<p>This study analyzed the effect of implementing a swirl nozzle incorporating internal torsion channels designed to induce tangential momentum at the gas injection stage in a ladle furnace, which is a key operation in secondary refining to achieve chemical and thermal homogenization. A multiphase mathematical model was developed using the volume of fluid (VOF) approach, considering a single injection located at three-quarters of the ladle radius. Three gas flow rates were evaluated: 600, 1500, and 1800 <InlineEquation ID="IEq1"> <EquationSource Format="TEX">${\text{L m}}^{ - 1}$</EquationSource> <EquationSource Format="MATHML"><math> <msup> <mrow> <mtext>L m</mtext> </mrow> <mrow> <mo>-</mo> <mn>1</mn> </mrow> </msup> </math></EquationSource> </InlineEquation>. At 600 <InlineEquation ID="IEq2"> <EquationSource Format="TEX">${\text{L m}}^{ - 1}$</EquationSource> <EquationSource Format="MATHML"><math> <msup> <mrow> <mtext>L m</mtext> </mrow> <mrow> <mo>-</mo> <mn>1</mn> </mrow> </msup> </math></EquationSource> </InlineEquation>, the flow pattern was dominated by a stable recirculation loop, ensuring efficient bath mixing and the shortest mixing time of 116 s. At 1500 <InlineEquation ID="IEq3"> <EquationSource Format="TEX">${\text{L m}}^{ - 1}$</EquationSource> <EquationSource Format="MATHML"><math> <msup> <mrow> <mtext>L m</mtext> </mrow> <mrow> <mo>-</mo> <mn>1</mn> </mrow> </msup> </math></EquationSource> </InlineEquation>, the plume energy increased, generating a larger circulation and secondary instabilities that disrupted the homogeneity, resulting in the longest mixing time (196 s). At 1800 <InlineEquation ID="IEq4"> <EquationSource Format="TEX">${\text{L m}}^{ - 1}$</EquationSource> <EquationSource Format="MATHML"><math> <msup> <mrow> <mtext>L m</mtext> </mrow> <mrow> <mo>-</mo> <mn>1</mn> </mrow> </msup> </math></EquationSource> </InlineEquation>, the plume expanded across a wider bath volume, decreasing the mixing time to 172 s, although the turbulence and wall shear stresses intensified, indicating a trade-off between efficiency and refractory wear.</p> Graphical abstract <p></p>

Implementation of a new swirl nozzle design and its effect on fluid dynamic patterns and shear stress in a ladle furnace

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发表日期：

2026年7月14日

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N. P. Zavala-Coria,
C. A. Hernández-Bocanegra,
J. A. Ramos-Banderas,
G. Solorio-Díaz,
N. M. López-Granados,
N. D. Herrera-Sandoval

摘要

This study analyzed the effect of implementing a swirl nozzle incorporating internal torsion channels designed to induce tangential momentum at the gas injection stage in a ladle furnace, which is a key operation in secondary refining to achieve chemical and thermal homogenization. A multiphase mathematical model was developed using the volume of fluid (VOF) approach, considering a single injection located at three-quarters of the ladle radius. Three gas flow rates were evaluated: 600, 1500, and 1800 ${\text{L m}}^{ - 1}$ ${L m}^{- 1}$ . At 600 ${\text{L m}}^{ - 1}$ ${L m}^{- 1}$ , the flow pattern was dominated by a stable recirculation loop, ensuring efficient bath mixing and the shortest mixing time of 116 s. At 1500 ${\text{L m}}^{ - 1}$ ${L m}^{- 1}$ , the plume energy increased, generating a larger circulation and secondary instabilities that disrupted the homogeneity, resulting in the longest mixing time (196 s). At 1800 ${\text{L m}}^{ - 1}$ ${L m}^{- 1}$ , the plume expanded across a wider bath volume, decreasing the mixing time to 172 s, although the turbulence and wall shear stresses intensified, indicating a trade-off between efficiency and refractory wear.

Graphical abstract