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<p>This study investigates the three-phase foaming phenomenon using a cold model comprised of silicone oil, paraffin wax powder, and compressed air. Two distinct solid–liquid systems, analogous to industrial slag operations, are evaluated: variations in silicone oil viscosity simulate liquid slag with uniformly precipitated solids, while silicone oil mixed with paraffin wax powder simulates slag containing undissolved additives such as lime or dolomite. Results reveal that, at equivalent viscosities, heterogeneous mixtures with undissolved solids exhibit distinct foaming behavior compared to homogeneous liquid phases (representing both fully liquid and liquid containing precipitated solid systems). The effects of liquid viscosity, gas velocity, liquid volume, and solid fraction are systematically examined to develop a new dimensionless correlation. The model was validated against experimental data with ±&#xa0;15&#xa0;pct accuracy and successfully reproduced high-temperature slag foaming data from the literature within ±&#xa0;10&#xa0;pct. These findings demonstrate the model’s broad applicability to industrial operations and highlight the critical need to differentiate between the roles of solid precipitates and undissolved additives in slag foaming dynamics.</p>

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Cold Modeling of Metallurgical Slag Foaming Behavior in Gas–Liquid–Solid System

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Sumanta Maji,
  • Amarendra K. Singh

摘要

This study investigates the three-phase foaming phenomenon using a cold model comprised of silicone oil, paraffin wax powder, and compressed air. Two distinct solid–liquid systems, analogous to industrial slag operations, are evaluated: variations in silicone oil viscosity simulate liquid slag with uniformly precipitated solids, while silicone oil mixed with paraffin wax powder simulates slag containing undissolved additives such as lime or dolomite. Results reveal that, at equivalent viscosities, heterogeneous mixtures with undissolved solids exhibit distinct foaming behavior compared to homogeneous liquid phases (representing both fully liquid and liquid containing precipitated solid systems). The effects of liquid viscosity, gas velocity, liquid volume, and solid fraction are systematically examined to develop a new dimensionless correlation. The model was validated against experimental data with ± 15 pct accuracy and successfully reproduced high-temperature slag foaming data from the literature within ± 10 pct. These findings demonstrate the model’s broad applicability to industrial operations and highlight the critical need to differentiate between the roles of solid precipitates and undissolved additives in slag foaming dynamics.