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In this work a fundamental Eulerian mathematical model was developed to study fluid flow and mixing phenomena in aluminum ladles equipped with impeller for deshidrogenization treatment. The effect of critical process parameters such as rotor speed, depth of immersion, gas flow rate, and type of rotor on the mixing behavior and vortex formation was analyzed with this model. The model simulates operation with and without gas injection and it was developed on the commercial CFD code PHOENICS 3.4 in order to solve all conservation equations governing the process, i.e. continuity, 3D turbulent Navier-Stokes and the k-e turbulence model for a two-phase fluid flow problem using the Inter Phase Slip Algorithm (IPSA). In order to realistically represent the process, shape of the furnace and three kinds of impellers were drawn by employing Body Fitted Coordinates (BFC). From the results it was concluded that mixing behavior is highly dependent on the rotor speed and on the rotor type. Mixing time is improved when: 1) Impeller is located at a depth of 0.229m into the aluminum bath, 2) By using high rotor speeds, 3) By using ladles with a high aspect ratio of Diameter to Height, and 4)By using an impeller with notches.

Mathematical modeling of mixing phenomena in ladles of aluminum equipped with impeller and gas purging for degassing