this is all taking into account the bare minimum and thus I conclude through various in game and out of game sources that kael’thas army likely numbered somewhere around 20,000. That seems like a reasonable number considering the losses it went through from dalaran all the way through to the taking of tempest keep. At the end of his “campaign” he attacked the kirin tor settlement in netherstorm. the survivors have stated the attacking army numbered in the thousands and this is despite losses at dalaran and shortly thereafter in outland, heavy losses in northrend trying to stop arthas, another portion of his army numbering in the thousands defecting to shattrath, and then whatever else happened between then and netherstorm.
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