There is significant evidence that droplets generated in steelmaking "bloat" apparently due to the inability of gas generated from the decarburisation reaction to escape from the surface of liquid metal droplets. A model to describe this behavior was developed by Brooks, Subagyo, Coley and Pan based on their own experimental work and calculations and previous studies by Fruehan and co-workers. This approach has been successfully incorporated into an overall process model of oxygen steelmaking. The unique feature of this model is to evaluate the decarburization reaction kinetics of individual metal droplets in the emulsion and to compare with the overall kinetics of oxygen steelmaking. The model suggests that the droplets become bloated and remain in the emulsion for relatively long periods (30+ seconds). This paper will evaluate the effects of droplet size, ejection angle and volume fraction on the bloating behavior of droplets and critically examine the repercussions of the new theory on plant design and operation.