Model Studies of Slag Metal Entrainment in Gas Stirred Ladles

Abstract

In gas stirred steelmaking ladles, entrainment of slag into metal and vice versa takes place. The slag entrainment has been shown to abruptly increase the mass transfer rates of refining reactions through high temperature and water modeling studies of the past. However such an effect has not been correlated with the degree of entrainment, since the latter has not been quantified in terms of operating parameters like gas injection rate and fluid properties. Much of the past works are limited to finding the critical conditions for onset of entrainment. The difficulty lies in measuring the degree of entrainment in industrial ladles or even in a water model. Mathematical modeling is also challenging due to the complexity of the multiphase phenomena. So in this thesis, a modular mathematical modeling approach is presented wherein the phenomena of slag entrainment into metal is resolved into four aspects, models developed for each and finally integrated to study its role. The individual models are (1) multiphase large eddy simulations to simulate slag entrainment in a narrow domain that receives its boundary conditions from (2) single phase RANS simulation of a full ladle, (3) a Lagrangian particle tracking method to compute the residence times of slag droplets in metal phase and (4) a kinetic model that integrates the above three models to compute mass transfer rate as a function of degree of entrainment. Mass transfer rate predictions comparable to a literature correlation were obtained. This supports the modeling approach and also the assessment of role of various system parameters on entrainment characteristics. In essence, the present work shows a systematic approach to model and study the complex multiphase phenomena.