Abstract:Frame blades were used to replace traditional propeller blades to enhance the leaching step efficiency of Becher process. A combined approach of leaching, electrochemical experiments, and numerical simulations was employed. Results demonstrate a significant improvement in leaching efficiency using frame blades compared to propellers, reducing reaction time from 15 to 10 h. Even at a stirring speed of 300 r/min, frame blades perform better than propellers at 500 r/min. Kinetics analysis indicates that the leaching process is controlled by surface chemical reactions. CFD-PBM simulations reveal that frame blades at 300 r/min generate larger bubbles and higher turbulent kinetic energy than propeller blades at 500 r/min. Frame blades enhance leaching efficiency by refining bubble size to improve oxygen mass transfer and by increasing turbulent kinetic energy for better mixing.

Key words: Becher process; CFD-PBM method; frame blade; reduced ilmenite; synthetic rutile; rust leaching