Mathematical simulation and experimental verification of melting resulting from the coupled effect of natural convection and exothermic heat of mixing

Abstract

When melting processes are associated with an exothermic heat of mixing, unique coupled transport phenomena take place. In this article, a mathematical model has been developed to simulate these unique coupled heat and mass transfer events. The model was based on the control-volume finite difference approach and on an enthalpy method. In order to verify the mathematical model, a low-temperature physical model was established consisting of ice and sulfuric acid solutions. In this physical model, both temperature and velocity measurements were carried out. The model predictions were compared with experimental measurements, and they were found to be in good agreement. The model was also applied to a high-temperature system, namely, the melting of silicon metal in liquid high carbon iron. The predictions distinguished two periods present in the entire melting process. In the first period, the silicon was heated up. The second period, i.e., free melting period, occurred in tandem with the exothermic reaction, and consequently, the melting process was greatly accelerated. As was the case with the low-temperature physical model, as with the high-temperature system, good agreement was obtained between the predicted results and the experimental measurements.