A reasonable tundish flow behavior could improve liquid steel cleanliness by promoting floating and removal of the inclusions. The flow behaviors of the tundish could be obtained by water model experiments and numerical simulations, respectively. However, the difference in density between the tracer and water in the experiment can contribute to notable errors. A new type of tracer, which is a mixture of potassium chloride (KCl) and ethanol, was proposed in this study to reduce the errors. The numerical simulation model was validated by the experimental data and its error was below 2%. By comparing the flow behaviors in seven tundishes with different inner structures obtained by simulation, it is found that the C1 can significantly reduce the dead volume ratio and C4 can improve the uniformity of liquid steel charged though each outlet. The structural strength of the baffle in C1 scheme was not considered, resulting in a crack of the baffle in the industrial trial. Industrial trials of the molten steel flow in the C4-based tundish were conducted and reported a reduction of 43.81% in the inclusions over the prototype.

Pressure hydrometallurgy has attracted much attention for its characteristics, such as the high adaptability of raw materials and environmental friendliness. Flashing (flash boiling or flash evaporation) refers to the phase change phenomenon from liquid to gas triggered by depressurization, which is an important connection between high-pressure processes and atmospheric ones in pressure hydrometallurgy. This paper takes the flashing process in zinc leaching and alumina Bayer processes as examples, describes the flashing process in pressure hydrometallurgy in detail for the first time, and shows the importance of the flashing process in energy recovery, solution concentration, and liquid balance, as well as increasing equipment life. According to solid holdup (the volume percentage of solid), this paper proposes to divide the flashing process into solution flashing (low solid holdup) and slurry flashing (high solid holdup). A further focus is put on reviewing the state of the art of related studies. The results reveal that the research on the flashing process in pressure hydrometallurgy is scarce and often oversimplified, e.g., ignoring the BPE (boiling point elevation) and NEA (non-equilibrium allowance) in solution flashing and the effect of solid particles in slurry flashing. Computational fluid dynamic (CFD) simulation is a promising tool for investigating the flashing process. Based on the progress made in other fields, e.g., seawater desalination, nuclear safety analysis, and engine fuel atomization, we suggest that solution flashing can be studied using the CFD–PBM (population balance model) coupled two-fluid model, since a wide size range of bubbles will be generated. For slurry flashing, the effect of solid holdup on the bubble nucleation rate and mechanism as well as other bubble dynamics processes should be accounted for additionally, for which a quantitative description is still lacking. Meanwhile, data for validating the numerical method are scarce because of the harsh experimental conditions, and further research is needed. In summary, this work presents an overview of the flashing processes in pressure hydrometallurgy and some guidelines for future numerical studies.