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 1011

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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Published Papers (2 papers)

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Research

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15 pages, 4626 KiB  
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
Viewed by 364
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 KiB  
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 307
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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