Numerical and Physical Simulation of Flux Entrainment Mechanism in Mechanical Stirring Processes

The entrainment mechanism of flux layer into a melt bath during its mechanical stirring was clarified in this study through numerical simulation with an aid of physical model experimentation using silicone oil and water. A three-phase multiphase flow was solved by three-phase Volume of Fluid method combining with Large Eddy Simulation model. The numerical results indicated that the entrainment of oil layer into water proceeds according to the following four steps: 1-flow development due to impeller rotation, 2-formation of low-level zone (LLZ), 3-formation of spiral deflection and 4-entrainment of oil droplet. The spiral deflections are formed due to the shear flow near the water-oil interface, and the entrainment of oil layer occurs at the deflected spots in the LLZ. Graphical Abstract