Three‑dimensional computational fluid dynamics analysis of an electric submerged arc furnace

A computational fluid dynamics (CFD) method is proposed to analyze the operation of a submerged electric arc furnace (SAF) used in ferronickel production. A three-dimensional mathematical model was developed for the time-dependent solution of fluid flow, heat transfer, and electromagnetic phenomena. Key properties of the slag, including density, viscosity, and electrical conductivity, were determined using classical molecular dynamics simulations and empirical relationships. The analysis highlighted that the slag’s electrical conductivity values significantly influence melting through high Joule heat generation in the slag region. The computed Péclet and Reynolds numbers demonstrated that the slag velocities are critical for heat transfer, indicating a laminar flow regime. The average slag velocity was calculated at 0.0001 m/s, with peaks near the electrodes. As the primary ferronickel production route involves reductive roasting of lateritic ores, understanding the roles of slag properties in enhancing mass and heat transfer and their effect on the metal recovery process is essential. Ultimately, slag and ferronickel electrical conductivity define the relationship between the ore's chemical composition and the final nickel quality.