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Continuous Fuming of Zinc-Bearing Residues: Part I. Model Development

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Abstract

The disposal of zinc-containing residues is an important sustainability issue currently facing the metallurgical industry. These residues can be treated by using zinc slag-fuming processes in which heavy metals are chemically reduced and evaporated from a molten slag bath. Continuous operation of these processes requires high zinc-fuming rates while retaining vessel integrity. To meet these challenges, a new generation of technologies is being developed that depends on the formation of a freeze lining on the internal reactor walls. A general zinc-fuming process model that simultaneously describes the chemical reactions, phase equilibria, and thermal- and heat-transfer outcomes of these processes has been developed using the FactSage thermodynamic databank system and the ChemApp programmer’s library for thermochemical applications. This simultaneous description of these processes allows the model to be used as part of a new approach to the design of freeze linings, namely, the use of slag engineering and composition adjustment to obtain optimum process efficiency and freeze lining behavior.

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Abbreviations

A bath :

surface area of the bath/postcombustor interface (m2)

A bottom :

total area of the bottom of the furnace (m2)

A fl :

total area of the hot face of the freeze lining (m2)

A roof :

total area of the roof of the furnace (m2)

h bath :

convection coefficient from the bath to the freeze lining (W m−2 K−1)

h pc→roof :

total heat-transfer coefficient from the postcombustion gas to the roof (W m−2 K−1)

h pc→sw :

total heat-transfer coefficient from the postcombustion gas to the vertical idewalls (W m−2 K−1)

h pc→zf :

total heat-transfer coefficient from the postcombustion gas to the bath (W m−2 K−1)

h water :

convection coefficient from the water to the furnace shell (W m−2 K−1)

ΔH m :

enthalpy change resulting from the change of temperature, phase transformations, dissolution, and chemical reactions in the mixer (W)

ΔH pc :

enthalpy change resulting from the change of temperature, phase transformations, dissolution, and chemical reactions in the postcombustor (W)

ΔH ph :

enthalpy change resulting from the change of temperature, phase transformations, dissolution, and chemical reactions in the preheater (W)

ΔH zf :

enthalpy change resulting from the change of temperature, phase transformations, dissolution, and chemical reactions in the zinc fumer (W)

ΔH M,tot :

total enthalpy change of the mixer (W)

ΔH PC,tot :

total enthalpy change of the postcombustor (W)

ΔH PH,tot :

total enthalpy change of the preheater (W)

ΔH ZF,tot :

total enthalpy change of the zinc fumer (W)

k fl :

thermal conductivity of the freeze lining (W m−1 K−1)

k ins,bottom :

thermal conductivity of the insulation layer of the furnace bottom (W m−1 K-1)

k refr,bottom :

thermal conductivity of the refractory layer of the furnace bottom (W m−1 K−1)

k refr,roof :

thermal conductivity of the refractory deposit on the postcombustor roof (W m−1 K−1)

k refr,sw :

thermal conductivity of the refractory deposit on the postcombustor sidewalls (W m−1 K−1)

k shell :

thermal conductivity of the furnace shell (W m−1 K−1)

Q bottom :

heat losses through the bottom of the furnace (W)

Q el :

electrical heat input in the preheater (W)

Q fl :

heat losses through the freeze lining (W)

Q hs :

heat input from the other heat sources in the preheater (W)

Q pc→zf :

heat exchange from the postcombustor to the zinc fumer (W)

Q walls :

heat losses through the walls of the postcombustor (W)

r fl :

inner radius of the freeze lining (m)

r refr,sw :

inner radius of the refractory sidewalls of the postcombustor (m)

r shell,in :

inner radius of the furnace shell (m)

r shell,out :

outer radius of the furnace shell (m)

R bottom :

total thermal resistance of the furnace bottom (K W−1)

R sidewall :

total thermal resistance of the postcombustor sidewalls (K W−1)

R roof :

total thermal resistance of the postcombustor roof (K W−1)

T bath :

bath temperature (K)

T liquidus :

liquidus temperature of the bath (K)

T pc :

postcombustor temperature (K)

T water :

water temperature in the furnace jackets (K)

t ins,bottom :

thickness of the insulation layer in the furnace bottom (m)

t refr,bottom :

thickness of the refractory layer in the furnace bottom (m)

t refr,roof :

thickness of the refractory layer in the furnace bottom (m)

t shell :

thickness of the furnace shell (m)

z bath :

height of the slag bath (m)

z pc :

height of the postcombustor (m)

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Authors and Affiliations

  1. Department Metaalkunde en Toegepaste Materiaalkunde (MTM), Katholieke Universiteit Leuven, B-3001, Heverlee, Belgium

    Karel Verscheure (Research Assistant), Bart Blanpain (Full Professors) & Patrick Wollants (Full Professors)

  2. Umicore Research, B-2250, Olen, Belgium

    Maurits Van Camp (Senior Metallurgist)

  3. Pyrometallurgy Research Centre, PYROSEARCH School of Engineering, The University of Queensland, Brisbane, Qld, 4072, Australia

    Peter Hayes (Professor) & Evgueni Jak (Associate Professor)

Authors
  1. Karel Verscheure
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  2. Maurits Van Camp
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  3. Bart Blanpain
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  5. Peter Hayes
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  6. Evgueni Jak
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Correspondence to Karel Verscheure.

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Manuscript submitted July 25, 2006.

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Verscheure, K., Van Camp, M., Blanpain, B. et al. Continuous Fuming of Zinc-Bearing Residues: Part I. Model Development. Metall Mater Trans B 38, 13–20 (2007). https://doi.org/10.1007/s11663-006-9009-y

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