CFD-based comparison of flows and mixing efficiencies in elliptical ladles with single and dual plug configurations

In secondary steelmaking, bottom argon stirring plays a critical role in homogenising temperature and chemical compositions within a melt of liquid steel. It can also enhance slag-metal refining reactions and contributes to improved metal cleanliness. The intermixing phenomena induced by argon injection through porous plugs installed in the ladle bottom, as well as the overall stirring efficiency, can be assessed using 95% mixing times.In this study, Computational Fluid Dynamics (CFD) based on quasi-single-phase modelling was carried out to compare the flow fields generated in an elliptically-shaped industrial 120-tonne ladle, using a single porous plug versus those produced by a dual-plug configuration. Additionally, a comparative analysis of the single- and dual-plug configurations was conducted based on flow characteristics, plume dynamics, wall shear stresses, and finally, slag open-eye formation using multiphase volume of fluid modelling. The results demonstrated that the dual-plug configuration outperformed the current single-plug setup.