An innovative electroslag remelting furnace with a water-cooled electrode was introduced to recycle the rejected electrolytic manganese metal (EMM) scrap. To clarify the desulfurization process in the rejected EMM scrap, a transient three-dimensional comprehensive numerical model was elaborated. Using the magnetic potential vector approach, the respective electromagnetic fields were calculated via the Maxwell equations. The Lorentz force and the Joule heating fields were derived as phase distribution functions and interrelated via the momentum and energy conservation equations as source terms, respectively. The molten manganese metal droplet motion, as well as the fluctuation of the slag–metal interface, was described by the volume-of-fluid (VOF) approach. Besides, the solidification was modeled via the enthalpy-based technique. A thermodynamic module was established to estimate the sulfur mass transfer rate between the molten manganese metal and the molten slag. Furthermore, a factor related to the magnitude and frequency of the alternating current and the physical properties of the melt was introduced to include the electro-emulsification phenomenon. An experiment has been carried out with a commercial-scale ESR device. The predicted values of the slag temperature and sulfur content in the final manganese ingot were found to agree reasonably with the corresponding measured data. Under continuous melting of the rejected EMM scrap, molten manganese metal droplets are formed at the domain inlet, grow, and fall down. Highly conductive molten manganese metal droplets significantly change distributions of the current streamline, the Joule heating, and the Lorentz force around and within it. Moreover, droplets are inclined to rotate and move inside the mold. With the renewal of the slag–manganese interface, sulfur in the molten manganese metal is constantly transferred to the molten slag. With the applied current ranging from 3000 to 4000 A, the average sulfur content of the manganese ingot dropped from 0.0447 to 0.0291 pct, and thus, the desulfurization rate rose from 55.3 to 70.9 pct.

中文翻译：

---

电渣重熔过程中废金属电解锰脱硫的CFD及实验研究

引入了带有水冷电极的创新电渣重熔炉，以回收废弃的电解锰 (EMM) 废料。为了阐明废弃EMM废料中的脱硫过程，建立了瞬态三维综合数值模型。使用磁势矢量方法，通过麦克斯韦方程计算各自的电磁场。洛伦兹力和焦耳加热场作为相位分布函数导出，并分别通过动量和能量守恒方程作为源项相互关联。熔融锰金属液滴的运动以及渣-金属界面的波动可以通过流体体积 (VOF) 方法来描述。此外，凝固过程是通过基于焓的技术模拟的。建立了一个热力学模块来估计熔融锰金属和熔融炉渣之间的硫传质速率。此外，还引入了与交流电流的大小和频率以及熔体物理性质相关的因素，包括电乳化现象。已使用商业规模的 ESR 设备进行了一项实验。发现最终锰锭中炉渣温度和硫含量的预测值与相应的测量数据合理吻合。在被拒绝的 EMM 废料的连续熔化下，熔融的锰金属液滴在域入口处形成、生长和落下。高导电的熔融锰金属液滴显着改变了电流流线的分布，焦耳热，以及它周围和内部的洛伦兹力。此外，液滴倾向于在模具内旋转和移动。随着渣-锰界面的更新，熔融金属锰中的硫不断转移到熔融渣中。施加电流3000～4000A，锰锭平均硫含量由0.0447%下降至0.0291%，脱硫率由55.3%上升至70.9%。