The elimination of inclusions in steelmaking processes has been widely studied. The removal of inclusions by slags containing the rare earth oxide Ce₂O₃ are studied using an integrated numerical model. The integrated model involves the inclusion motion model, interfacial tension calculation model, surface tension calculation model of slag, and the mass action concentration model, based on ion and molecule coexistence theory. The motion behaviors of both solid Al₂O₃ inclusions and 50%wtAl₂O₃–50%wtCaO liquid inclusions of varied sizes at CaO-Ce₂O₃-SiO₂-Al₂O₃(-MgO) slag systems are evaluated. The results show that it is more difficult to remove the inclusions with smaller sizes and in slag with a higher viscosity. Liquid inclusions are more difficult to remove than solid inclusions. It is found that the CaO-Ce₂O₃-SiO₂-Al₂O₃-MgO refining slag shows a better ability to remove Al₂O₃ inclusions than that of the CaO-SiO₂-Al₂O₃-MgO slag. The reason for this is that the addition of the rare earth oxide Ce₂O₃ can decrease the viscosity of slags, as well as improving the wetting effects of slags on Al₂O₃ inclusions. For two slags systems, the CaO-Ce₂O₃-SiO₂-Al₂O₃-MgO slag system shows a better ability to remove Al₂O₃ inclusions than the CaO-Ce₂O₃-SiO₂-Al₂O₃ slag system. The addition of 5% to 8% Ce₂O₃ in a CaO-SiO₂-Al₂O₃-MgO slag is an optimized case for industrial applications.

The improvement in mixing conditions in a vacuum refining unit plays an important role in enhancing the purity and decarburization of molten steel. Mixing time is an important index to evaluate the operation efficiency of a metallurgical reactor. However, in water models, the effect of salt tracer dosages on the measured mixing time in a vacuum reactor is not clear. In this study, a water model of a Single Snorkel Refining Furnace (SSRF) was established to study the effect of salt solution tracer dosages on the mixing time of monitor points. The experimental results show that, in some areas at the top of the ladle, the mixing time decreases first and then increases when increasing the tracer dosage. Numerical simulation results show that, when the tracer dosage increases, the tracer flows downwards at a higher pace from the vacuum chamber to the bottom of the ladle. This may compensate for the injection time interval of large dosage cases. However, the mass fraction of the KCl tracer at the right side of the bottom is the highest, which indicates that there may be a dead zone. For the dimensionless concentration time curves and a 99% mixing time, at the top of the vacuum chamber, the curve shifts to the right side and the mixing time decreases gradually with the increase in tracer dosage. At the bottom of the ladle, with the increase in tracer dosage, the peak value of the dimensionless concentration time curve is increased slightly. The mixing time of the bottom of the ladle decreases significantly with the increase in tracer dosage. However, in the dead zone, the mixing time will increase when the tracer dosage is large. At the top of the ladle, the effect of the tracer dosage is not obvious. The mixing time of the top of the ladle decreases first and then increases when increasing the tracer dosage. In addition, the mixing time of the top of the ladle is the shortest, which means that sampling at the top of the ladle in industrial production cannot represent the entire mixing state in the ladle.

The flow field, tracer dispersion and uniformity of strands in two designs of four-strand tun-dishes under normal conditions and single-strand blockage conditions are studied by numerical simulation. The casting speed (flow rate) of strands are increasing uniformly or non-uniformly to improve the strand blockage condition. The uniformity of strands of the cases are evaluated by a novel outflow percentage analysis method. The results show that the flow field in the tundish does not change significantly when the single-strand is blocked or the casting flow rate is increased. After blockage of one strand, the consistency of each strand of u-shaped weir tundish is better than that of double-weir tundish. With the uniform increasing of the casting flow rate, the response time of each strand decreases and the outflow percentage increases. However, the uniformity of strands improved slightly in double-weir tundish but decreased in u-shaped tundish. For the double-weir tundish, significantly increasing the casting flow rate of the strand located in the blocked part by a factor of 1.5 and slightly increasing the casting flow rate of the other strands by a factor of 1.25, the consistency of each strand is the best. For the u-shaped weir tundish, the consistency of each strand is improved by non-uniform increasing of the casting flow rate of the strands. The flow rate of the strand located in the blocked part and the other strands is increased by a factor of 1.25, and 1.375 or 1.2 and 1.4 are the optimized cases.