Turbulent Fluid Flow Phenomena in Metals Processing

Operations: Mathematical Description of the Fluid Flow

Field in a Bath Caused by an Impinging Gas Jet
JULIAN SZEKELY AND SHIGEO ASAI

A mathematical representation is developed for describing the flow field in liquids or melts,
agitated by a symmetrically placed impinging gas jet. The problem is formulated by the
statement of the a x i - s y m m e t r i c a l turbulent fluid flow equations using the Prandtl-Komogorov
model for the eddy viscosity. The resultant differential equations are solved numerically
and the computed results are shown to be in reasonable agreement with experimental data
reported in the literature. This problem is thought to be relevant to various metals refining
operations and the results should also be helpful for the interpretation of laboratory scale
studies in which molten metals are contacted with impinging gas jets.

T H E R E are many metals processing operations in a major component of the complete solution. It is noted,
which agitated metal baths are contacted with gas furthermore, that reacting systems involving melts and
s t r e a m s , or moving metal s t r e a m s are being pro- impinging jets are being used in a number of laboratory
cessed in a turbulent regime. Oxygen steelmaking, scale kinetic studies;a-9 the representation to be devel-
vacuum degassing and argon-agitated ladles are good oped here should be helpful in aiding the interpretation
examples for the first group, whereas continuous c a s t - of these investigations.
ing would be a representative of the second group of
these problems. I. STATEMENT OF THE PROBLEM
A quantitative description of the turbulent velocity
field in these systems would be v e r y helpful both in Let us consider a liquid (metal) contained in a cy-
providing a better understanding of these p r o c e s s e s lindrical bath, which is agitated by a symmetrically
and in the development of improved technologies. placed impinging gas jet, such as sketched in Fig. 1.
While turbulent flow phenomena received a great Ideally, our objective would be to calculate the ve-
deal of attention during the past five decades, the ac- locity field within the liquid for a known cavity shape
tual quantitative computation of the more complex r e - and known values of the vortlcity (or velocity) at the
circulating type flow fields has only become possible surface of the cavity. However, in the present in-
largely through the pioneering efforts of Spalding and
his co-workers, z whose p r i m a r y aim has been to de-
velop design equations for furnace calculations. r,~
The work to be described in this paper represents
part of an ongoing p r o g r a m aimed at the adaptation of
turbulent flow theory and the previously mentioned
computational techniques to problems in process met-
allurgy. In a previous paper, 2 modeling equations were
developed for the representation of the fluid flow field
in the mold region of a continuous casting machine. /
The present paper is concerned with the modeling of
! \
the flow field in liquid (metal) systems as caused by I
an impinging gas jet. /
/
The principal practical motivation for the work is
i
the relevance of this problem to many metals refining
operations where molten metals are made to r e a c t
with impinging gas jets, such as oxygen steelmaking
and top blown copper converting. It is realized that
in these practical systems the flow field in the melt
is further complicated by gas evolution; it is thought,
nonetheless that the information to be obtained from
the computation should be helpful in providing at least

JULIAN SZEKELY is Professor of Chemical Engineering and I / / / / / / / / / / / / /,/,/ /,/ / / / // /,

Director, Center for Process Metallurgy, State University of New York R
at Buffalo, Buffalo, N.Y. 14214. SHIGEO ASAI, Postdoctoral Fellow
at the Center for Process Metallurgy, is on leave from the Department
of Iron and Steel Engineering, Nagoya University, Japan. Fig. 1--A sketch of a metal bath s t i r r e d by an impinging gas
Manuscript submitted July 13, 1973. jet.

METALLURGICAL TRANSACTIONS VOLUME 5,FEBRUARY 1974-463

stance there was insufficient fundamental information The two length scales, kp and ~td, appearing in Eqs.
for estimating the vorticity so this quantity was treated [6] and [9] were defined as:
as an adjustable p a r a m e t e r , assumed to be uniform
over the surface of the cavity. ~ -- d[1 - e x p ( - A ~ Re~)] [10]
Let r and z denote the radial and the axial coordi- ~d = d [1 - exp (-Ad Ret)] [11]
nates and let the corresponding velocity components
be designated by v r and v z , respectively. where, Re t the turbulent Reynolds number is given as:
Ret = d p k l/a/~ [12]
1.1 Governing Equations It is noted that the relationships used here for evalu-
The problem may be stated by expressing the e q u a - ating the turbulent viscosity followed a procedure out-
tions of continuity, motion, and turbulent energy. lined by Wolfshtein, ~ who proposed the two length
For the purpose of computation these equations are scales appearing In Eqs. [10] and [11]. Here •u is the
more conveniently written in t e r m s of the v o r t i c i t y , 4, length scale relating to viscosity, whereas Ad is the
and the s t r e a m f u n c t i o n , r defined as: characteristic length scale in the dissipation term. In
the original Wolfshteln p a p e r " these quantities were
0vr ~vz used for the description of one-dimensional flows; in
o~ or [1] the present case their use is extended to the r e p r e s e n -
and tation of two-dimensional recirculating flow systems,
because no suitable expression exists in the literature
Vr _ 1 O~ Vz : ~ 0_.r162 [2-3] for the system considered here.
pr Oz ' pr Or In the computation of Xp and )td the quantity d was
The v o r t i c i t y t r a n s p o r t equation, obtained from the r taken as one tenth of the grid space; it is apparent from
and z components of the e q u a t i o n o f m o t i o n is written inspection of Eqs. [6] and [10-11] that the numerical
as: value of d plays an important role In determining the
value of Pt and thus the actual flow pattern. The pro-
cedure for calculating d, used in the present case, was
so chosen as to provide an agreement between the ex-
perimentally measured and the computed location of
the vortex.
- 0--r- ~ /~e = 0 [4]
It may be remarked here that in a v e r y recent pub-
where ge is the sum of the molecular and the turbulent lication, r~ Launder and Spalding suggested an alterna-
contributions, i . e . , ge = t~ + ~ t . tive scheme for computing $~t which would require the
The required relationship between the stream func- solution of an additional independent differential equa-
tion and the vorticity may be obtained by combining tion for )tg. This more involved procedure will not be
Eqs. [1-3] and thus we have: used in this work, although it is felt that attention should
be drawn to this potentially attractive alternative.
-~- ~- +-~ --~ + ~ : o [51
1.2 Boundary Conditions
The turbulent viscosity, /~t, which is a component of
In a physical sense the boundary conditions have to
the effective viscosity /~e appearing in Eq. [4] was
computed by using an expression proposed by Kol- express the following constraints:
mogorov t~ and Prandtl n I) The turbulent energy is zero at all the solid s u r -
faces, furthermore, the gradient of turbulent energy
~t c~'/~x~
: [6] must also be zero at the axis of s y m m e t r y and at the
free surfaces.
where
2) The stream function is zero at all the bounding
Cp is a constant surfaces and also at the axis of symmetry.
~t~ is the length scale of the viscosity 3) The vorticity is zero at the free surface; the value
k is the turbulent energy of the vortlcity at the axis of s y m m e t r y and at the solid
Here k is evaluated by solving the turbulent energy surfaces may be deduced from a relationship proposed
balance equation: by Gosman. t
4) The conditions at the surface of the cavity may be
represented using a relationship proposed by Launder
and Spalding ~ between shear s t r e s s and vortictty.
The mathematical form of these boundary conditions
gt Ok is given in the following:

z =0, r c < r < R ; r = 0 , ~ = 0 , Ok/az = 0 [13]

where ~2 is the rate of generation of turbulent kinetic
energy defined as: r =0, h < z <H; $ = O, ~ = O, Ok~Or = 0 [14]
e = 2Pt{(Ovz/Oz) 2 + ( a v r / B r ) z + r :R, 0 < z < H; • = O, ~ : (~)p- r
[st / ( p ( R / 3 + (5/24)Nnp)) - (R + Y n p ) ( R / 6 + N n p / 8 )
N is the dissipation of turbulent energy given as: /R/(R/3 + 5/24Nnp) ~ np, k = 0 [15]
Y = C d pka/2/~ d [9] z =H, 0 < r <R: r =0, ~ : 3 ( r Cnp)/(rpNnZp)

464-VOLUME 5, F E B R U A R Y [974 METALLURGICAL TRANSACTIONS

 -0.5~np, k =0
z = - ( h / r c ) r + h: ~ =0, ~=~c, k -
CeP
1.3 The Method of Solution
The governing equations, viz. Eqs. [4], [5], and [7]
were solved n u m e r i c a l l y using a p r o c e d u r e r e c o m -
mended by Gosman et al. z and f u r t h e r d e s c r i b e d by
Yadoya. z~ The finite difference r e p r e s e n t a t i o n involved
the use of a 16 • 21 g r i d and the actual computation was
p e r f o r m e d on the CDC 6400 digital computer of the
State University of New York at Buffalo. The c o m p i l a -
tion of the p r o g r a m , written in F o r t r a n IV, r e q u i r e d
about 7 s; a typical run r e q u i r e d about 200 s of c o m -
p u t e r time.
The computation involved an t t e r a t i v e p r o c e d u r e and
h e r e the following convergence c r i t e r i o n was employed:
[t6] e n e r g y for the s a m e s y s t e m . It is noted that for the
s y s t e m considered, the turbulent e n e r g y a p p e a r s to
be quite s m a l l , a p a r t f r o m regions in the vicinity of
the cavity and the f r e e surface. Apart from these r e -
gions turbulent mixing was not thought to be signifi-
cant and the actual flow field could have been r e g a r d e d
as l a m i n a r .
This behavior is consistent with the e x p e r i m e n t a l
findings of Wakeltn that the m a s s t r a n s f e r p r o c e s s in
this s y s t e m could be r e p r e s e n t e d in t e r m s of a s u r -
face renewal type model, b a s e d on the r a d i a l v e l o c i -
ties on the f r e e s u r f a c e - - i n the absence of turbulent
t r a n s p o r t between the bulk and the f r e e s u r f a c e . The
o b s e r v a t i o n s show that impinging gas j e t s would be a
r
it
zl

;; < o.o18 [ 81

which provided r e a s o n a b l e computational a c c u r a c y .

IL COMPUTED RESULTS
The n u m e r i c a l v a l u e s for the p a r a m e t e r s used in
the computation a r e l i s t e d in Table I; t h e s e were so
s e l e c t e d as to allow a d i r e c t c o m p a r i s o n with the / / / / / / / / , / / / / ///+" / / / / / +" / / / /" / / +. / / / ' / / / / / / / / / . 2

w a t e r model t e s t done by Wakelln. ~ Fig. 2--The computed streamline pattern.

A t y p i c a l set of the computed r e s u l t s is p r e s e n t e d
in F i g s . 2, 3, 5, and 6. F i g s . 2 and 3 show the c o m -
puted s t r e a m l i n e p a t t e r n and the v e l o c i t y p r o f i l e s . It F

is of i n t e r e s t to c o m p a r e t h e s e computed r e s u l t s with
e x p e r i m e n t a l m e a s u r e m e n t s r e p o r t e d b y Wakelin ~ on
.z~la 15 ii 8,7 6.8 5.7 5.3 5,3 4.3
the CO~-water s y s t e m s and shown in Fig. 4. The r e a -
4.7 kZ.U p.s /2.4 /a.7 .~'5., ~ 6.J ~.o
s o n a b l y good q u a n t i t a t i v e a g r e e m e n t b e t w e e n m e a s u r e -
m e a t s and p r e d i c t i o n is r e a d i l y a p p a r e n t and should
t,., /,., .o.,, i,.o
p r o v i d e s o m e confidence in the computed r e s u l t s . I
In c o m p a r i n g F i g s . 3 and 4 it is of i n t e r e s t to note t2., '~z.=~ kz.~ '~z.+ \z.r \a.o \s.~ \z., z.__a /43
that in both c a s e s fluid was e n t r a i n e d f r o m the bulk I
t a. 3 ~ u.s ~l.e \Z.Z NZ.S \a.a ~33.S 3.9 4.2 .6
into a flat moving_ s u r f a c e l a y e r and a v o r t e x was ! o.s 9,.o /
f o r m e d by fluid r e t u r n i n g to the c e n t e r of the tank d.~ j.r .~.a ~.r &, ...2.5 ~.5 a.,
after deflection at the wall; f u r t h e r m o r e a c o n e - s h a p e d o.a o.~ p.~ ,., ~.,~ &o :z..._~ 2.4 2.1 I.I
s t a g n a n t a r e a e x i s t e d at the bottom of the bath b e n e a t h I

the cavity. I0.0~ o., 0.~ o.~ 0., ,., ,.~ 1,2 0.8 C, II

Fig. 5 shows the computed p r o f i l e s of the v o r t i c i t y ~'N-~\\x\ x \ \ \xxx\ \ \ \ \ xxxx x xx xxxxxxxxxxxxxxxx,x \xxx xxx\ x\ \x,

for the s a m e s y s t e m . Fig. 3--The computed velocity profiles (cm/s).

Fig. 6 shows the computed p r o f i l e s of the t u r b u l e n t

Table I. Numerical Values of Parameters Used in the C o m p u t a t i o n //'•--=25• -.=Io~ --lr~ ~0-" -8"-*"
~ ~ 8 ~ , r - = 4 :.~ ~C~._T"
-5.5... - ~ ' . 4 : ""
-5...,7 -,~,
~0
z(cm)
R: 37 (cm) ">'-' "; 2 1-2 1.3 1 f .4, -
H: 29 (cm) I \22" k \ \- ,i5 2~5 2.9 ./-3-.,.. ~ -5
> 3"2 ~ ]'. " ,%
h: 2.6 (cm) .'8 ~ 1"8 2 "~
rc: 3.7 (cm)
~c: - 2 5 (l/s)
Ad: 0.263(Ref. 12)
Ap: 0.016(Ref. 12) 1"8 N 2'4. 3'~ ~3"5 1 .4/4
Cd: 0.416(Ref. 12)
Cu: 0.220(Ref. 12)
.+2- \
1 -( ~2'3 3.1~ ""3-5- "=" .,,/J
Prt: 1.53(Ref. 12)
,, f a -- ~ "-2"5-" -- r " ~ " ( " " - "
Ce: 0.08 (Ref. 13)
p: 1(g/eraa) 0 10 20 30 r (cm)
,u: 0.0133(g/cm.s) Fig. 4--The experimental measurements of the velocity d i s L
tribution reported by Wakelin on the CO2-water systems.

METALLURGICALTRANSACTIONS VOLUME 5, FEBRUARY 1974-465

 r

zl "
_~5//~ o ~/;/
6 water

molten steel

5 mercury

/ \
//f--, '
4
,/
!

Fig. 5--The computed profiles of the vortieity.

O
r

Z ~"

0.7 I~lO" Ixlo"~ ~ I•

vo 2
'l

IxlO"7 IxlO" Ix I ,I

//////////////////// 0 -,//////////../////////////

Fig. 6--The computed profiles of the turbulent energy (em2/s2). -I

r a t h e r p o o r m e a n s for a g i t a t i n g liquid p o o l s . It is -2
noted that the p r o p e r t y v a l u e s u s e d in the c o m p u t a -
tion c o r r e s p o n d e d to t h o s e of an aqueous s y s t e m b e -
c a u s e this a l l o w e d a d i r e c t c o m p a r i s o n b e t w e e n p r e -
d i c t i o n s and p r e v i o u s l y r e p o r t e d m e a s u r e m e n t s . -5 I I I I I I
C l e a r l y , s i m i l a r c a l c u l a t i o n s could be r e a d i l y p e r - 0 .2 .4 .6 .8 1.0
f o r m e d f o r s y s t e m s involving m o l t e n m e t a l s .
r/R
F i g s . 7 and 8 show the c o m p u t e d r a d i a l and a x i a l
Fig. 7--The computed radial velocity profiles at a depth of 2.7
v e l o c i t y p r o f i l e s at a depth of 2.7 cm f o r m o l t e n s t e e l cm for water, molten steel and mercury.
and m e r c u r y ; the c o r r e s p o n d i n g p r o f i l e s for w a t e r a r e
a l s o shown, f o r the p u r p o s e of c o m p a r i s o n . The g e -
III. CONCLUDING REMARKS
o m e t r y of the v e s s e l and of the c a v i t y c o n s i d e r e d in
the c o m p u t a t i o n of F i g s . 7 and 8 was the s a m e a s that A mathematical representation has been developed
c o n s i d e r e d in the d e v e l o p m e n t of the p r e v i o u s l y given f o r d e s c r i b i n g the flow f i e l d in l i q u i d s o r m e l t s , a g i -
F i g s . 2, 3, 5, and 6. The v o r t i c i t y at the w a l l s of the tated by a symmetrically placed impinging gas jet.
c a v i t y w e r e a g a i n c o n s i d e r e d to be the s a m e and the This p r o b l e m is of pra~,tical r e l e v a n c e to a n u m b e r
only d i f f e r e n c e was p r o v i d e d by the d i f f e r e n t p r o p e r t y of m e t a l s r e f i n i n g opera,~ions, including oxygen s t e e l -
v a l u e s of the f l u i d s , v i z : ~ F e = 0.05 g / c m s; P F e = 7.0 m a k i n g and t o p - b l o w n c o p ? e r c o n v e r t i n g , although
g / c m 3 ; ~Hg = 0.015 g / c m S, and Prig = 13.6 g / c m ~. It t h e s e " r e a l s y s t e m s " a r e n : g r e c o m p l e x b e c a u s e of
is noted t h a t the v e l o c i t y p r o f i l e s s e e n in F i g s . 7 and g a s evolution in the b a t h - - w h l c h w a s not r e p r o d u c e d
8 a r e v e r y s i m i l a r and that t h e r e is only a r e l a t i v e l y here.
s m a l l d i f f e r e n c e even in the a b s o l u t e v a l u e s of the The p r o b l e m was f o r m u l a t e d b y the s t a t e m e n t of
v e l o c i t y . It m u s t be s t r e s s e d , h o w e v e r , that the a s - the t u r b u l e n t fluid flow equations and the P r a n d t l -
s u m p t i o n of identical v o r t i c i t i e s at the s u r f a c e of the K o l m o g o r o v m o d e l was used f o r c a l c u l a t i n g the t u r -
c a v i t y i m p l i e s much g r e a t e r m o m e n t u m t r a n s p o r t bulent viscosity.
f r o m the gas to the liquid f o r the c a s e of the liquid The c o m p u t a t i o n was p e r f o r m e d u s i n g a t e c h n i q u e
m e t a l s . It follows that a much h i g h e r j e t m o m e n t u m p r o p o s e d b y G o s m a n and c o - w o r k e r s 1 and the c o m -
would b e r e q u i r e d to m a i n t a i n the s a m e c i r c u l a t i o n puted r e s u l t s w e r e shown to b e in r e a s o n a b l e a g r e e -
r a t e s and c a v i t y g e o m e t r i e s in liquid m e t a l s than the m e n t with e x p e r i m e n t a l m e a s u r e m e n t s r e p o r t e d b y
corresponding values for water. Wakelin. 3

466 VOLUME 5, FEBRUARY 1974 METALLURGICAL TRANSACTIONS

 5 an a d j u s t a b l e p a r a m e t e r . Thus the r e s u l t s p r e s e n t e d
m a y be helpful f o r I n t e r p r e t i n g e x p e r i m e n t a l m e a s u r e -
m e n t s in c o u r s e of which m e t a l s a r e r e a c t e d with i m -
pinging g as s t r e a m s and that the t ech n i q u e outlined
4 w0ter
h e r e would r e p r e s e n t a c o m p o n e n t f o r the u l t i m a t e
m o d e l i n g of the B a s i c Oxygen F u r n a c e .
. . . . molten steel

~ - ~ mercury ACKNOWLEDGMENTS
The a u t h o r s wish to thank the A. E. A n d e r s o n F ounda -
tion f o r p a r t i a l s u p p o r t of this i n v e s t i g a t i o n .

NOMENCLATURE
0
A#, Ad, Cd, C e , Cl~ c o e f f i c i e n t (-)
E d d i s t a n c e p a r a m e t e r (cm)
0 H depth of bath (cm)
h depth of c a v i t y (cm)
k t u r b u l e n t k i n e t i c e n e r g y (cm2/s 2)
0 y.p g r i d s p a c e b e t w e e n the n e a r e s t g r i d point to
wall and wall (cm)
Pr t t u r b u l e n t P r a n d t l n u m b e r (-)
r horizontal co-ordinate
-I r a d i u s in c a v i t y (cm)
re
R r a d i u s in the v e s s e l
Ret t u r b u l e n t Reynolds n u m b e r (-)
vr v e l o c i t y of r - d i r e c t i o n ( c m / s )
-2 v e l o c i t y of z - d i r e c t i o n ( c m / s )
vz
xj the v a l u e s of the dependent v a r i a b l e at
point j
vertical co-ordinate
-5

Greek letters
-41 I I I I X#, ~d length s c a l e (cm)
0 .2 .4 .6 .8 1.0 ~t m o l e c u l a r v i s c o s i t y ( g / c m s)
#e e f f e c t i v e v i s c o s i t y ( g / c m s)
r/R t u r b u l e n t v i s c o s i t y ( g / c m s)
~t
Fig. 8--The computed axial velocity profiles at a depth of 2.7 vorttcity (I/s)
cm for water, molten steel and mercury. ~c v o r t i c t t y at c a v i t y ( I / s )
P d e n s i t y ( g / e r a 3)
s t r e a m function ( g / s )
The c o m p u t e d r e s u l t s i n d i c a t e that t h e t u r b u l e n t
e n e r g y of the s y s t e m was r e l a t i v e l y low in the bulk
of the liquid which a p p e a r s to be c o n s i s t e n t with m a s s Suffixes
t r a n s f e r r e s u l t s r e p o r t e d by Wakeltn f o r the COz- p wall point
w a t e r and the O ~ - s i l v e r s y s t e m s . np the n e a r e s t g r i d point to wall
It is to be noted that the a g r e e m e n t b e t w e e n p r e d i c -
t i o n s and m e a s u r e m e n t s was obtained by a s s u m i n g
that the shape of the c a v i t y was known and by t r e a t i n g REFERENCES
the v o r t t c l t y as a s p a t i a l l y u n i f o r m , a d j u s t a b l e p a r a m - 1. A. D. Gosman,W.M'.Pun, A- K. Runchal,D. B. Spalding,and M. Wolfshtein:
e t e r o v e r the c a v i t y s u r f a c e . Heat and Mass Transfer in Reeirculating Flows, AcademicPress, London and
NewYork, 1969.
F u r t h e r work would be highly d e s i r a b l e , with a v i e w 2. J. Szekelyand R. T. Yadoya: Met. Trans., 1973,vol. 4, p. 1379.
of d e v e l o p i n g Independent r e l a t i o n s h i p s b e t w e e n the 3. D. H. Wakelin:Ph.D. Thesis, Universityof London, England, 1966.
m o m e n t u m of the I m p in g i n g gas jet, the shape of the 4. Y. Kawaiand K. Mori: Tetsu-to-Hagane. 197(1,vol. 56, p. 695.
c a v i t y , and the s p a t i a l d i s t r i b u t i o n of the v o r t i c i t y on 5. Y. Niiri,K. Ito, and K. Sano: Tetsu-to-Hagane, 1969,vol. 55, p. 437.
the c a v i t y s u r f a c e . Some w o r k has b e e n done on r e - 6. L. F. Bamhardt: Ph.D. Thesis, MIT,Cambridge,Mass., 1965.
7. M. lnouyeand T. Choh: Trans. Iron Steellnst. Jap., 1968, vol.8, p. 134.
lating the shape of the c a v i t y to the j e t m o m e n t u m , a
8. S. Ban-ya,T. Shinohora, H. Tozaki,and T. Fuwa: Proceedingsof International
r e v i e w of which is a v a i l a b l e tn Ref. 3; h o w e v e r , the Conferenceon the Scienceand Technologyof Iron and Steel,Section,3, p.
d e v e l o p m e n t of the d e s i r e d r e l a t i o n s h i p b e t w e e n j et 539, 1970.
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e l s within the bath f r o m s u r f a c e v e l o c i t y m e a s u r e - AcademicPress, London and New York, 1972.
m e n t s by t r e a t i n g tl~e v o r t i c i t y at the c a v i t y w al l s as 14. R. T. Yadoya: Ph.D. Thesis,State Univ.of N.Y. at Buffalo, 1972.

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