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A R T I C LE I N FO A B S T R A C T
Keywords: The dynamic evolution of metallurgical slag foaming is vital for the efficiency and safety of the metallurgical
Slag foaming processes. Based on the similarity principle via Morton number, the dynamic evolution of Basic Oxygen Furnace
Foam structure (BOF) slag foaming was studied through physical modelling in this investigation. The steady-state structure
Dynamics evolution characteristics and the dynamic evolution of slag foaming were analyzed under the different of superficial gas
Superficial gas velocity
velocity (us). It was found that the foaming height increased first and consequently decreased as the us increased,
while the four different types of steady-state foam structure characteristics were summarized and the dynamic
evolution of slag foaming was analyzed. At 0.08 mm∙s−1 < us ≤ 0.50 mm∙s−1, the foam system presented two-
layer structure (called Partial Foaming I), while the foaming height increased linearly with the us increased;
following gas supply interruption, the foam decayed at a uniform rate. At 0.50 mm∙s−1 < us < 10.00 mm∙s−1,
the foam structure evolved into the Entire Foaming I, which was stacked by the spherical bubbles and the
deformed bubbles; also, the decaying rate of the foam decreased as the liquid level decreased following the gas
supply stop. When us was 0.60 mm∙s−1, the foam had the maximum stability, because its structure was in close
proximity to densest packing of spherical bubbles. At 10.00 mm∙s−1 ≤ us ≤ 16.67 mm∙s−1, the foam structure of
Entire Foaming II occurred, while the liquid level fluctuated sharply due to the poor stability of the polyhedral
bubbles with high size at the upper levels. Moreover, the foaming height reached the peak value; in addition, the
liquid level rapidly decreased due to the polyhedral bubble breakage after gas supply interruption. At
16.67 mm∙s−1 < us < 53.33 mm∙s−1, the foam structure evolved into the Partial Foaming II, due to the strong
disturbance of high-speed air flow, while the foaming height decreased with the rise of us. As the us further
increased, the high-speed gas flow penetrated the liquid phase, leading to the foam disappearance.
⁎
Corresponding author at: Key Laboratory for Ecological Metallurgy of Multimetallic Ores (Ministry of Education), Northeastern University, Shenyang 110819,
China.
E-mail address: zhangbo@smm.neu.edu.cn (B. Zhang).
https://doi.org/10.1016/j.expthermflusci.2020.110041
Received 16 September 2019; Received in revised form 12 December 2019; Accepted 8 January 2020
Available online 09 January 2020
0894-1777/ © 2020 Elsevier Inc. All rights reserved.
R. Wang, et al. Experimental Thermal and Fluid Science 113 (2020) 110041
foaming height through the cold physical modelling method. Ghag et al.
[10] conducted foaming experiments with compressed air as the gas
source along with glycerol solution to simulate metallurgical slags. The
results indicated that Δh increased with the increase of us. A model of
slag foaming was developed by Wu et al. [9,11], which adopted the
silicone oil to simulate metallurgical slag. The model revealed that Δh
increased first and consequently decreased as us increased. Many pre-
vious studies [9–11,14] had demonstrated that us had a significant
impact on Δh, but these were merely focused on the steady-state of slag
foaming. In fact, the slag foaming is a complex dynamic evolution
process [15,16]. Nevertheless, the generation → development-stabi-
lity → decaying process of slag foaming was hardly reported in previous
studies.
us = Q A (2)
where, us is the superficial gas velocity (m/s), Q is the gas flow rate
(m3/s) and A is the cross-sectional area of the container (m2).
Fig. 1. Mo number of Basic Oxygen Furnace slag.
At present, BOF has become the main steelmaking method. The BOF
slag is mainly composed of CaO-SiO2-FeOx-MgO with the functions of
removing harmful elements, absorbing inclusions, and improving heat stabilizing valve, respectively. The us increased from zero, until in-
transfer, etc. The foaming process of BOF slag arose from the huge creased to no foaming phenomenon. A ruler was attached to the outside
carbon oxide is very typical. Furthermore, the splashing accident wall of the vessel to measure both Δh and bubble size. The videos were
caused by the improper foaming of BOF slag remains to be resolved. taken to record the foaming process of the glycerol solution with a
Thus, the foaming phenomenon of BOF Slag will be the research em- camera (type: Nikon-3400; Japan), from which the Δh could be directly
phasis in this study. obtained according to the ruler attached on the vessel after experi-
The dynamic evolution of slag foaming highly depends on the cor- ments. In addition, a video captures was saved from the video, and then
responding structure characteristics (bubble shapes, bubble sizes, bub- imported into the Image-Pro Plus 6.0 software. The image scale was set
bles numbers and gas fraction). In this investigation, the structure with the ruler attached on the vessel presented in the video captures.
characteristics of foaming slag were analyzed, while the dynamic evo- The bubble diameter was measured using the function of the statistical
lution of slag foaming process was explored under the different con- size of Image-Pro Plus 6.0.
ditions of us through physical modelling. The research results could
provide reference for the accurate control of slag foaming. 3. Results and discussion
In present experiments, the glycerol solution was employed to si- A foam constitutes a dispersion system, consisting of gas as the
mulate BOF slag. The physical properties of the BOF slag and the ex- dispersed phase (discontinuous phase) and liquid as the dispersion
perimental glycerol solution are listed in Table 1 [17]. Considering that medium (continuous phase) [20]. The foaming process could be simply
the physical properties (viscosity and surface tension) had a significant described as follows. The bubbles in the liquid always rise rapidly, due
influence on slag foaming behavior [9,18–20], the Morton (Mo) number to the density difference between gas and liquid, forming the bubble
was selected to meet the similarity between the BOF slag and glycerol aggregates (foam), separated by a liquid film at the liquid surface.
solution. Its calculation method is expressed in Eq. (3). The Mo number Fig. 3 presents the liquid level changes under different conditions of
of experimental glycerol solution was 6.7 × 10−4, located within the us. It was observed during the experimentation that the steady-state
Mo number range of the BOF slag, as presented in Fig. 1. structure characteristics and Δh changed constantly with increasing us.
Fig. 4 presents the steady-state Δh variation with us. With the foam
Mo = (μ4 g ) (σ 3ρ) = (v 4ρ3g ) σ 3 (3) structure characteristics and the change rule in the Δh as the main
where, μ and v are the viscosity (Pa∙s) and kinematic viscosity (m2∙s−1) baseline, the slag foaming of different us was classified the four foaming
of the liquid phase, respectively; ρ is the density of liquid phase types, namely Partial Foaming I, Entire Foaming I, Entire Foaming II
(kg∙m−3); σ is the liquid surface tension (N∙m−1) and g is the gravity and Partial Foaming II. The dynamic evolutions of different foaming
acceleration (m∙s−2). types presented the considerable differences.
The schematic diagram of the experimental apparatus is presented
in Fig. 2. The plexiglass vessel had a bottom length of 0.05 m and a 3.2. Partial foaming I
height of 1.00 m. The initial height of glycerol solution (volume:
250 mL) was 0.10 m to create the slag foaming per experiment. Com- When the us was too low, a low amount of tiny bubbles rose slowly
pressed air was injected into glycerol solution through a silicon oxide within glycerol solution. Certain scattered clusters of bubbles as-
filter dispersion (pore size: (16–30) × 10−6 m) above the gas chamber. sembled on the liquid surface, but no foam layer or liquid level change
The flow rate (0–8000 mL/min) and pressure (0.2 MPa) of the com- were observed. The minimum superficial gas velocity um for onset of
pressed air were controlled through a rotameter and a pressure foaming was defined to correspond to the situation when only a single
Table 1
Physical properties of BOF slag and glycerol solution.
Temperature (oC) Density (kg∙m−3) Viscosity (mPa∙s) Surface tension (mN∙m−1)
2
R. Wang, et al. Experimental Thermal and Fluid Science 113 (2020) 110041
Fig. 2. Schematic diagram of experimental apparatus. (1-Air compressor; 2-Gas tank; 3-Pressure stabilizing valve; 4-Flow meter; 5-Chamber; 6-Silicon oxide filter; 7-
Flange; 8-Glycerol solution; 9-Plexiglass cylinder; 10-Video camera).
3
R. Wang, et al. Experimental Thermal and Fluid Science 113 (2020) 110041
4
R. Wang, et al. Experimental Thermal and Fluid Science 113 (2020) 110041
where, ΔP is the pressure difference inside and outside the bubble (Pa),
σ is the surface tension of the liquid (N/m) and r is the radius of the
bubble curvature (m).
As presented in Fig. 3(b), the decaying rate of the foam decreased as
the liquid level dropped following the gas supply interruption. When
the us was 0.60 mm∙s−1, the decaying duration of foam was the longest.
It was inferred that the foam had the maximum stability, because its
Fig. 9. Bubble size distribution of different heights (us = 10.00 mm∙s−1).
structure was in almost similar to the densest packing of spherical
bubbles.
occurred, the increase in the liquid level ended with a sharp drop (see
3.4. Entire foaming II Fig. 3(a)), caused by the formation of polyhedral bubbles at upper
layers. The liquid level fluctuated sharply (see Fig. 3(a)), due to the
When the us further increased to poor stability of the large polyhedral bubbles at the upper levels. As
10.00 mm∙s−1 ≤ us ≤ 16.67 mm∙s−1, the lower layers remained aforementioned, the Ostwald ripening effect and the drainage behavior
spherical, while the upper layers were polyhedral foam, as presented in of the Plateau boundary were the main reasons of the polyhedral foam
Fig. 8(a). This was defined as Entire foaming II. instability. Moreover, the Ostwald ripening effect of the bubbles of
The Δh expanded, exceeding more than four times of the initial li- different heights opened a gas passage, resulting in a dramatic foam
quid level, reaching a peak value. It was observed that the polyhedral collapse.
bubbles at upper layers were generated by the coalescence of smaller As it could be observed from Fig. 3(b), the foam decaying rate (slope
bubbles. In this polyhedral foam structure, every three adjacent poly- of the decaying curve) of Entire foaming I and II was quite higher
hedral bubbles formed a triangular concave Plateau boundary [25–27], compared to Partial foaming I, indicating that the structure of spherical
as presented with a red circle in Fig. 8(a). In addition to the Ostwald foam was significantly more stable than the non-spherical foam struc-
ripening effect as mentioned above, the drainage behavior of the Pla- ture. In addition, the liquid level of Entire foaming II rapidly decreased,
teau boundary [25,26,28–30] was another important reason for the due to the polyhedral bubble breakage subsequently to gas supply in-
instability of the polyhedral foam structure. Fig. 8(b) presents the terruption. Moreover, the foam decay rate of Entire foaming II appar-
Plateau boundary morphology. Due to the different radius of curvature, ently decreased with the liquid level drop following the gas supply
the pressure on the bubble film was higher than on the Plateau interruption, which was highly related to the bubble sizes at different
boundary. This would cause the liquid to be drained from the bubble heights. As presented in Fig. 9, the bubble sizes significantly decreased
film (Point A) towards the Plateau boundary (Point B). As a result, the as the height dropped. It was observed that the foam decayed from the
Δh of Entire foaming II sharply fluctuated from 40 cm to 51 cm top to the bottom following the gas supply interruption. As a result, the
(us = 13.33 mm/s), due to the poor instability of the polyhedral foam decay rate of foam slowed down as the bubble size decreased.
structure.
When Entire foaming II (10.00 mm∙s−1 < us ≤ 16.67 mm∙s−1)
5
R. Wang, et al. Experimental Thermal and Fluid Science 113 (2020) 110041
6
R. Wang, et al. Experimental Thermal and Fluid Science 113 (2020) 110041
Fig. 12. Foam structures of different foaming types (a) us < 0.08 mm∙s−1; (b) us = 0.08 mm∙s−1; (c) 0.10 mm∙s−1 ≤ us ≤ 0.50 mm∙s−1; (d)
0.50 mm∙s−1 < us < 10.00 mm∙s−1; (e) 10.00 mm∙s−1 ≤ us ≤ 16.67 mm∙s−1; (f) 16.67 mm∙s−1 < us < 53.33 mm∙s−1; (g) us ≥ 53.33 mm∙s−1.
height increased first and consequently decreased as the superficial gas interests or personal relationships that could have appeared to influ-
velocity increased. The different structure characteristics of foaming ence the work reported in this paper.
slag and dynamic evolution laws of slag foaming were presented.
(1) In the range of 0.08 mm∙s−1 < us ≤ 0.50 mm∙s−1, the foam Acknowledgments
layer began to form and expanded slowly, while the foaming system
presented two-layer structure (Partial foaming I). The bubble-dispersed Financial support to this project is provided by National Key R & D
phase was in the lower layer, while the spherical bubbles were stacked Program of China, China, Grant No. 2017YFC0805100; National
into a foam phase on upper layers. The foaming height increased lin- Natural Science Foundation of China, China; Grant No. 51774087;
early with the rise of us. The foam decayed at a uniform rate following Liaoning Provincial Natural Science Foundation of China, China, Grant
gas supply interruption. No. 2019-MS-123 and Fundamental Research Funds for the Central
(2) In the range of 0.50 mm∙s−1 < us < 10.00 mm∙s−1, Entire Universities, China, Grant No. N180725008.
foaming I occurred. The bubble size of upper layers was significantly
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