In order to investigate the temperature distribution, a three-dimensional finite element model （FEM） was developed to simulate the temperature regime in the channels of double-loop inductor, and the simulated results were compared with experimental data from low load trials of a 400 kW inductor. The results of numerical simulations, such as the temperature and Joule heating rate, show reasonable correlation with experimental data. The results indicate that Joule heating rate and the temperature reach the maximum at the comers and the minimum at the centre of the cross-section area. The temperature difference between the inlet and outlet is in an inverse proportion to mass transport. Joule heating rate and the temperature are directly proportional to power frequency. It is concluded that mass transport and power frequency play a critical role in determining the temperature regime and Joule heating rate, the relative permeability of the magnetic core shows no significant influence on temperature regime and Joule heating rate, when the relative permeability varies from 5 000 to 10 000.
In order to investigate Joule heating power,a three-dimensional finite element model(FEM) was developed to predict Joule heating power in the channels of double-loop inductor. The simulated results were compared with experimental data from low load trials for a 400 kW inductor. The results,such as power factor and Joule heating power,show reasonable correlation with experimental data,and Joule heating rate reaches the maximum at the corners and the minimum at the centre of the cross-section area. With increasing relative permeability of iron core,length of coils,current frequency and resistivity of metal melt,the power factor and Joule heating power change. It is concluded that current frequency,the resistivity and length of the coil play a critical role in determining the power factor and Joule heating power,whereas relative permeability of the magnetic core shows no significant influence on them.
The residence-time distribution （RTD） and the compartment model were applied to characterizing the flow regions in red mud separation thickener’s feedwells. Combined with the experimental work, validated mathematical model as well as three-dimensional computational fluid dynamics （CFD） model was established to analyze the flow regions of feedwells on an industrial scale. The concept of RTD, although a well-known method for the characterization of mixing behavior in conventional mixers and reactors, is still a novel measure for the characterization of mixing in feedwells. Numerical simulation results show that the inlet feed rate and the aspect ratio of feedwells are the most critical parameters which affect the RTD of feedwell. Further simulation experiments were then carried out. Under the optimal operation conditions, the volume fraction of dead zone can reduce by10.8% and an increasement of mixing flow volume fraction by 6.5% is also observed. There is an optimum feed inlet rate depending on the feedwell design. The CFD model in conjunction with the RTD analysis then can be used as an effective tool in the design, evaluation and optimization of thickener feedwell in the red mud separation.
In order to acquire the flow pattern and investigate the settling behavior of the red mud in the separation thickener,computational fluid dynamics(CFD),custom subroutines and agglomerates settling theory were employed to simulate the three-dimensional flow field in an industrial scale thickener with the introduction of a self-dilute feed system.The simulation results show good agreement with the measurement onsite and the flow patterns of the thickener are presented and discussed on both velocity and concentration field.Optimization experiments on feed well and self-dilute system were also carried out,and indicate that the optimal thickener system can dilute the solid concentration in feed well from 110 g/L to 86 g/L which would help the agglomerates' formation and improve the red mud settling speed.Furthermore,the additional power of recirculation pump can be saved and flocculants dosage was reduced from 105g/t to 85g/t in the operation.
