Numerical Study on Droplet Splashing Behavior of Slag‐Splashing for Converter Protection Using Volume of Fluid‐Discrete Phase Model Two‐Way Conversion Model

Limited quantitative research exists on the complex phenomenon of slag splashing in converters. A comprehensive modeling framework is developed to fill this gap, integrating a 3D two‐phase flow model with a volume of fluid‐discrete phase model two‐way conversion model. This framework explores droplet behavior during splashing for converter protection, encompassing the mutual conversion between slag and discrete droplets induced by top‐blowing oxygen. It also tracks the trajectories of all droplets, enabling a detailed quantitative analysis of the splashing process. The Eulerian wall film model is used to simulate liquid film formation on the converter wall. Model predictions are validated against 1:10 scale experimental data from a 50 t converter. This assessment covers splashing rates, droplet locations, and size distribution under various operating conditions. Parametric studies identified an optimal top‐blowing flow rate of 8.80 Nm 3 h −1 and an oxygen lance height of 233.2 mm, balancing splashing effectiveness with production cost and safety.