The formation of freeze lining (FL), a protective layer of solidified slag,
holds significant economic value in industrial processes by safeguarding furnace
reactors and refractories from corrosive molten slag and providing a thermal
barrier that minimizes energy consumption. To deepen our comprehension of FL
formation, a collaborative research project has been undertaken, bringing
together academic partners from the University of Leoben (Austria) and the
University of Leuven (Belgium), alongside industrial partners RHI Magnesita and
Aurubis-Beerse. This collaboration has led to the development of a novel
computational fluid dynamic (CFD) model capable of simulating FL formation
across a broad range of applications. The model has undergone rigorous testing,
ranging from controlled laboratory experiments to industrial processes, that
validated its robustness and versatility. This model framework provides a solid
foundation that should be expanded with new fundamental knowledge of FL
formation and validated in other relevant industrial settings.