In secondary steelmaking, the optimal size and position of open‐eye is important for effective alloying practice. In the current work, the effect of the top layer thickness and density on the formation of open‐eye in a gas stirred ladle was investigated. A one‐fifth scale water model of 150‐ton ladle was established with single and dual plug configurations for the physical modeling measurements. Air, water and three different oils were used to simulate the argon, liquid steel and slag in the water model, respectively. A transient Computational Fluid Dynamics (CFD) model based on Eulerian Volume of Fluid (VOF) approach was developed for numerical modeling of the fluid flow behavior. The physical modeling results show that the relative open‐eye area decreases from 46.7 to 5.6% when top layer thickness was increased from 0.75 to 7.5 cm using a gas flow rate of 7.5 NL min⁻¹. The effect of the number of plugs on the open‐eye area for the same range of top layer thickness mentioned above was also studied. The relative open‐eye area generated due to the gas injection through the dual plugs decreased from 49.9 to 5.8%. To study the effect of top layer properties, rapeseed oil, castor oil and paraffin oil were employed for studying the effect of density and dynamic viscosity on the open‐eye formation. The results revealed that a larger open‐eye is formed when the density is increased. Furthermore, it was found out that the density of the upper phase dominates the open‐eye formation while dynamic viscosity has only minor effect. The results obtained from numerical simulations and physical modeling were found to be in good agreement.

A high titania slag that is used as a feedstock for TiO₂ manufacturing is obtained by ilmenite smelting (FeO.TiO₂). The composition of the slag obtained by smelting is dependent on the composition of the mineral used for slag preparation, i.e., ilmenite in our study. At the laboratory scale, ilmenite slags are mostly obtained by using ilmenite as the raw material. An easy and simple way would be to prepare the synthetic slag using the individual components and heating them to high temperature in a furnace. The titania slag has a high oxidizing nature and requires an inert atmosphere to prevent oxidation of the slag as well as the molybdenum crucible. This paper describes the preparation of synthetic ilmenite slag using an induction furnace and the study of the composition and the phases formed in the slag. X-ray powder diffraction (XRD), scanning electron microscopy (SEM), and inductively coupled plasma-optical emission spectroscopy (ICP-OES) were used as analytical techniques for studying the slag. A comparison between obtained synthetic slag and industrial ilmenite slag was performed to test the possibility of preparing slags in the laboratory as per the required composition. The slags show similar phase formation as obtained in industrial ilmenite slags, which means that the synthetic slags are identical to the industrial slags.

The feasibility of using laser-induced breakdown spectroscopy (LIBS) for the compositional analysis of ilmenite slag was explored. The slag was obtained from a pilot-scale ilmenite smelting furnace. The composition of major oxides TiO₂, FeO, and MgO are determined by the calibrated LIBS method. LIBS measurements are done under normal atmosphere and temperature. A Q-switched Nd:YAG laser operating at 355 nm was used to create a plasma on an ilmenite slag sample. The characteristic lines based on the NIST database of Fe, Mg, and Ti can be identified on the normalized LIBS spectra for the slag samples. The spectral range chosen for the study is 370 to 390 nm. Calibration curves were plotted using the data collected from various industrial ilmenite samples of varying compositions of TiO₂, FeO, and MgO. The univariate simple linear regression technique was used to do the analysis and the prediction accuracy was checked by the root mean square error (RMSE). To validate the application of LIBS, both qualitative and quantitative analysis is done and compared to the analytical ICP-OES results. The model predicts the magnesium content with the highest accuracy and gives good prediction for iron and titanium content. This study demonstrates the capability of using LIBS for the surface analysis of the ilmenite slag sample.

The upgradation of the ilmenite ore, using a pyrometallurgy method, is performed using a carbothermic reduction of the ilmenite. A high titania slag is obtained which is used as a feedstock for the TiO₂ pigment production. The slag is cooled after tapping in big molds and can take ten days to cool. This cooling method has remained the same since the inception of ilmenite smelting and recently rapid cooling through granulation has been utilized. The work presented in this paper focuses on the microstructural study of the slags that were prepared using different techniques and cooled at different cooling rates. Various analytical techniques, such as X-ray powder diffraction (XRD), scanning electron microscopy (SEM), inductively coupled plasma-optical emission spectroscopy (ICP-OES), and X-ray photoelectron spectroscopy (XPS) were used to exhibit the similarity of these synthetic slags to the properties of high titania ilmenite slag. The slag consisted mostly of pseudo-brookite phase with a M₃O₅ stoichiometry and smaller amounts of silicate and rutile phase. A glassy phase of silica was observed and most of the impurities were found to be present in the silicate phase. These silica phases were observed to be separate from the pseudo-brookite phase and along the phase boundaries. Micro-cracking of the slag surface, which is the characteristic of the M₃O₅ phase formed in the ilmenite slag, were observed under the SEM analysis. The XPS analysis revealed that faster cooling does result in lower amount of oxidation but the difference in the TiO₂ and Ti₂O₃ composition can have larger impact on oxidation than the cooling speed.