Advanced Simulation and Modeling Technologies of Metallurgical Processes—2nd Edition

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: 10 December 2025 | Viewed by 1726

Special Issue Editor

Key Laboratory for Ecological Metallurgy of Multimetallic Mineral (Ministry of Education), School of Metallurgy, Northeastern University, Shenyang 110819, China
Interests: blast furnace; iron ore sintering; iron ore reduction reaction; charging law in blast furnace; software development in ironmaking process; shaft furnace; low carbon ironmaking technology
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Special Issue Information

Dear Colleagues,

Due to the rapid developments in computer technologies during the last two decades, computer-based process modeling has become an important tool for the improvement in existing process technologies and the development of innovative ones. With the help of numerical process simulations, complex and costly experimental trials can now be reduced to a minimum. In particular, for metallurgical processes, computer simulations are of outstanding importance.

The current numerical methods for metallurgical processes cover a wide array of applications, such as multiphase flow, multi-physics processes, optimization, and process simulation. The detailed and vast amounts of simulation data allow a thorough analysis of the relevant processes and their interactions that reveal the underlying physics. A deep understanding is of critical importance for process design and performance. In this Special Issue, we tried to select contributions which focus on innovative models/techniques/methods and provide some new insights into the different areas of metallurgical processes in ironmaking and steelmaking.

In this Special Issue, we seek to provide a wide set of articles on various aspects of simulation and modeling technologies in metallurgical processes. It is hoped that this open access Special Issue will provide a place for anyone to familiarize themselves with the current state of technologies in metallurgical processes. Articles on the ironmaking and steelmaking process are desired, such as data-driver modeling in sintering, blast furnaces and basic oxygen furnaces, gas–solid flow behavior by means of CFD, particle motion behavior by means of the discrete element method (DEM), new process development based on carbon peaking and carbon neutralization, the application of mathematical models, and new methods of visualization and intelligence.

Dr. Haifeng Li
Guest Editor

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Keywords

  • forecasting modeling
  • sintering
  • blast furnace
  • basic oxygen furnace
  • gas–solid flow behavior
  • carbon peaking and carbon neutralization
  • application of mathematical models
  • methods of visualization and intelligence
  • discrete element method (DEM)

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Related Special Issue

Published Papers (4 papers)

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Research

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21 pages, 8437 KB  
Article
Numerical Simulation of the Solid Particle Entrainment Behavior in Bottom-Blown Ladle
by Cheng Wang, Wentao Lou, Jie Zeng, Zeyu Wang and Jianfeng Xie
Metals 2025, 15(9), 963; https://doi.org/10.3390/met15090963 - 29 Aug 2025
Viewed by 167
Abstract
The entrainment behavior of solid particles from the top liquid surface into molten steel exerts a crucial influence on rapid slagging and efficient desulfurization during the refining process. A Euler–Euler mathematical model was established to describe the multiphase flow field and the entrainment [...] Read more.
The entrainment behavior of solid particles from the top liquid surface into molten steel exerts a crucial influence on rapid slagging and efficient desulfurization during the refining process. A Euler–Euler mathematical model was established to describe the multiphase flow field and the entrainment behavior of solid particles in a bottom-blown ladle. This model was validated by comparison with water model experiments. The effects of bottom-blowing tuyere number, gas flow rate, and solid particle size on the flow field and particle entrainment behavior were investigated. It was found that increasing the gas flow rate enhances the participation of particles in the ladle; however, the entrainment effect changes minimally when the gas flow rate exceeds 192 Nm3/h. Increasing the number of tuyeres adversely affects particle entrainment and mixing efficiency, while simultaneously expanding the size of the “open eyes”. The particle size of the refining slag has a significant impact on the entrainment effect: when the particle size exceeds 10 mm, the particles are hardly entrained in the ladle. Reducing the particle size is more conducive to increasing the entrainment amount, but excessively small particles will significantly enlarge the size of the “open eyes”. Full article
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17 pages, 8531 KB  
Article
Numerical Simulation of Bubble Flow in Continuous Casting Mold with Bubble Swarm Correction of Drag Coefficient
by Qingrui Lai, Zhiguo Luo, Yongjie Zhang, Zongshu Zou and Haifeng Li
Metals 2025, 15(9), 952; https://doi.org/10.3390/met15090952 - 27 Aug 2025
Viewed by 183
Abstract
This study employs a numerical simulation approach to investigate argon bubble flow behavior within a steel continuous casting mold, with a focus on the impact of bubble swarm correction models. Three scenarios are compared: one without any correction and two incorporating drag coefficient [...] Read more.
This study employs a numerical simulation approach to investigate argon bubble flow behavior within a steel continuous casting mold, with a focus on the impact of bubble swarm correction models. Three scenarios are compared: one without any correction and two incorporating drag coefficient corrections, specifically designed for bubble swarm effects. The results demonstrate that incorporating these correction models significantly improves the predictive accuracy of simulations. In particular, the inclusion of a bubble swarm correction model reduces the error in predicted bubble trajectories by 51.7% and 23.0%, respectively, when measured by Hausdorff distances against experimental trajectory data, compared to the scenario without corrections. These findings underline the importance of selecting an appropriate drag correction model for accurate simulations of bubble dynamics and their interaction with the liquid steel in continuous casting molds. This study highlights that drag correction models tailored to the specific conditions of the continuous casting process are essential for achieving realistic predictions. Full article
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15 pages, 4626 KB  
Article
Numerical Simulation of Fluid Flow and Solidification in Round Bloom Continuous Casting with Alternate Final Electromagnetic Stirring
by Bingzhi Ren, Lilong Zhu, Hongdan Wang and Dengfu Chen
Metals 2025, 15(6), 605; https://doi.org/10.3390/met15060605 - 28 May 2025
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Abstract
Final electromagnetic stirring (F-EMS) effectively improves macrosegregation and central porosity in round bloom continuous casting, while the flow and solidification of molten steel under F-EMS have a direct impact on metallurgical properties. Fluid flow and solidification behavior in a 600 mm round bloom [...] Read more.
Final electromagnetic stirring (F-EMS) effectively improves macrosegregation and central porosity in round bloom continuous casting, while the flow and solidification of molten steel under F-EMS have a direct impact on metallurgical properties. Fluid flow and solidification behavior in a 600 mm round bloom continuous casting process with F-EMS were simulated. The influence of the liquid fraction model on strand temperature distribution was investigated. The flow of molten steel was analyzed under both continuous and alternate stirring modes. The results indicated that in continuous stirring mode, the stirring velocity fluctuates between peaks and troughs over a specific period. The closer the F-EMS is to the meniscus, the larger the mushy zone area and the higher the stirring velocity. Due to the 10+ s rise time for current intensity, a 25 s forward and reverse stirring duration is recommended for Φ600 mm round bloom continuous casting with F-EMS. Full article
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Review

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25 pages, 7708 KB  
Review
A Review of Heat Transfer and Numerical Modeling for Scrap Melting in Steelmaking Converters
by Mohammed B. A. Hassan, Florian Charruault, Bapin Rout, Frank N. H. Schrama, Johannes A. M. Kuipers and Yongxiang Yang
Metals 2025, 15(8), 866; https://doi.org/10.3390/met15080866 - 1 Aug 2025
Viewed by 492
Abstract
Steel is an important product in many engineering sectors; however, steelmaking remains one of the largest CO2 emitters. Therefore, new governmental policies drive the steelmaking industry toward a cleaner and more sustainable operation such as the gas-based direct reduction–electric arc furnace process. [...] Read more.
Steel is an important product in many engineering sectors; however, steelmaking remains one of the largest CO2 emitters. Therefore, new governmental policies drive the steelmaking industry toward a cleaner and more sustainable operation such as the gas-based direct reduction–electric arc furnace process. To become carbon neutral, utilizing more scrap is one of the feasible solutions to achieve this goal. Addressing knowledge gaps regarding scrap heterogeneity (size, shape, and composition) is essential to evaluate the effects of increased scrap ratios in basic oxygen furnace (BOF) operations. This review systematically examines heat and mass transfer correlations relevant to scrap melting in BOF steelmaking, with a focus on low Prandtl number fluids (thick thermal boundary layer) and dense particulate systems. Notably, a majority of these correlations are designed for fluids with high Prandtl numbers. Even for the ones tailored for low Prandtl, they lack the introduction of the porosity effect which alters the melting behavior in such high temperature systems. The review is divided into two parts. First, it surveys heat transfer correlations for single elements (rods, spheres, and prisms) under natural and forced convection, emphasizing their role in predicting melting rates and estimating maximum shell size. Second, it introduces three numerical modeling approaches, highlighting that the computational fluid dynamics–discrete element method (CFD–DEM) offers flexibility in modeling diverse scrap geometries and contact interactions while being computationally less demanding than particle-resolved direct numerical simulation (PR-DNS). Nevertheless, the review identifies a critical gap: no current CFD–DEM framework simultaneously captures shell formation (particle growth) and non-isotropic scrap melting (particle shrinkage), underscoring the need for improved multiphase models to enhance BOF operation. Full article
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