Numerical study of hybrid Euler–Euler multiphase modeling in bottom-purged industrial-scale steel ladle

In steelmaking, inert gas injection is widely employed during ladle refining to enhance mixing and promote chemical reactions. Argon is injected through the bottom of the ladle, inducing a turbulent recirculating flow that improves heat and mass transfer. This agitation promotes molten metal homogenization, inclusion removal via the slag layer, alloy mixing, and slag-metal reactions. In this study, a numerical model based on a Hybrid RANS/LES turbulence approach was developed to simulate gas–liquid flow in an industrial 185-ton steel ladle. Two injection configurations were analyzed: a central injector and one placed near the ladle wall. Model validation was carried out using experimental data from a 1:5.25 scale physical model, focusing on gas velocity magnitude and void fraction distributions. Additional results included the prediction of wall shear stress to support the assessment of flow-induced effects on refractory wear. Numerical results showed good agreement with experimental measurements, demonstrating the model’s capability to capture key flow features. The findings support the hybrid modeling strategy as a robust and computationally efficient tool for simulating multiphase flows in steelmaking, offering valuable insights into flow structures and operational impacts of gas stirring under realistic industrial conditions.