Mathematical Modeling of Fluid Flow in a Water Physical Model of an Aluminum Degassing Ladle Equipped with an Impeller-Injector

In this work, a 3D numerical simulation using a Euler–Euler-based model implemented into a commercial CFD code was used to simulate fluid flow and turbulence structure in a water physical model of an aluminum ladle equipped with an impeller for degassing treatment. The effect of critical process parameters such as rotor speed, gas flow rate, and the point of gas injection (conventional injection through the shaft vs a novel injection through the bottom of the ladle) on the fluid flow and vortex formation was analyzed with this model. The commercial CFD code PHOENICS 3.4 was used to solve all conservation equations governing the process for this two-phase fluid flow system. The mathematical model was reasonably well validated against experimentally measured liquid velocity and vortex sizes in a water physical model built specifically for this investigation. From the results, it was concluded that the angular speed of the impeller is the most important parameter in promoting better stirred baths and creating smaller and better distributed bubbles in the liquid. The pumping effect of the impeller is increased as the impeller rotation speed increases. Gas flow rate is detrimental to bath stirring and diminishes the pumping effect of the impeller. Finally, although the injection point was the least significant variable, it was found that the “novel” injection improves stirring in the ladle.