Three-dimensional fluid flow model for gas-stirred ladles

A three-dimensional mathematical model has been developed to simulate the fluid flow phenomena in gas-stirred ladles. It can predict the velocity profile and flow pattern of the liquid and the gas bubbles. The two-phase fluid flow phenomena were analyzed by using the SOLA-SURF technique supplemented with the K-e two-equation turbulence model. The interactions between the gas bubble motion and the liquid flow were also considered. The movements of the gas bubbles were calculated and the extent of the plume zone determined. The effects of various design/operation conditions, such as gas flow rate, location of the porous plug, and addition of an immersion hood, can be evaluated. Flow intensity and stirring ability increase with increased gas flow rate. The dead zone near the bottom corner of the ladle exists whether the porous plug is centered or off-centered; this problem only slightly improves when gas flow rate is increased. Addition of an immersion hood not only provides a slag-free and protective atmosphere inside the hood, but also reduces the dead zone.