Modeling on Reduction Reaction of Metal Oxides for Submerged Arc Furnace in Ferrochrome Pellets Smelting Process

A three-dimensional transient multi-physical field model with comprehensive reduction reaction consideration has been developed to capture the complex processes of a three-phase submerged arc furnace. The multi-physics model integrates electromagnetic, fluid flow, reduction reaction, and thermodynamics phenomenon in unison computational framework. The furnace internal structure consists of arc and furnace charge, for which the physical properties include temperature dependence. Aiming to search the optimum design for more efficient industrial operation, the electrode insertion depth is investigated. The predicted temperature distribution of high temperature is in agreement with the measurement and simulation results. The result shows that the temperature of arc zone is maximum, which is 5897.17 K. The high-temperature area of furnace charge is near the arc zone. The temperature distribution is similar with current density. With the increase of electrode insertion depth, the average voltage drop of three arc zones is 11.43, 11.12, 10.83, and 10.35 V, respectively. When the electrode insertion depth is 1.99 and 1.79 m, the maximum magnetic field intensity around the electrode bottom is of 0.068 and 0.063 T. Cr 2 O 3 mainly reacts under the arc bottom, while iron oxides are reduced less in the same location. An optimum electrode insertion depth exists according to the simulation results.