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The relationship between slag structure and viscosity is studied, employing Raman spectroscopy for the five-component slag system of MnO-SiO2-CaO-Al2O3-MgO and its subsystems. This study aims to investigate the influence of variations in slag composition on viscosity, which is crucial for optimizing industrial processes. Based on industrial slag compositions produced in a silicomanganese submerged arc furnace, 17 slags with a fixed content of MnO of 10 wt% are synthesized with varying contents of SiO2 of 33 to 65 wt%; CaO within the range of 14 to 40 wt%; and fixed contents of Al2O3 and MgO of 17 and 6 wt%, respectively. The slag compositions are divided into four groups, ranging from low basicity (0.38) to high basicity (0.80), with each group containing the four slag systems of MnO-SiO2-CaO, MnO-SiO2-CaO-Al2O3, MnO-SiO2-CaO-MgO, and MnO-SiO2-CaO-Al2O3-MgO, with fixed basicity. Additionally, a five-component composition with the lowest basicity of 0.28 is considered. Raman spectroscopy measurements are performed in the wavenumber range of 200 to 1200 cm − 1 using a green source laser with a 532 nm wavelength. The high-wavenumber region of the Raman spectra (800 to 1200 cm − 1 ) is deconvoluted to quantitatively investigate the effect of each oxide on the slag structure and the degree of polymerization (DOP) of the silicate network. Results indicate that measured NBO/T increases with increasing basicity, demonstrating a reduction in DOP of the silicate structure. This depolymerization effect is more pronounced in slags containing Al2O3 compared to those without it. In a group of slags with similar basicity, the substitution of SiO2 with Al2O3 leads to further depolymerization. In contrast, substituting CaO with MgO has little effect on the silicate structure in slags without Al2O3 but causes depolymerization in slags containing Al2O3. To study the relationship between structure and viscosity, viscosity data obtained from FactSage are used as reference values. The predictions of slag viscosity using the Raman-structure model and the NBO/T viscosity model are then compared to the FactSage results. The adjustable parameters of the Raman-structure model are re-determined using the FactSage data for the studied slag compositions. The NBO/T viscosity model employs both calculated NBO/T values from the slag compositions and measured NBO/T values from the deconvolution results. The findings of this study reveal good agreement between the predictions of the Raman-structure model and the FactSage viscosity data. [ABSTRACT FROM AUTHOR]

Fluidized beds are pivotal in the process industry and chemical engineering, with Computational Fluid Dynamics (CFD) playing a crucial role in their design and optimization. Challenges in CFD modeling stem from the scarcity or inconsistency of experimental data for validation, along with the uncertainties introduced by numerous parameters and assumptions across different CFD codes. This study navigates these complexities by comparing simulation results from the open-source MFIX and OpenFOAM, and the commercial ANSYS FLUENT, against experimental data. Utilizing a Eulerian–Eulerian framework and the kinetic theory of granular flow (KTGF), the investigation focuses on solid-phase properties through the classical drag laws of Gidaspow and Syamlal–O'Brien across varied parameters. Findings indicate that ANSYS Fluent, MFiX, and OpenFOAM can achieve reasonable agreement with experimental benchmarks, each showcasing distinct strengths and weaknesses. The study also emphasizes that both the Syamlal–O'Brien and Gidaspow drag models exhibit reasonable agreement with experimental benchmarks across the examined CFD codes, suggesting a moderated sensitivity to the choice of drag model. Moreover, analyses were also carried out for 2D and 3D simulations, revealing that the dimensional approach impacts the predictive accuracy to a certain extent, with both models adapting well to the complexities of each simulation environment. The study highlights the significant influence of restitution coefficients on bed expansion due to their effect on particle–particle collisions, with a value of 0.9 deemed optimal for balancing simulation accuracy and computational efficiency. Conversely, the specularity coefficient, impacting particle–wall interactions, exhibits a more subtle effect on bed dynamics. This finding emphasizes the critical role of carefully choosing these coefficients to effectively simulate the nuanced behaviors of fluidized beds. [ABSTRACT FROM AUTHOR]

To achieve better process control of silicon (Si) alloy production using aluminum as a reductant of calcium silicate (CaO-SiO2) slag, it is necessary to understand the reaction phenomena concerning the behavior of formed phases at the metal-slag interface during conversion. The interfacial interaction behavior of non-agitated melt was investigated using the sessile drop method for varying time and temperature, followed by EPMA phase analysis at the vicinity of the metal–slag interface. The most remarkable features of the reaction were the accumulation of solid calcium aluminate product layers at the Al alloy–slag interface and spontaneous emulsion of Si-alloy droplets in the slag phase. The reduction is strictly limited at 1550 °C due to the slow transfer of calcium aluminates away from the metal-slag interface into the partially liquid bulk slag. Reduction was significantly improved at 1600–1650 °C despite an interfacial layer being present, where the conversion rate is most intense in the first minutes of the liquid–liquid contact. A high mass transfer rate across the interface was shown related to the apparent interfacial tension depression of the wetting droplet along with a significant perturbed interface and emulsion due to Kelvin–Helmholtz instability driven by built-up interfacial charge at the interface. The increased reaction rate observed from 1550 °C to 1600–1650 °C for the non-agitated melt was attributed to the advantageous physical properties of the slag phase, which can be further regulated by the stoichiometry of metal–slag interactions and the composition of the slag. [ABSTRACT FROM AUTHOR]