Process Modeling and Optimization of a Submerged Arc Furnace for Phosphorus Production

This article presents a process model of a phosphorus-producing, submerged arc furnace, incorporating accurate, multi-field thermodynamic, kinetic, and industrial data with computational flow dynamic calculations. The objective is to unify the sciences of kinetics and equilibrium thermodynamics to improve modeling efficiency. The methodology involves creating a structurally three-dimensional model that utilizes boundary conditions, initial values, and material specifications drawn from industrial measurements and laboratory experiments. Results indicate the model identifies a narrow, gas–solid reduction zone where most phosphorus production occurs, demonstrating that rapid reaction rates, in combination with prolonged residence times, significantly lessen the influence of changing reaction rates on the process. Additionally, the study reveals that most thermal exchanges between newly introduced pellets and gaseous products occur in the upper 0.5 m of the furnace bed. Flow analysis uncovers areas of low and recirculating gaseous flow velocities that contribute to dust accumulation in the system. The findings enhance the understanding of energy consumption and efficiency in phosphorus production via submerged arc furnaces.