Numerical Investigation of Gas–Liquid Multiphase Flow Characteristics and Nozzle Structure Optimization for a Multi-Hole Oxygen Lance in a Vanadium Extraction Converter

To optimize the hydrodynamic conditions of the converter vanadium extraction process, a three-dimensional multiphase flow model of the top-blowing system in a 200 t vanadium extraction converter was established based on computational fluid dynamics (CFD). Conventional 3-hole and “3+1”-hole (with a central nozzle) oxygen lance schemes were designed to investigate the effects of nozzle design Mach numbers and inter-nozzle flow distributions on jet characteristics, impact cavity morphology, and internal molten bath flow fields, aiming to select the optimal oxygen lance nozzle structure. The results indicate that for oxygen lances without a central nozzle, lowering the design Mach number mitigates shock wave energy dissipation and enlarges the gas–liquid reaction surface area; however, due to the lack of longitudinal penetrating force from a central jet, a large stagnation dead zone is prone to forming at the bottom. For oxygen lances with a central nozzle, the inter-nozzle flow distribution governs the impact cavity morphology and the evolution of the flow field. Excessive central flow causes the impact cavity to exhibit a “deep and narrow” profile and exacerbates surface kinetic energy dissipation, whereas insufficient central flow results in a “shallow and wide” cavity that makes it difficult to drive deep circulation. Based on a multi-objective evaluation, the “3+1” configuration adopting a 1:1 balanced flow ratio between the central nozzle and a single peripheral nozzle (Case 2#) effectively balances the allocation of jet momentum between radial expansion and longitudinal penetration, achieving synergistic optimization of the gas–liquid reaction interface expansion and deep-bath stirring, thus serving as the optimal scheme. The findings of this study provide an important theoretical reference for the engineering design and industrial trials of oxygen lance nozzles in large-tonnage vanadium extraction converters.