Numerical simulation of inclusion movement behavior in an overflow super gravity purification reactor

An industrial design of an overflow supergravity purification reactor was proposed to achieve continuous separation of aluminum melt and inclusions and to establish a process technology prototype for the implementation of a new process for aluminum melt supergravity purification. The rotation model was established by FLUENT, and the characteristics of the pressure field in the melt were simulated through the VOF model under different gravity coefficients and temperatures, with the DPM discrete phase model used to study the separation law of inclusions on this basis. The results indicated that an increasing pressure gradient existed along the direction of supergravity inside the aluminum melt, and the pressure value at the same position increased with increasing gravity coefficient. The pressure value of the aluminum melt near the wall was 5.75×10⁵ Pa under supergravity with G=500. The separation efficiency of Al₂O₃ inclusions (18 μm) in aluminum melt increased with increasing gravity coefficient, and the separation efficiency of inclusion particles reached 100% at G=500. In the supergravity field with G=48, as the temperature of the aluminum melt increased, the separation efficiency of Al₂O₃ inclusions (18 μm) in the aluminum melt was slightly improved. At 1 173 K, the separation efficiency of the inclusions reached 99.05%. The greater the density difference between the inclusions and aluminum melt, the more significant the separation effect of inclusions. When the density of inclusions was 3 970 kg/m³, their separation efficiency reached 97.73%. The separation effect of those inclusions was very significant as the particle size increased. When the particle size was over 50 μm, their separation efficiency was as high as 100%.