Modeling the dynamics of electromagnetically agitated metallurgical flows: levitation, cold crucible, aluminium electrolysis, etc.

We present practical modelling techniques for electromagnetically agitated liquid metal flows involving dynamic change of the fluid volume and shape during melting and the free surface oscillation. Typically the electromagnetic field is strongly coupled to the free surface dynamics and the heat-mass transfer. Accurate pseudo-spectral code and the k-omega turbulence model modified for complex and transitional flows with free surfaces are used for these simulations. The considered examples include magnetic suspension melting, induction scull remelting (cold crucible), levitation and aluminium electrolysis cells. The process control and the energy savings issues are analysed

Demonstration thermo-electric and MHD mathematical models of a 500 kA A1 electrolysis cell

In the present study, a 3D full cell quarter thermo-electric model of a 500kA demonstration cell has been developed and solved. In parallel, a non-linear wave MHD model of the same 500 kA demonstration cell has been developed and solved. A preliminary study of the impact of the interactions between the cell thermo-electric and MHD models will be presented

Model experiments using slag during CdO recovery

A new method of production of cadmium from shredded cadmium-containing batteries using electroslag remelting was proposed, investigated theoretically and experimentally. The reduction of cadmium from cadmium oxide with carbon occurs in electroslag remelting equipment in a liquid slag bath. The resulting molten cadmium is collected in a crucible under a layer of molten flux. The intensity of the reduction process is affected by the liquid flux movement. This movement is caused by thermal convection and also by the electrical current interacting with the magnetic field. The work explores the possibility of intensifying the process using the external magnetic field. Magnetic fields are induced by different configurations of permanent magnet systems located outside the bath