000 Nm³/h. These results indicate that the current industrial PSCs are well within the ranges of these dimensions, with the possible exception of the tuyere diameter, which is typically 0.05 m.