A three-dimensional discrete phase model–volume of fluid coupled model has been developed to study the argon/steel/slag/air multiphase flow and mixing phenomena in an industrial gas-stirred ladle taking the coalescence, expansion and breakup of the argon bubbles as well as the fluctuant slag layer into account. The simulated results of the flow rate and bubble size evolution of the water model, as well as the slag eye size, are in good agreement with the experimental results reported in the literature. The modeling results show that the expansion of bubbles has a significant impact on the bubble size evolution and multiphase flow in an industrial ladle. The effects of different plug configurations on the flow characteristics and mixing time in the ladle are also investigated.
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