Branch of the National Research University “Moscow Power Engineering Institute”, Smolensk, Russia:

S. V. Pancnehko, Professor, Chair of Physics
M. I. Dli, Professor, Head of a Chair of Management and Information Technologies in Economics, e-mail: midli@mail.ru
V. V. Borisov, Professor, Chair of Computer Engineering
D. S. Panchenko, Engineer

Considered are thermalphysic processes in an ore-smelting electrothermal reactor, which is a reaction bulk with different phase composition, where transfer of energy is carried out in separate zones at temperatures above 2000 К. In the paper, a two-dimensional model of the near-electrode crucible reaction zone is presented as well as analytical solutions for describing thermalphysic processes in a reaction zone which characterize conditions of the target product manufacturing are obtained. Experimental study of electrothermal reactor operating modes has been hampered by the absence of reliable sensors and reactionary character of the medium, that’s why elaboration of the adequate mathematical models which can be realized using numerical methods is a currently central problem. However, in some cases operating figures of technological reactors may be estimated through analytical investigations owing to the use of the valid approximations. Analytical approach allows one to discover the main regularities of the influence of different factors on the process under consideration, to estimate the influence degree, to obtain a qualitative picture of an object behavior, to draw a conclusion about capability of control and extent of an effect on the control system. Calculations has been fulfilled for a technological process of phosphorus obtaining, but similarity of manufacturing processes for calcium carbide, titanium carbide, fused corundum as well as for nickel in a certain sense, gives ground to suggest that the conclusions presented in this paper are suitable for electrothermal process of a broad spectrum. There are obtained distributions of the Joule heat emission flux density, distribution of temperatures in the region of chemical and physical transformations. It is determined that target processes are localized in a near-electrode zone with the formation of crucibles unrelated. However, energy transfer processes enlarge an effective area of reactions and should be taken into account during designing and mode control. Neglecting heat efficiency may introduce large errors in analysis of the modes.

This work is done in the framework of the basic part of State task of the Ministry of Education and Science of the Russian Federation No. 2014/123 to perform public works in the field of scientific activities, project No. 2493.

1. Chumakov Yu. A., Mazmanyan V. A., Rumyantsev D. V., Tsemekhman L. Sh., Egorov P. A. Analiz raboty rudno-termicheskikh pechey kombinata “Pechenganikel” v usloviyakh izmeneniya sostava shikhty (Analysis of the ore-thermal furnace operation at “Pechenganickel” combine under conditions of charge composition changing). Tsvetnye Metally = Non-ferrous metals. 2014. No. 1. pp. 16–21.
2. Strunskii B. M. Rudnotermicheskiye plavilnye pechi (Orethermal smelting furnaces). Moscow : Metallurgiya, 1972. 368 p.
3. Kondrashev V. P., Mironov Yu. M., Kozlov A. I. et al. Issledovaniye rezhimov raboty promyshlennykh elektropechey dlya proizvodstva karbida kaltsiya (Research of operating modes of industrial electric furnaces for calcium carbide production). Collected articles : Ore-smelting furnaces. Мoscow : Energoatomizdat, 1988. pp. 32–38.
4. Panchenko S. V., Shirokikh T. V. Teplofizicheskie protsessy v shikhtovoy zone elektrotermicheskikh rudovosstanovitelnykh reaktorov (Thermal physics processes in charge zone of electrothermal ore-reduction reactors). Teoreticheskie osnovy khimicheskoy tekhnologii = Theoretical Foundations of Chemical Engineering. 2014. Vol. 48, No. 1. pp. 1–6.
5. Meshalkin V. P., Panchenko S.V., Panchenko D. S., Menshikov V. V., Kazak A. S. Komputernoye modelirovaniye teplomassoobmennykh protsessov v rudovosstanovitelnom elektrotermicheskom reaktore (Computer simulation of heat-mass exchange processes in an ore-smelting electrothermal reactor). Teoreticheskie osnovy khimicheskoy tekhnologii = Theoretical Foundations of Chemical Engineering. 2015. Vol. 49, No. 5. pp. 1–7.
6. Panchenko S. V., Meshalkin V. P., Dli M. I., Borisov V. V. Komputerno-vizualnaya model teplofizicheskykh protsessov v elektrotermycheskom reaktore (Computer-visual model of thermalphysic processes in electrothermal reactor). Tsvetnye Metally = Non-ferrous metals. 2015. No. 4. pp. 55–60.
7. Panchenko S. V. Teplofizika protsessov geterogennogo reagirovaniya pri vydelenii gazofaznykh produktov (Thermal physics of heterogeneous ractions during educing gas-core products). Trudy Mezhdunarodnoy nauchno-tekhnicheskoy konferentsii “Energetika, informatika, innovatsii — 2015” (Proceedings of the International Scientific and Technical Conference “Power Engineering, Information Science and Innovations — 2015”). Vol. 1. Smolensk : Universum, 2015. pp. 137–141.
8. Panchenko S. V., Panchenko D. S., Glebova N. B. Protsessy perenosa v geterogennom vosstanovitelnom reaktore (Transfer processes in heterogeneous reduction reactor). Teoreticheskie osnovy khimicheskoy tekhnologii = Theoretical Foundations of Chemical Engineering. 2004. Vol. 38, No. 6. pp. 1–5.
9. Panchenko S. V., Panchenko D. S., Glebova N. B. Gidrodinamika barbotazhnogo sloya geterogennogo vosstanovitelnogo reaktora (Hydrodynamics of bubbling fluidized bed of heterogeneous reduction reactor). Teoreticheskie osnovy khimicheskoy tekhnologii = Theoretical Foundations of Chemical Engineering. 2005. Vol. 39, No. 1. pp. 1–4.
10. Panchenko S. V., Panchenko D. S., Glebova N. B. Formirovanie dissipativnykh structur v reaktsionnoy zone geterogennogo vosstanovitelnogo reaktora (Formation of dissipative structures in the reaction zone of a heterogeneous reduction reactor). Teoreticheskie osnovy khimicheskoy tekhnologii = Theoretical Foundations of Chemical Engineering. 2005. Vol. 39, No. 2. pp. 1–6.
11. Dantsis Ya. B., Ershov V. A., Zhilov G. M. et al. Elektrotermicheskiye protsessy khimicheskoy tekhnologii (Electrothermal processes of chemical technology). Under the editorship of V. A. Ershov. Leningrad : Khimiya, 1984. 464 p.
12. Valkova Z. A., Dantsis Ya. B., Zhilov G. M., Antonos E. R. Issledovanie elektricheskogo polya vanny fosfornoy pechi (Research of electric field of the bath of a phosphorus furnace). Issledovaniye i razrabotka elektrooborudovaniya i sistem avtomaticheskogo upravleniya moshchnykh rudnotermicheskikh pechey : sbornik nauchnykh trudov (Research and development of electrical equipment and automatic control systems of high-power ore-thermal furnaces : scientific proceedings). Leningrad : LenNIIGiproKhim, 1975. Iss. 20. pp. 34–41.
13. Zhilov G. M., Valkova Z. A., Tarasov V. A., Tavrin N. Yu. Vliyanie elektrotekhnologicheskogo rezhima na paramtery pechnogo gaza fosfornoy pechi (Electrotechnological mode influence on parameters of the phosphorous furnace kiln gas). Sovershenstvovaniye protsessov i apparatov proizvodstva karbida kaltsiya, fosfora i fosfornykh soley : sbornik nauchnykh trudov (Improvement of processes and devices of calcium carbide, phosphorus and phosphate salts manufacturing : scientific proceedings). Leningrad : LenNIIGiproKhim, 1988. pp. 93–98.
14. Panchenko S. V., Pak M. I., Baykuchukov A. N. Rasprede lenie skorostey gasovykh potokov v sloye shikhty fosfornoy pechi (Velocity distribution of gas flows in the burden layer of a phosphorus furnace). Promyshlennaya teplotekhnika = Industrial Heat Engineering. 1989. Vol. 11, No. 4. pp. 102–104.
15. Hariharan M., Rafi K. Mohd., Raghavan D. Modelling of calcium carbid furnace. Bulletin of Electrochemistry. 1990. No. 6 (3). pp. 298–301.
16. Panchenko S. V., Shirokikh T. V. Teplogidravlika dvizhushchegosya dispersnogo sloya tekhnologicheskykh agregatov (Heathydraulics of a moving dispersed layer of technological units). Teoreticheskie osnovy khimicheskoy tekhnologii = Theoretical Foundations of Chemical Engineering. 2016. Vol. 50, No. 2. pp. 1–8.
17. Ershov V. A., Reutovych L. N., Guralnik P. A. et al. O zondiorvanii vanny fosfornoy elektropechi (On probing the bath of a phosphorus electric furnace). Tezisy dokladov Vsesouznogo nauchno-tekhnicheskogo soveshchaniya “Termiya-75” (Abstracts of the All-Union Scientific and Technical Meeting “Thermiya-75”). Leningrad : LTI, 1975. pp. 26–29.
18. Eksteen J., Frank S., Reuter M. Dynamic structures in variance based data reconciliation adjustments for a chromite smelting furnace. Minerals Engineering. 2004. Vol. 15. pp. 931–943.
19. Yang Y., Xiao Y., Reuter M. Analysis of transport phenomena in submerged arc furnace for ferrochrome production. International Ferroalloy Congress, SAIMM, 2004. pp. 15–25.
20. Scheepers E., Adema A. T., Yang Y., Reuter M. A. The development of a CFD model of a submerged arc furnace for phosphorus production. Minerals Engineering. 2006. Vol. 19. pp. 1115–1125.