Generation of Droplets in Slag-Metal Emulsions through Top Gas Blowing

The behavior of metal droplets in a slag-metal-gas emulsion through impinging gas blowing was investigated experimentally using a cast iron-slag-nitrogen gas system at high temperatures. A mathematical model of the emulsification process for determining the generation rate, size distribution, and residence time of metal droplets has been developed and successfully validated using experimental data. From the present work, it was found that the generation rate and size distribution of metal droplets is strongly influenced by the ratio of the inertial force of blown gas to the surface tension and buoyancy forces of the liquid metal. A new dimensionless number, i.e. blowing number, which represents the ratio of inertial to surface tension and buoyancy forces and also the departure of the system from its stable condition defined by the Kelvin-Helmholtz criterion, is proposed. A functional relationship of generation rate and size distribution of metal droplets with the blowing number is proposed.