Numerical Simulation Study of Gas-Liquid Two-Phase Flow in a Pressurized Leaching Stirred Tank

The gas-liquid flow and oxygen content in a pressurized leaching stirred tank significantly influence the chemical reaction rates, while the specific dynamics of gas-liquid flow in the sulfuric acid system remain largely unexplored. In this study, a mathematical model of gas-liquid flow within a stirred tank is developed using the Euler-Euler approach, with the turbulence and drag force models being validated against experimental data. Utilizing this validated and reliable model, this study investigates the impacts of the sulfuric acid concentration, baffles, air inlet velocity, and bubble diameter on the flow field and gas holdup in a two-phase system consisting of a sulfuric acid solution and oxygen. The findings indicate that introducing a specific concentration of sulfuric acid decreases the solution velocity and increases the gas holdup within the tank. However, once the sulfuric acid concentration reaches a certain threshold, further increases have a diminished effect on the gas-liquid phases. The installation of baffles enhances the turbulent kinetic energy and increases the gas holdup while only resulting in a minimal 1.2% increase in power consumption. Additionally, the inlet velocity and bubble diameter have a relatively minor impact on the tank’s flow field. However, increasing the inlet velocity significantly boosts the gas holdup, whereas an increase in the bubble diameter marginally reduces it. Furthermore, introducing a sulfuric acid solution into the tank can enhance the gas holdup when the gas inlet velocity is low. Conversely, when the gas inlet velocity is high, the addition of sulfuric acid results in a decrease in the gas holdup. The conclusions from this study contribute to enhancing the mixing effectiveness and oxygen content within the tank, providing a substantial theoretical basis for optimizing the design and operating conditions of pressurized leaching stirred tanks.