CFD Predictions for Mixing Times in an Elliptical Ladle Using Single- and Dual-Plug Configurations

Abstract

Argon bottom stirring is commonly practiced in secondary steelmaking processes due to its positive effects on achieving uniform temperatures and chemical compositions throughout a steel melt. It can also be used to facilitate slag metal refining reactions. The inter-mixing phenomena associated with argon gas injection through porous plugs set in the bottom and its stirring efficiency can be summarized by evaluations of 95% mixing times. This study focuses on investigating the impact of different plug positions and ratios of argon flow rates from two plugs on mixing behavior within a 110-tonne, elliptical-shaped industrial ladle. A quasi-single-phase modeling technique was employed for this purpose. The CFD findings revealed that the optimal position of the second plug is to be placed diametrically opposite the existing one at an equal mid-radius distance (R/2). An equal distribution of argon flow rates yielded the best results in terms of refractory erosion. A comparative study was conducted between single- and dual-plug-configured ladles based on flow behavior and wall shear stresses using this method. Furthermore, a transient multiphase model was developed to examine the formation of slag open eyes (SOE) for both single- and dual-plug configurations using a volume of fluid (VOF) model. The results indicated that the dual-plug configuration outperformed the current single-plug configuration.