In this paper a mathematical model is presented to predict the macroexothermic phenomena>occurring when exothermic additions in lump form are assimilated in ferrous metals. The macroexothermic phenomena take place during the free assimilation period of exothermic additions in ferrous metals. These phenomena are characterized by unique coupled heat, mass and momentum transport phenomena. The presence of a moving boundary complicates further these phenomena. The model uses the Simpler algorithm to solve numerically the pertinent partial differential equations. The extensive verification of the model was carried out in two contexts. The first was, in a low temperature physical model consisting of ice immersion in different sulfuric acid solutions. The melting of ice in these solutions is extremely exothermic. In this physical model, both temperature and velocity measurements were carried out. The model results were compared with experimental measurements and they were found to be in excellent agreement. The second context employed high temperatures, involving the assimilation of silicon in high carbon liquid iron. The model was also applied to predict the position of the moving boundary for these high temperature experiments and a good agreement was obtained. In addition new dimensionless convective heat transfer correlations that quantify these complex phenomena are presented.
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