Project OpTwinFlow

Optimization of steelmaking processes with flow based digital twins and advanced data analyses

Overall approach

As part of OpTwinFlow, a digital twin is being developed for a process in secondary metallurgy in steel production. This is made possible by a combination of improved sensor data and real-time flow simulations. This results in better process control, which in turn allows a reduction of used resources and energy. OpTwinFlow is an important building block in the transformation to green steel production processes.

The expected outcome of OpTwinFlow is a more accurate monitoring of the Ruhrstahl-Heraeus (RH) process, which will help reduce process times. This reduction results in lower energy consumption, lower CO2 emissions and reduces the number of RH systems required to meet the increased demands.

In addition, fundamental knowledge about flow-based digital twins and their integration into complex industrial processes is created on a cross-sectorial basis. In particular, the developed models and the used methods can be beneficial for other energy-intensive processes that involve gas-liquid flows and are also difficult to monitor.


The overall goals of this 36-months project are:

  • Creation of a digital twin of a key steelmaking process and synchronizing the twin with real-time plant data
  • Extraction of process-relevant parameters including estimation of the prediction quality
  • Minimization of the process time while maintaining the product quality
  • Saving of CO2 emissions and energy
  • Better process understanding
  • Transferability to other flow-based processes in resource-intensive industry


Project runtime:

1 April 2023 – 31 March 2026

Funding scheme:

Call: Produktion und Material 2022: Schlüsseltechnologien als Basis für die Produktion der Zukunft 2022, Grant Agreement no. 45974027
Granting authority: FFG

Project consortium:

Beginning with the project coordination, the consortium is composed as follows: