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Numerical Study of Evaporation Behavior of Molten Manganese Metal During Electroslag Recycling Process

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Abstract

Electroslag remelting (ESR) technology has been adopted to recycle the rejected electrolytic manganese metal scrap. In this study, a transient 3D coupled numerical model accounting for the electromagnetism, multiphase flow, heat transfer, and solidification was elaborated and used to simulate the evaporation behavior of the molten manganese metal (MM) during the ESR process. The volume of fluid approach was employed to capture the interfaces between the gaseous manganese, molten slag, and molten MM. The evaporation rate of the molten MM was defined by applying the Lee model, while the enthalpy-porosity formulation described the solidification. An industrial experiment via a commercial-scale ESR furnace was conducted for the model validation. The research findings indicate that the molten MM’s evaporation occurs during the droplet falling and in the metal pool. Then, gaseous manganese bubbles ascend to the molten slag-free surface, thus promoting the melt movement, especially the slag-metal pool interface fluctuation. The evaporation rate of the molten MM is promoted by the increased applied current and the reduced ambient gauge pressure. The recycling ratio drops from 81.75 to 71.79 pct with the applied current increase from 3000 to 4000 A and drops from 78.19 to 73.71 pct with the ambient gauge pressure reduction from 0 to − 1000 Pa.

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Abbreviations

\( \vec{A} \) :

Magnetic potential vector (V s/m)

A mg :

Specific surface area of a gaseous manganese bubble (m−1)

A mush :

Mushy zone resistance constant

\( \vec{B} \) :

Magnetic flux density (T)

\( \bar{c}_{p} \) :

Specific heat of mixture phase at constant pressure (J/(kg K))

\( \vec{D} \) :

Electric flux density (C/m2)

\( \vec{E} \) :

Electric field intensity (V/m)

\( \vec{F}_{D} \) :

Damping force (N/m3)

\( \vec{F}_{L} \) :

Lorentz force (N/m3)

\( \vec{F}_{S} \) :

Solute buoyancy force (N/m3)

\( \vec{F}_{ST} \) :

Interfacial tension (N/m3)

\( \vec{F}_{T} \) :

Thermal buoyancy force (N/m3)

f ℓ :

Liquid fraction

\( \bar{H} \) :

Enthalpy of mixture phase (J)

\( \vec{H} \) :

Magnetic field intensity (A/m)

\( \bar{h} \) :

Sensible enthalpy of mixture phase (J)

h f g :

Formation enthalpy of gaseous manganese (J)

h f m :

Formation enthalpy of molten MM (J)

\( \bar{h}_{ref} \) :

Reference sensible enthalpy of mixture phase (J)

\( \vec{J} \) :

Current density (A/m2)

k T :

Effective thermal conductivity (W/(m K))

\( \bar{L}_{f} \) :

Latent heat of fusion of mixture phase (J/kg)

L mg :

Latent heat of vaporization (J/kg)

M m :

Molecular weight of manganese

\( \dot{m}_{mg} \) :

Evaporation rate from molten MM to gaseous manganese (kg/s)

p :

Local static pressure (Pa)

p msat :

Saturated vapor pressure of manganese (Pa)

Q e :

Heat dissipation by evaporation (W)

Q J :

Joule heating (W)

Q m :

Heat dissipation by melting (W)

R :

Ideal gas constant (J/(mol K))

T :

Temperature (K)

T msat :

Saturated temperature of manganese (K)

T ℓ :

Liquidus temperature (K)

T ref :

Reference temperature (K)

t :

Time (s)

\( \vec{v} \) :

Velocity (m/s)

\( \vec{v}_{cast} \) :

Casting velocity (m/s)

α g :

Volume fraction of gaseous manganese

α m :

Volume fraction of molten MM

α s :

Volume fraction of molten slag

β :

Accommodation coefficient

\( \bar{\mu }_{0} \) :

Vacuum permeability of mixture phase (H/m)

\( \bar{\mu } \) :

Viscosity of mixture phase (Pa s)

\( \bar{\rho } \) :

Density of mixture phase (kg/m3)

ρ g :

Density of gaseous manganese (kg/m3)

ρ m :

Density of molten MM (kg/m3)

ρ s :

Density of molten slag (kg/m3)

\( \bar{\sigma } \) :

Electrical conductivity of mixture phase (Ω−1 m−1)

\( \bar{\phi } \) :

Physical property of mixture phase

ϕ g :

Physical property of gaseous manganese

ϕ m :

Physical property of molten MM

ϕ s :

Physical property of molten slag

φ :

Electrical potential (V)

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Acknowledgments

The authors appreciate the financial support from the National Natural Science Foundation of China (Grant No. 51804227). The industrial experiment was also supported by the Hubei Rising Technology Co., Ltd., China.

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Authors and Affiliations

  1. The State Key Laboratory of Refractories and Metallurgy, Wuhan University of Science and Technology, Wuhan, 430081, China

    Qiang Wang, Ru Lu, Zhu He & Guangqiang Li

  2. Key Laboratory for Ferrous Metallurgy and Resources Utilization of Ministry of Education, Wuhan University of Science and Technology, Wuhan, 430081, China

    Qiang Wang, Ru Lu, Zhu He & Guangqiang Li

  3. School of Metallurgy, Northeastern University, Shenyang, 110004, China

    Fang Wang

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  1. Qiang Wang
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Correspondence to Guangqiang Li.

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Manuscript submitted July 21, 2020; accepted November 11, 2020.

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Wang, Q., Lu, R., Wang, F. et al. Numerical Study of Evaporation Behavior of Molten Manganese Metal During Electroslag Recycling Process. Metall Mater Trans B 52, 665–675 (2021). https://doi.org/10.1007/s11663-020-02036-y

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