Novel Insights into Low-Carbon Metallurgical Process Simulation and Optimization

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

Deadline for manuscript submissions: 31 October 2026 | Viewed by 799

Special Issue Editors


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Guest Editor
National Materials Service Safety Science Center, University of Science and Technology Beijing, Beijing 100083, China
Interests: characterization of extreme service behavior of materials/components; low-carbon spray metallurgy technology; electric arc furnace steelmaking; converter steelmaking; numerical simulation
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Guest Editor
School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China
Interests: system optimization of metallurgical manufacturing processes; data analysis and intelligent control for metallurgical manufacturing processes; carbon footprint analysis and diagnosis of metallurgical processes
School of Minerals Processing and Bioengineering, Central South University, Changsha 410083, China
Interests: electric arc furnace steelmaking; metallurgical process optimization; low-carbon technologies; life cycle assessment; clean energy utilization; techno-economic analysis; machine learning; data mining; numerical simulation

Special Issue Information

Dear Colleagues,

The metallurgical industry stands at a critical juncture in its transition toward carbon neutrality. Responsible for a significant share of global industrial CO2 emissions, the sector is actively exploring breakthrough technologies including hydrogen-based direct reduction, renewable energy-powered electrolysis, and novel smelting routes . However, the complexity of high-temperature multiphase reactions, coupled with the high cost and technical risk of physical trials, makes process optimization particularly challenging. Computational modeling and simulation have emerged as indispensable tools to accelerate this low-carbon transition. From particle-scale discrete element method (DEM) and computational fluid dynamics (CFD) to system-level process integration, numerical approaches enable researchers to visualize internal furnace phenomena, optimize operating parameters, and quantify energy efficiency and emissions reduction potential before industrial implementation. Recent advances in multi-physics coupling, digital twin technologies, and AI-accelerated surrogate models are opening new frontiers for process intensification.

This Special Issue aims to showcase novel insights into the simulation and optimization of low-carbon metallurgical processes. We invite contributions on hydrogen-based ironmaking, electric smelting furnaces, renewable energy integration, process-scale life cycle assessment, and innovative numerical methods. By bringing together cutting-edge research from academia and industry, this issue seeks to advance the scientific understanding and practical deployment of sustainable metallurgical technologies.

Dr. Fuhai Liu
Dr. Kai Feng
Dr. Hang Hu
Guest Editors

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Keywords

  • low-carbon metallurgy
  • process simulation
  • numerical optimization
  • hydrogen metallurgy
  • electric smelting
  • computational fluid dynamics
  • discrete element method
  • multi-physics coupling
  • artificial intelligence
  • digital twin
  • life cycle assessment
  • carbon emission

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Published Papers (2 papers)

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Research

19 pages, 2414 KB  
Article
Optimization of Copper-Embedded Cathode Collector Bars for Reducing Cathode Voltage Drop and Horizontal Current in Aluminum Electrolysis
by Jinfeng Han, Chunchun Dong, Yuran Chen, Yapeng Kong and Xuemin Liang
Metals 2026, 16(6), 639; https://doi.org/10.3390/met16060639 - 10 Jun 2026
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Abstract
Aluminum electrolysis is an energy-intensive process in which the cathode voltage drop (CVD) and horizontal current in the molten aluminum layer directly affect energy consumption and cell stability. In this study, a three-dimensional electro-thermal model of a 400 kA prebaked aluminum electrolysis cell [...] Read more.
Aluminum electrolysis is an energy-intensive process in which the cathode voltage drop (CVD) and horizontal current in the molten aluminum layer directly affect energy consumption and cell stability. In this study, a three-dimensional electro-thermal model of a 400 kA prebaked aluminum electrolysis cell was established to optimize copper-embedded cathode collector bars. Using a staged parameter-screening and integrated optimization strategy, the effects of copper rod longitudinal position, diameter, and embedded length on CVD, horizontal current density, cathode surface current uniformity, and thermal response were systematically evaluated. Under the present modeling conditions, the configuration with a longitudinal position of 1.0 m, diameter of 0.05 m, and embedded length of 1.0 m provided a favorable balance between electrical performance and copper consumption. This design reduced the equivalent voltage drop by 142.7 mV and decreased the average horizontal current density in the molten aluminum layer to approximately 4900 A/m2. The peak cathode surface current density was also reduced, corresponding to a predicted cathode service-life increase of approximately 13.2% based on a relative wear model. A preliminary economic analysis indicated that an initial investment of CNY 424,000 could yield conservative annual electricity cost savings of approximately CNY 114,000, with a simple payback period of about 3.7 years. These results provide quantitative guidance for the structural design and industrial evaluation of copper-embedded cathode collector bars. Full article
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30 pages, 3196 KB  
Article
Analysis of EAF Energy Efficiency Characteristics Based on Industrial Data and Energy Balance
by Hongjin Zhang, Guangsheng Wei, Fuhai Liu, Shenghai Han, Xiaodan Zhong, Jianzhong Wang and Xiaoyun Luo
Metals 2026, 16(6), 594; https://doi.org/10.3390/met16060594 - 29 May 2026
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Abstract
Improving energy efficiency of electric arc furnace (EAF) steelmaking is a key pathway for the iron and steel industry to achieve carbon neutrality. Based on statistical data from 56 industrial EAFs, this study established and validated a comprehensive mass and energy balance model [...] Read more.
Improving energy efficiency of electric arc furnace (EAF) steelmaking is a key pathway for the iron and steel industry to achieve carbon neutrality. Based on statistical data from 56 industrial EAFs, this study established and validated a comprehensive mass and energy balance model with a verification error of less than 5% and systematically quantified the effects of furnace type, furnace capacity, hot metal charging ratio, and scrap preheating on EAF energy efficiency through statistical analysis and scenario simulation. The results show that furnace type is the decisive factor for energy efficiency; Consteel and shaft furnace EAFs with scrap preheating are significantly more efficient than conventional EAFs, with the shaft furnace exhibiting the highest preheating efficiency and best stability. The scale effect of furnace capacity on energy efficiency is weak and fully overshadowed by furnace type. Each 10% increase in hot metal ratio reduces specific power consumption by about 50 kWh/t in conventional furnaces, and the optimal hot metal ratio is 40–50% to balance power consumption and total energy consumption. Scrap preheating saves electricity by recovering physical heat, with each 100 °C temperature increase reducing power consumption by 25 kWh/t; compared with the Consteel process, the shaft furnace process reduces total energy consumption by approximately 14% and increases energy efficiency by 9%. This study provides theoretical support and practical guidance for process optimization in the low-carbon transformation of EAF short-flow steelmaking. Full article
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