A water/oil physical model is built up to investigate the slag behavior under the side gas‐blowing condition of an AOD process. The critical side‐blowing air flow rates for the top oil entrainment and emulsification are investigated. In addition, the oil entrainment with the existence of solid particles is studied. Specifically, the influences of the tuyere size, oil viscosity, oil thickness, and volume fraction of solid particles in oil on the mixing phenomena are studied. It is found that oil viscosity is an important factor for the initial oil entrainment and emulsification. Oil thickness only has a slight influence on these phenomena. The critical air flow rate for both initial oil entrainment and emulsification increases slightly with an increased tuyere size from 2.0 to 3.2 mm. Empirical equations have been proposed to predict the critical air flow rate for the initial oil entrainment and emulsification. Furthermore, solid particles in oil are found to increase the critical air flow rate for an initial entrainment. This may be due to the increase of oil viscosity when solid particles exist in oil. In addition, a new model is developed to predict the oil viscosity when solid particles exist inside it.
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