Mixing Time and Correlation for Ladles Stirred with Dual

Porous Plugs
JAYANTA MANDAL, SUJOY PATIL, M. MADAN, and DIPAK MAZUMDAR

Bulk mixing times up to a degree of 95 pct were measured in three different, cylindrical-shaped water
model ladles (D
0.60 m, 0.45 m, and 0.30 m, respectively) in which, water was agitated by air intro-
duced through two tuyeres/nozzles placed diametrically opposite at the base of the vessels at 1/2 R
positions. To this end, the electrical conductivity measurement technique was applied. A range of gas
flow rates and liquid depths were investigated (viz. 0.7  L/D  1.2 and 0.002  m (watt/kg) 0.01)
and these were so chosen to conform to the practical ladle refining conditions. In the beginning, extensive
experimental trials were carried out to assess the reliability of the measurement technique. In addition,
some experiments were carried out to determine the location of the probe in the vessel such that measured
mixing times could be interpreted as the bulk mixing times.
It was observed that for smaller gas flow rates (or specific energy input rates), 95 pct bulk mixing
times tend to decrease appreciably with increasing gas flow rates (e.g., mix  Q0.58). However, for
relatively higher flow rates, the dependence was found to be less pronounced, mixing times decreasing
nearly in proportion to a third power of gas flow rates. Similarly, it was found that there exists a critical
gas flow rate for any given vessel beyond which mixing times in dual plug stirred configuration are
somewhat shorter than those in equivalent axi-symmetrical systems. A dimensional analysis followed
by multiple regression of the experimental data (for m  0.07 W/kg) indicated that mixing times in
ladles fitted with dual plugs located diametrically opposite at R/2 locations could be reasonably
described via mix, 95 pct
15Q0.38L0.56R2.0 in which L is the depth of liquid (m), R is the vessel radius
(m), and Q is the ambient flow rate (referenced to mean height and temperature of the liquid). Finally,
the adequacy and appropriateness of the correlation was demonstrated with reference to the experimental
data derived from a 0.20 scale, tapered cylindrical-shaped water model of a 140 T industrial ladle as
well as scaling equations and modeling criteria reported in the literature.

I. INTRODUCTION mixing, as well as to promote better slag/metal intermixing

THE efficiency of many chemical processing operations
carried out in the present day steelmaking ladles is intricately
related to mixing phenomena. Mixing enhances chemical
reactions by bringing in reactants together and removing
products from reaction sites. In addition, it also influences
the extent of thermal and particulate inhomogeneities within
the ladle. It is therefore desirable to ascertain the extent of
mixing in order to evaluate the process performance of argon-
or nitrogen-stirred ladles.
Mixing phenomena, by and large, have been investigated
in aqueous models of gas-stirred ladle systems in which a
centrally or an asymmetrically placed single porous plug/nozzle
is used to stir the contents of the ladle. A great deal of infor-
mation on these is already available in the literature and sum-
marized by Mazumdar and Guthrie[1] in a review. While fluid
model studies on gas-stirred systems using a single, axisym-
metric/asymmetric plug/nozzle have been relatively common,
not much information on ladles fitted with dual plugs/nozzles
is available in the literature. It is to be noted that occasionally
it might be necessary to bubble an industrial ladle with two
or more porous plugs, in order to achieve gentle but rapid
JAYANTA MANDAL, Engineer, is with Ispat Industries, Dolvi,
Maharastra, 402107, India. SUJOY PATIL, Graduate Student, M. MADAN,
Senior Project Associate, and DIPAK MAZUMDAR, Professor, are with
the Department of Materials and Metallurgical Engineering, Indian Insti-
tute of Technology, Kanpur, 208016, India. Contact e-mail: dipak@iitk.ac.in
Manuscript submitted September 18, 2003.
and to avoid explosive degassing effects under vacuum. Given
such, the relevance of the present study to industrial steel-
making practice is readily apparent.
Joo and Guthrie[2] were among the first to investigate mixing
phenomena in a ladle fitted with twin porous plugs both exper-
imentally and computationally. Their study indicated that shorter
mixing times (relative to conventional axisymmetrical/
asymmetrical gas bubbling) can be achieved by injecting gases
through two porous plugs, located diametrically opposite at
midbath radius position (i.e., at 1/2R). Reconstructed from
Reference 2, this is shown in Figure 1, in which mixing times
for an axisymmetrically placed single porous plug/nozzle is
shown vis á vis the same for twin plug bubbling as a function
of net gas flow rates. There, it is at once evident that the twin
plug configuration ensures relatively faster mixing only at mod-
erately higher gas flow rates. The figure also appears to suggest
that such advantages associated with twin plug bubbling are
likely to fade away at lower operating gas flow rates. This
aspect, however, was not given sufficient attention by Joo and
Guthrie in their work and has not since been confirmed through
any subsequent investigation.
In a later work, Zhu et al.[3] carried out similar investi-
gations on ladles fitted with one or more porous plugs. Their
observations reproduced from Reference 3 and shown in
Figure 2 clearly indicate that mixing times, regardless of the
magnitude of gas flows, are smaller in the dual-plug-stirred
system than those in the equivalent axisymmetrical system.
Such observations are grossly similar to those reported by
Joo and Guthrie, while some dissimilarity between the two

METALLURGICAL AND MATERIALS TRANSACTIONS B VOLUME 36B, AUGUST 2005—479


Fig. 1—Experimentally measured 95 pct mixing times in a water model ladle
as a function of gas flow rates for two different nozzle/plug configurations
(reconstructed from Ref 2).
Fig. 2—Experimentally measured 95 pct mixing times in a water model ladle
(D
0.40 m) as a function of gas flow rates for two different nozzle/plug
configurations.[3]
sets of experimental results,[2,3] particularly at relatively small
operating flow rates, is evident. Zhu and co-workers also
proposed an empirical correlation for estimating 95 pct mix-
ing times in ladles operated with multiple porous plugs/noz-
zles (up to a maximum of three plugs) according to
tmix
8.52
m0.33 N 0.33 [1]
Equation [1] suggests that at an equivalent specific poten-
tial energy input rate, m, any increase in the number of
porous plugs/nozzles is likely to lead to a corresponding
increase in mixing times. This is in direct opposition to the
experimental results presented in Figures 1 and 2. It is instruc-
tive to note here that Eq. [1] was developed by Zhu and co-
workers in light of empirical correlations proposed several
years back by Nakanishi et al.[4] for their bottom blowing
steelmaking converter, fitted with multiple tuyeres/nozzles.
The brief review presented above evidently suggests that
more systematic study of mixing phenomena in dual-plug-
stirred ladle is required. Similarly, it is apparent from the
480—VOLUME 36B, AUGUST 2005
above that a physically plausible, effective correlation for
estimating mixing times does not yet exist for such systems.
As such, the influence of the operating variables such as gas
flow rates (Q), depth of liquid (L), and radius of the vessel
(R) are likely to exert on mixing is not known with any
certainty for such a system. Consequently, the primary objec-
tive of the present work has been to experimentally inves-
tigate mixing phenomena in ladles fitted with dual porous
plugs/nozzles over a wide range of operating conditions and,
thereby, to develop an effective correlation for estimating
mixing times in such systems. Toward these, experimental
observations and a discussion on 95 pct mixing times derived
from three different size water model ladles, in which water
is agitated by air introduced through a pair of nozzles located
diametrically opposite at midbath radius position, are pre-
sented in the following Sections III(B) and III(C).
II. EXPERIMENTAL WORK
As pointed out already, mixing times were measured in
three different cylindrical vessels (i.d.
0.60 m, 0.48 m, and
0.30 m), in which water was agitated by injecting air or N2
through a pair of nozzles located at the bottom of the vessel
at the midbath radius position. No attempt has been made to
investigate mixing phenomena as a function of nozzle locations
since it is rather well known[2] that porous plugs/nozzles placed
diametrically opposite at midbath radius position ensure the
best mixing conditions. Prior to monitoring mixing, air/N2
was bubbled into the water bath at the desired flow rate for
a few minutes to ensure the stability of the flow in the vessel
as well as to remove any inhomogeneities present in the bath.
The gas flow rates investigated were so chosen to ensure a
gentle stirring condition as is typically encountered in actual
ladle metallurgy steelmaking operations[1] (viz.
0.001 to
0.015 Nm3/t min). It is to be noted here that while lower end
flow rates are typically used in industry for bath homoge-
nization (i.e., of thermal or material), relatively large gas flow
rates are used to achieve enhanced slag-metal reactions. The
objective of this study was to primarily investigate bath homog-
enization, it was deliberately decided to use smaller flow rates,
embodying a fraction of the entire range of gas flow rates
mentioned previously.
A conductivity probe supplied with a digital conductivity
meter (Eutech make, Cyberscan 200, Eutech Instruments Pte
Ltd., Singapore) was employed to record changes in the local
ion concentration of a pulse tracer (NaCl or H2SO4) added
directly to a point on the liquid-free surface, lying midway
between the “eyes” of the two surfacing plumes (e.g., the axis
of symmetry). The change in local ion concentration around
the probe tip was measured through the changes in the water’s
electrical conductivity and recorded manually via the digital
conductivity meter. Thus, data on conductivity were collected
typically every 2/3 seconds and simultaneously stored in a
computer using the Cyber Comm Portable software, Eutech
Instruments Pte Ltd., Singapore. On addition of tracer, con-
siderable oscillations in the conductivity value were observed,
which essentially resulted from the periodic fluctuations of the
amount of tracer passing through the probe tip. For each exper-
iment, the recording of tracer response was carried out until
the concentration of the tracer in the bath was considered to
have reached a homogeneously mixed value. Experimental
METALLURGICAL AND MATERIALS TRANSACTIONS B

Fig. 3—A typical tracer response curve and the procedure adopted to esti-
mate 95 pct mixing times.
data were subsequently analyzed through MICROSOFT
EXCEL* software and a plot between conductivity vs time was
*MICROSOFT EXCEL is a trademark of Microsoft Corporation,
104 m3/s)
Redmond, WA.
generated. This is shown in Figure 3 from which corresponding
mixing times were estimated. These are defined in the present
context as the time required for the monitoring point concen-
tration to fall continuously within a 5 pct deviation of the well
mixed/homogeneous value. By keeping the probe tip immersed
in the slowly moving/mixing region of the vessel (discussed
in Section III), measured mixing times were interpreted as
the bulk mixing times. The present approach therefore ensured
that by the time the monitoring point reached a degree of 95 pct
homogeneity, the bulk of the liquid was practically well mixed.
A set of at least five measurements was made for each exper-
imental condition and thereby an average mixing time was
determined. The variation in successive measurements was
found to be sensitive to gas flow rates as well as vessel size.
Maximum variation between successive measurements for the
largest vessel (D
0.60 m) was found to be around 15 pct.
III. RESULTS AND DISCUSSION
A. Adequacy of the Experimental Technique
Since the digital conductivity meter–probe assembly was
applied to measure mixing times in the gas-stirred water
model ladles for the first time and mixing was monitored
through manual recording of conductivity data (as opposed
to continuous measurements, typically used in such studies),
it was decided to assess the reliability of the present technique
prior to any detailed measurement of mixing times. To this
end, experiments were carried out in one of the vessels
(D
0.60 m) for a central/axisymmetric gas injection con-
figuration and 95 pct bulk mixing times were measured as
a function of gas flow rates (varying between 1.95 and 3.0
vations indicated that the recirculating fluid moves rather
104 m3/s) and vessel aspect ratio (in the range 0.8 to 1.2).
In Figure 4, measured 95 pct bulk mixing times for var-
ious operating conditions are compared directly with equiv-
alent estimates derived from a well-established empirical
correlation[5] (viz. mix,95 pct
25.4 Q0.33 L1.0 R2.33). There,
reasonable agreement between measurements and predictions
104 m3/s), keeping
METALLURGICAL AND MATERIALS TRANSACTIONS B
Fig. 4—Adequacy of the present experimental technique illustrating the
correspondence between measured mixing times (for an axisymmetric gas
injection configuration) and those estimated on the basis of an equivalent
correlation reported by Mazumdar and Guthrie.[5]
Table I. Ninety-Five Percent Mixing Times as Registered
by a Conductivity Probe Placed at Different Locations in the
Bath (D
0.60 m, L/D
1.0, and Q
2.83
Height of the
Probe Tip from the Average
Bottom of the Probe Mixing
Vessel (m) Location Times (s)
0.04 A 30
B 27
C 23
0.46 A 23
B 22
C 30
Nozzles/plugs are located in 0.53 A 19
this central vertical plane B 15
C 20
evidently indicates the reliability of the present approach.
It is important to mention here that the tracer addition as
well as the monitoring point locations in these experiments
(e.g., Figure 4) were essentially identical to those for which
the correlation[5] was originally developed.
B. Determination of the Monitoring Point Location
for Registering Bulk Mixing Times
The bulk mixing times (mixing times registered from a
probe located in the slowest moving region in the bath) rather
than local mixing times are a parameter of practical impor-
tance. However, none of the two previous studies[2,3] specif-
ically shed any light on the slowly moving/mixing region
in the dual-plug-stirred ladle system. Consequently, flow
visualization studies (through addition of KMnO4 solution
to the bath) were carried out to identify the regions that are
relatively slowly moving/mixing in the system. Visual obser-
slowly in the vicinity of the ladle bottom, and there, three
distinct pockets of slowly moving regions (e.g., marked by
“A”, “B”, and “C” in Table I) appear to exist.
To confirm this and hence to identify the slowest mixing
region in the vessel, mixing times were measured in the largest
vessel (D
0.60 m and Q
2.83
VOLUME 36B, AUGUST 2005—481
the probe immersed at nine different locations in the bath.
In all these experiments, the tracer was added through the
free surface immediately above the line of symmetry. It should
be mentioned here that this tracer addition location remained
invariant throughout the present investigation. In Table I a
summary of these measurements is presented. There, it is
evident that mixing is more rapid in regions close to the
free surface, whereas toward the base of the vessel, mixing
is relatively sluggish. Furthermore, Table I indicates that
the registered mixing time is the longest provided the probe’s
tip is collinear with the plugs and placed near the junction
of the vertical side wall and base of the vessel. The exact
dimensionless probe location in the study was r/R
0.89
and z/L
0.93. In all experiments, the conductivity probe
was therefore placed at location A, as shown in Table I.
104 m3/s is practically equivalent to 1/3,[1,6] it is
C. Variation of Mixing Times with Gas Flow Rates
A series of experiments were carried out in which 95 pct
bulk mixing times were measured in the largest vessel as a func-
tion of gas flow rates. Since mixing time vs gas flow rate rela-
tionships are known to be specific[5] to the operating flow
regimes, a rather wide range of gas flow rates was applied. In
Figure 5, a log-log plot between 95 pct bulk mixing times and
gas flow rates is presented. There, in the spirit of numerous pre-
vious studies, two distinct line segments have been fitted through
the experimental data points. These indicate that initially mix-
ing time decreases rather sharply (e.g., mix  Q0.58) with
increasing net gas flows, up to about 2
104 m3/s (or inertial and gravitational forces in gas-stirred-ladle systems are
12 L/min). Thereafter, the decrease in mixing times with gas
flow appears to be somewhat less pronounced (viz. mix  Q0.35).
A similar behavior between gas flow rates and mixing
times was also reported by many investigators for axisym-
metrical gas-stirred-ladle systems.[1] In such context, it has
been suggested[6] that a shift in such a relationship essen-
tially results from a change in the flow pattern within the
Fig. 5—Ninety-five percent bulk mixing times in a water model ladle (D

0.60) fitted with twin porous plugs at different gas flow rates.
482—VOLUME 36B, AUGUST 2005
system. Thus, Mazumdar and Guthrie[5] pointed out that in
axisymmetrical gas-stirred systems at low operating gas flow
rates, a relatively weak, secondary recirculation typically
exists at the bottom of the vessel adjacent to the vertical side
wall. This disappears beyond a critical gas flow rate leading
to the characteristic flow patterns of an axisymmetrical gas-
stirred ladle system (e.g., large recirculating vortices on either
side of the line of symmetry).[5] Tracer dispersion tests carried
out in the larger model ladle indicated that similar phenomena
are at work in the dual-plug-stirred system as well. Conse-
quently, the shift in mixing time vs gas flow rate relationship
beyond a flow rate of 12 L/min as depicted by Figure 5
appears to be the result of a changing hydrodynamic condition
within the system. Since the exponent on Q beyond 12 L/min
or 2
therefore reasonable to consider the flow phenomena beyond
this critical flow rate to be essentially dominated by the inertial
and gravitational forces, as discussed in Section III(D).
D. Development of a Correlation for Mixing Times
in Ladles Stirred with Dual Plugs/nozzles
Because the mixing time vs gas flow rates relationship in
the dual-plug-stirred system is shown to be specific to the oper-
ating flow regimes, it is unlikely that a single empirical cor-
relation could effectively describe mixing times in such systems
across the entire range of gas flow rates. Because industrial
ladles are massive and kinematic viscosity of steel is small,
likely to be relatively more important (in comparison to vis-
cous forces). Consequently, from the viewpoint of practical
relevance, it is desirable that a correlation of relevance to the
inertial-force-dominated flow regime be developed (m  0.007
W/kg, as in Figure 5). Toward this, as our first step, a num-
ber of experiments were carried out in the remaining two
vessels as a function of gas flow rates to identify the corre-
sponding critical gas flow rates, Qc. As mentioned already, a
set of at least five measurements were made for each experi-
mental condition from which an average mixing time was
determined and considered for subsequent analysis.
In the inertial- and gravitational-force-dominated flow
regime (viz. Froude dominated flows), the thermophysical
properties of the liquid (i.e., in the absence of any upper
buoyant phase) do not influence flow phenomena to any
appreciable extent. Consequently, a functional relationship
between mixing times mix and the key operating parameters,
namely, the gas flow rate, Q, the liquid depth, L, and the
radius of the vessel, R, can be expressed as[7]
tmix
f (Q, L, R, g) [2]
In terms of the relevant dimensionless groups, Eq. [1] can
be conveniently recast in the following form:
tmix2g L a Q2 b

C0 a b a 5 b [3]
R R gR
in which C0, a, and b are the three constants to be determined
through consideration of experimentally measured mixing
times and the corresponding operating parameters L, R, and
Q, respectively. Thus, on the basis of the experimentally
measured 95 pct bulk mixing time and the corresponding
operating parameters, the three dimensionless groups in
METALLURGICAL AND MATERIALS TRANSACTIONS B
 (a)
Fig. 6—A comparison between experimental 95 pct bulk mixing times in
three different water model ladles with those deduced on the basis of Eq. [5]
illustrating the adequacy of the proposed correlation.

Eq. [3] were estimated and a multiple regression analysis

carried out embodying the Polymath software.[8] On the basis
of the values of C0, a, and b thus derived, Eq. [3] can be
represented in the following explicit form:
tmix,95 pct2 g L 1.12 Q2 0.38

936 a b a 5b
R R gR
or, alternatively, in terms of the key operating variables, L,
R, and Q as
tmix,95 pct  15Q0.38L0.5R2.0
The value of the multiple regression correlation coefficient
for Eq. [4] was about 0.70 and the corresponding variance
was 0.009. The adequacy of Eq. [5] with respect to the exper-
imental data derived from the three different water model
ladles is illustrated in Figure 6. Included in the same figure
are also the upper/lower bound of uncertainty of the corre-
lation (or the fitted line) vis á vis the experimental data
points. These indicate that Eqs. [4] and [5] simulate mixing
times within 21 pct and 32 pct.
To investigate the extent of data scatter in Figure 6, a
detailed analysis was carried out and the derivation of the
correlation examined from a different standpoint embody-
ing experimental data derived from only one single vessel
(i.e., D
0.60 m). Thus, a large number of experiments
(over and above those considered in Figure, 6) were car-
ried out in the larger vessel for various gas flow rates and
liquid depths, and the results thus obtained are shown in
Figures 7(a) and (b). These appear to suggest that mixing
times in ladles fitted with dual plug/nozzle follow the rela-
tionships mix,95 pct  Q0.35 and mix,95 pct  L0.56, respec-
tively. On the basis of such, one may represent Eq. [3] as
tmix 2 g L 1.12 Q2 0.35

C0 a b a 5b
R R gR
[4]
[5]
(b)
Fig. 7—Experimentally measured mixing times in the dual-plug-stirred
ladle (D
0.60 m) as a function of (a) gas flow rates and (b) liquid depths.
Or, alternatively,
tmix,95 pct  C0Q0.35L0.56R1.93 [7]
0.35
To determine the pre-exponent C0, the parameter, Q
L0.56 R1.93, appearing on the right-hand side of Eq. [7] has
been plotted in Figure 8 as a function of 95 pct mixing time,
mix, and a straight line passing through the origin fitted
through the experimental data points. Evidently, C0
mix, 95 pct,
when Q0.34 L0.56 R1.93
1.0. The C0 was thereby found
to be
12.5 (m0.34 s0.66). The explicit form of Eq. [7] accord-
ingly becomes.
tmix,95 pct  12.5 Q0.34 L0.56 R1.93 [8]
It is at once apparent that Eq. [8] has a form practically iden-
tical to that of Eq. [5] and simulates experimental observa-
[6] tions within 7 pct. In addition to these, a limited number
of experiments were also carried out in the three vessels

METALLURGICAL AND MATERIALS TRANSACTIONS B VOLUME 36B, AUGUST 2005—483


Fig. 8—The variation of 95 pct bulk mixing times with the parameter Q0.34
L0.56 R1.93 for dual-plug gas bubbling (D
0.60 m).
Fig. 9—Regression equation and its adequacy to experimental mixing times
derived from three different water models fitted with dual porous plugs
located diametrically opposite at R/3 positions.
with tuyeres/nozzles located at the R/3 locations. The resul-
tant regression equation (correlation coefficient
0.60 and
variance
0.01) and its adequacy to experimental data is
illustrated in Figure 9. There, it is readily seen that the
correlation for R/3 location of the plugs also has a form
analogous to those of Eqs. [5] and [8], respectively. On the
basis of the evidence presented so far, it is therefore reason-
able to conclude that despite moderate scatter of experimental
data with respect to the fitted line (viz. Figure 6), the values
of the pre-exponent, C0, as well as the exponents a and b,
as suggested via Eq. [4], are plausible and physically realistic.
Given such, it is reasonable to assume that
(1) If experimental data on mixing times from different size
vessels are applied to derive an empirical equation
484—VOLUME 36B, AUGUST 2005
through regression, a correlation coefficient close to unity
is unlikely to result (viz. Figure 6).
(2) On the other hand, experimental data derived from a single
vessel and subjected to regression is likely to lead to a
significantly higher correlation coefficient (viz. Figure 8).
(3) In essence, however, the predictive capabilities of the
correlation derived from either a single or a set of vessels
are not likely to be markedly different, as mixing models
derived from these two approaches are shown to have
similar functional forms. Indeed, sample calculations
suggest that if estimates of mixing times are to be derived
via Eqs. [5] and [8] over a range of experimental con-
ditions (e.g., vessel aspect ratio and specific gas flow
rates similar to those considered in this work) embodying
a 220-kg water model through to a 220 T industrial
size ladle, these would tend to differ by a maximum of
about 38 pct or so.
With reference to the experimental data and regression
results presented so far, it should be noted that flow phe-
nomena in the gas-stirred ladle systems are inherently tran-
sient.[9,10] Thus, long-term and short-term wandering of the
bubble plume, continuous fluctuation of spout, etc. tend to
make the associated flow field transient and, accordingly,
to influence any measurements. The situation is aggravated
further when two gas bubblers, instead of one, are applied.
Of equal importance is the trajectory of the added tracer
(these influence mixing), which was found to be vastly dis-
similar in different size vessels. For example, in the bigger
vessel, the tracer (saturated solution of NaCl) added imme-
diately over the cenline penetrated to about one-quarter of
the bath depth to be entrained by the rising plumes. In con-
trast, in the smallest ladle (D
0.30 m), the tracer was
found to penetrate right up to the bottom of the vessel from
where it dispersed within the system. Furthermore, tracer
trajectories were not reproducible enough and were influ-
enced significantly due to the wandering of the bubble
plumes. These, as one would normally anticipate, are likely
to introduce some error in measurements and uncertainty
in the final conclusions. Given such, the extent of deviation
of the fitted line from the experimental data points can be
attributed to the inherent characteristics of gas-stirred ladle
systems and the experimental procedure. It is instructive to
note here that previous attempts[11] to unify experimental
data from a different group of investigators and different
vessel sizes via a single correlation was also shown to be
associated with pronounced data scatter, comparable to those
shown in Figure 6. In contrast, regression of experimental
data derived from a single vessel would typically produce
less scatter, having an uncertainty of the order of 20 pct
or less.[11]
Although mixing time correlations similar to Eq. [5] are
available for axisymmetrical bubble-stirred ladle systems, no
such correlation has yet been reported for ladles fitted with
dual plug/nozzle. Therefore, some comparison can at best be
made between reported correlation on the axisymmetrical gas-
stirred system and the present one. To this end, it is interest-
ing to note some similarity between the present correlation
and the one (viz. mix,95 pct  25.4Q0.33 L1.0 R2.33) developed
earlier by Mazumdar and Guthrie[7] for the axisymmetrical
gas-stirred ladle system (e.g., ladles fitted with a central
tuyere/nozzle). It is readily apparent that the values of the
METALLURGICAL AND MATERIALS TRANSACTIONS B
pre-exponent (25.4 vs 15) and the exponent on gas flow rate
(0.33 vs 0.38) in the previous and present correlation are
vary similar. Furthermore, a near 1/3 exponent on Q in
Eq. [5] appears to confirm that the operating flow regimes in
the dual-plug-stirred systems is dominated by the inertial
and gravitational forces. In contrast, the exponent on the depth
of liquid, L, in Eq. [5] is seen to be substantially smaller (by
about a factor of 2 or so). Clearly, the advantage afforded by
taller vessels during dual-plug bubbling seems to be some-
what limited, in comparison to an equivalent axisymmetrical
system, as is exemplified by a relatively smaller exponent
on the depth of liquid, L, in Eq. [5]. This is to be expected
since plume-plume and plume-wall interactions become more
intense with increasing liquid depth (note that the average
diameter of plume increases with increasing liquid depth in
the vessel).
E. A Comparison of the Present Work with the
Axisymmetrical Gas-Stirred Ladle System
A series of experiments were also carried out under con-
ditions identical to those in Figure 5 by injecting gas into the
system through a centrally fitted nozzle. In Figure 10, a com-
parison between 95 pct bulk mixing times for axisymmetrical
and dual-plug gas bubbling is shown for a wide range of gas
flow rates. There, mixing times in the axi-symmetrical system
are somewhat shorter for small gas flow rates than those of
the dual-plug gas injection configuration. However, as the gas
flow is increased, such differences tend to fade away, and
eventually mixing time in the dual-plug-stirred system becomes
shorter. It is instructive to note from Figure 10 that the gas
flow rate beyond which dual-plug bubbling ensures superior
bath mixing is nearly equivalent to the critical flow rate sug-
gested in Figure 5 (e.g., 12 L/min). As a consequence, it is
therefore reasonable to assume that the beneficial effects (to
the tune of 20 to 25 pct) of dual-plug gas bubbling on mixing
are limited to the inertial and gravitational force dominated
flow regime alone (m  0.007 W/kg)
To rationalize such observations, dye tracer (KMnO4) dis-
persion tests were carried out for the two different nozzle
configurations at various gas flow rates. It was observed that
in the dual-plug-stirred system at low operating gas flow, a
significant portion of the added tracer (added through the
surface over the line of symmetry) tends to get caught
between the two rising plumes. Furthermore, the transport
of the tracer to the probe tip gets delayed, owing to a rela-
tively small angular velocity prevalent in the system at such
flows. In contrast to this, at equivalent gas flows, the tracer
added over the eye of the plume in an axisymmetrical gas-
stirred bath is transported to the probe tip relatively easily
first via the strong radial surface flows and, subsequently,
via the downwardly moving fluid adjacent to the vertical
side walls. As a consequence of such, the registered bulk
mixing times in the axisymmetrical system particularly at
low gas flows can be expected to be relatively smaller. How-
ever, as the gas flow rate is increased, a strong three-dimen-
sional flow pattern (which is characteristically absent in
axisymmetrical gas-stirred systems) sets in the dual-plug-
stirred system, facilitating ready transport of the tracer to
the probe tip from all regions within the vessel. This latter
phenomenon appears to be responsible for the observed
shorter mixing times in the dual-plug-stirred system at
relatively high gas flow rates.
The correlation proposed in the present study, the experi-
mental data presented so far, together with many previous
studies reported in the literature[1] clearly indicate that dimen-
sions of the ladle (viz. L and R) together with the operating
gas flow rates exert considerable influence on mixing in
ladles. However, such explicit influence of the vessels’
dimensions on mixing has not been accounted for in the
empirical equation of Zhu et al.[3] mentioned earlier. Simi-
larly, while the present correlation indicates the beneficial
effects of the dual plug on mixing, particularly in the inertial-
force-dominated flow regime, the correlation of Zhu et al.
(viz. Eq. [1]) indicates quite the opposite. It is reiterated that
Eq. [1], in contrast to the results presented so far, suggests
that increasing the number of plugs for the same net gas
flow rate is not beneficial for exacerbating mixing in the
gas-stirred ladle system.
F. An Assessment of the Present Correlation and Its
Applicability to Tapered, Cylindrical Vessels
In addition to the arguments and analysis presented so far
in favor of the correlation developed in this study, it is also
important to demonstrate the internal consistency and ade-
quacy (Eq. [5]) from a purely theoretical standpoint. Thus,
applying Eq. [5] between the model and full scale system,
the ratio between the corresponding 95 pct bulk mixing times
can be expressed as
Qmod 0.38 Lmod 0.5 Rmod 2.0

a b a b a b
tmix,mod
[9]
tmix, f s Q f s L f s R f s
L mod Rmod
Incorporating

l together with the scaling
L f s Rf s
equation Qmod
2.5 Qf s in Eq. [9], it can be readily shown
that the ratio between 95 pct bulk mixing times in the model
ladle and the full scale system can be correlated explicitly
via the geometrical scale factor, , according to
tmix,mod
Fig. 10—Variation of mixing times with gas flow rate for two different  l0.5 [10]
gas injection configurations (i.e., axisymmetrical vs dual). tmix, f # s

METALLURGICAL AND MATERIALS TRANSACTIONS B VOLUME 36B, AUGUST 2005—485

This latter equation, as one would note here, can be readily
derived from the first principles considering geometrical and
dynamical similarities between the model and the full scale
systems.[12]
Finally, mixing times in a 140 T industrial ladle fitted with
dual plugs were also investigated experimentally via a
0.2
scale water model ladle. The operating parameters of the
model vis á vis those of the full-scale systems are summarized
in Table II. There, the operating gas flow rates in the model
ladle were estimated in accordance with the scaling rela-
cessing units tend to make direct experimental observations
difficult, if not impossible. Naturally therefore comprehensive
experimental investigations encompassing high-temperature
industrial data have been few and far between. Nonetheless,
limited evidence available in the literature[1,13] does appear
to suggest that results derived from appropriately scaled down
water model studies provide useful quantitative information
of the actual steelmaking operations. A detailed discussion
on the subject has been recently published in a review by
Mazumdar and Evans.[13] It is however sufficient to note that
tionship:[12] Qm
2.5 Qf s. Moreover, the industrial as well
as the model vessels, as reflected from Table II, are slightly
tapered, since tapered rather than perfectly cylindrical shapes
are more typical of industrial practice. Parallel to the exper-
imental measurements, equivalent estimates were also derived
in a straightforward fashion via Eq. [5] embodying a mean
vessel radius, Reff. Results thus obtained are shown in Table III.
There close agreement between experimental measurements
and prediction is readily evident. This further suggests that
Eq. [5] is equally effective in tapered, cylindrical-shaped
ladles. With reference to the experimental results presented
in Table III, it is important to mention here that the minimum
experimental mixing corresponding to Q
2.8
104 m3/s sent mixing time correlation and many others reported in the
and L
0.7 m appears to be the result of experimental error
or uncertainty, as mixing time has been shown to decrease
with increasing gas flow rates.
As a concluding point, visual opacity, relatively large size,
and high operating temperatures prevalent in liquid steel pro-
water modeling in conjunction with computational fluid
dynamics (CFD) is now routinely applied in industrial R&D
and academia alike to investigate, optimize, and design steel-
making processes. To this end, it should be emphasized here
that the correlation developed in this study (and in fact, prac-
tically all the mixing time correlation reported in the literature)
is truly applicable to an idealized, slag-free situation. This
seriously impairs the applicability of such correlations to
industrial ladles, since slag rather than no slag is more typ-
ical of industrial practice and the presence of slag is known
to considerably influence mixing in ladles. It is therefore
apparent that in order to increase the generality of the pre-
literature, the influence of the upper slag phase on mixing
must be realistically accounted for in such correlation. To
date, such a correlation has not been possible. Efforts are
currently ongoing in our laboratory to develop correlations
for fluid mixing in ladle covered with an upper slag phase.

Table II. Physical Dimensions of the Full Scale (140 T) and

Model (0.2 Scale) Ladle Systems IV. CONCLUSIONS

0.20 Scale Full Scale An experimental investigation on mixing phenomena in
Parameters Model System a ladles fitted with dual plugs has been carried out. From
Base diameter, m 0.52 2.68 the present study, the following conclusions can be drawn.
Top diameter, m 0.58 2.99
Tapering angle, deg 2.34 2.34 1. Mixing time depends on the gas flow rate and vessel size.
Liquid depth, m 0.62 3.20 For a given vessel geometry, mixing time depends on gas
Dimensionless porous plug 0.58* 0.50 flow rate according to mix  Q0.58 for low operating flow
location from the axis rates. However, beyond a critical gas flow rate (m

of the vessel 0.007 W/kg), the relationship changes to mix  Q0.35.
Gas flow rates, m3/s 1.3
104 8.05
103 2. Beyond the critical gas flow rate, an invariant flow pattern
(corrected to mean height to to in the system is established. The critical flow rate
and temperature of the liquid) 4.2
104 25.14
103 corresponds to the onset of the inertial-and gravitational
*The porous plugs located at the midbath radius position of a perfectly force-dominated flow regime.
cylindrical-shaped ladle corresponded to 0.58R position for the present mar- 3. In the inertial- and gravitational force-dominated flow
ginally tapered vessel. The effect of such small distortion was ignored.
regime, 95 pct bulk mixing times in ladles fitted with

Table III. Experimentally Measured 95 Percent Bulk Mixing Times for the Tapered Model Ladle (Table II)
and Their Comparison with Those Predicted from the Present Correlation (mix
15Q0.38L0.5Reff2.0)

Net Gas Flow Experimental 95 Pct Bulk

Rate (m3/s) Liquid Depth (m) Effective Radius (m) Mixing Time (s) Predicted Mixing Time (s)
Q L Reff mix [15Q0.38L0.5Reff2.0]
2.00
104 0.60 0.273 34.3 36.7
2.33
104 0.60 0.273 32.3 34.6
2.66
104 0.60 0.273 30.6 33
3.33
104 0.60 0.273 28.0 30
1.887
104 0.707 0.275 33.5 29.5
2.839
104 0.707 0.275 24.1 25
3.006
104 0.707 0.275 25.7 24.7
3.334
104 0.707 0.275 28.2 24

486—VOLUME 36B, AUGUST 2005 METALLURGICAL AND MATERIALS TRANSACTIONS B

 dual plug/nozzle (placed diametrically opposite at midbath m specific potential energy input rate, W/kg
radius positions) can be reasonably described in terms of  mixing time, s
the three key parameters, L, R, and Q (referenced to mean
height and temperature of the liquid), via mix,95 pct
Subscripts
15Q0.38L0.5R2.0 mod model
4. Mixing times in axisymmetrical gas-stirred systems at f s full scale
relatively high gas flows (m 0.007 W/kg or so) are mix mixing
somewhat longer than those in dual-plug-stirred systems.
The trend is, however, opposite for smaller operating flow REFERENCES
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pp. 1-20.
mixing times in tapered, cylindrical-shaped ladles with 2. S. Joo and R.I.L. Guthrie: Metall. Trans. B, 1992, vol. 21B, pp. 765-78.
equal effectiveness. 3. M. Zhu, T. Inomoto, I. Sawada, and T.C. Hsiao: Iron Steel Inst. Jpn.,
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2.5 Qf s can be used 5. D. Mazumdar and R.I.L. Guthrie: Metall. Trans. B, 1986, vol. 17B,
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 geometrical scale factor (Lmod/Lf s) pp. 447-61.

METALLURGICAL AND MATERIALS TRANSACTIONS B VOLUME 36B, AUGUST 2005—487