Optimization of Pellet Distribution in a Smelting Reduction Reactor Using VOF‐DPM Gas–Liquid–Particle Simulation

Blast furnace processes have traditionally dominated ironmaking; however, multistage smelting reduction iron bath reactors offer a promising alternative. The optimization of these reactors is currently hindered by an inadequate understanding of gas–liquid–solid interactions and pellet distribution dynamics. To address this, the present study employs a coupled Volume of Fluid (VOF) and Discrete Phase Model (DPM) approach to simulate multiphase flow within the reactor. This methodology systematically evaluates pellet distribution, concentration gradients, and flow‐field interactions under varying lance diameters and bottom blowing configurations. Key findings indicate that implementing a spiral feeding method reduces the pellet sedimentation rate by 44% compared to conventional feeding techniques. In the absence of bottom blowing, pellet settling is minimized, resulting in the highest local concentration. The single‐hole configuration ranks second in mitigating the settling rate and maintaining concentration. Consequently, operating no bottom blowing combined with a lance diameter of 125 or 175 mm yields the optimal concentration. Furthermore, the single‐hole configuration achieves superior uniformity in pellet distribution, corresponding to a coefficient of variation (CV) between 23.7% and 29.6%. Conversely, double‐hole configuration induces severe pellet segregation, with the CV reaching up to 37.1%.