Numerical Simulation of the Separation and Removal of Inclusion Cluster at the Steel–Slag Interface

Nonmetallic inclusions in steel directly affect the cleanliness of molten steel. The separation of inclusions at the steel–slag interface, as the final step of inclusion removal, plays a critical role in determining overall removal efficiency. Therefore, it is essential to investigate the separation behavior of inclusions at the steel–slag interface and the factors influencing their removal for producing high–quality steel. In this article, numerical simulations of the separation process of the inclusion cluster at the steel–slag interface are conducted by using the volume of fluid (VOF), six degrees of freedom (6‐DOF) model, dynamic mesh, and overset mesh. The effects of various physical parameters on the separation behavior of the inclusion cluster in the molten steel–inclusion cluster–slag system are systematically studied. The results show that the inclusion cluster exhibits three distinct motion behaviors at the interface: complete transfer to the slag phase, oscillation between molten steel and slag, and stable retention at the interface. By comparing the displacement and velocity of the inclusion cluster under different parameter conditions during the separation process, the sensitivity of these parameters on inclusion cluster removal is ranked as follows: contact angle > interfacial tension > slag viscosity > inclusion cluster density.