Application of Modeling to the Developme

The hydrodynamics in an electrolysis pilot cell have been modeled to upscale the direct iron production process based on alkaline electrolysis of an iron oxide suspension. This study evaluates two dispersed phases involved in the three-phase process: solid and gas phase hydrodynamics. Existing literature is used to assess the suspension flow characteristics, applying available correlations to the specific case under investigation. The analysis reveals that the minimum required velocity for the transportation of finely ground iron oxide along the cathode surface is notably low, falling within the laminar regime, which corresponds to a minimal pressure drop. Additionally, the behavior of the oxygen phase produced at the anode is examined at two scales; the trajectory of a single bubble sliding on the anode is predicted, offering insights into possible bubble dynamics based on their diameter. Further, literature results for gas-liquid flow in pipes are referenced to study the gas-phase pattern, predicting a separation of the gas phase from the liquid phase, with the lighter phase in contact with the upper part of the cell. The findings confirm the potential of this design for effective transportation of particles and gas recovery with minimal energy consumption.