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Introduction

Model development and numerical simulation are a central theme within the K1-MET competence centre. Area 4 on numerical modelling and simulation brings together knowledge from the other areas and allows us to apply our results to a wide range of industrial and research applications.

Contact person

Bernhard König
Management Area 4

 +43 732 6989 75624

Objectives & Motivation

  • Comprehensive modelling tools for metallurgical process flows
  • Focus on the iron making process
  • High quality simulation tools from particle scale to plant scale
  • Continuous, discrete and coupled simulation engines
  • Quality and risk management through integral automated testing
  • High quality simulation tools from small scale to plant scale
  • Continuous, discrete and coupled codes
  • Open source technology: flexible and free

Results and application

The existing library of modelling techniques have enjoyed extensive international success, in particular in the open source community. Hence, the main global aims of Area 4 are to consolidate existing models, harness the current momentum within the open source community, and to streamline further developments.

State of the art software development techniques are used to streamline and consolidate the existing models and to create libraries of applications for the K1-MET partners. Both industrial and academic partners can readily use the code base and be directly involved in further development. This strong coupling between development and application leads to shorter development cycles, better code quality, and provides industrial context to high level academic code developments. The K1-MET Simulation Platform is dedicated to this consolidation, quality guarantee, and distribution management of the K1-MET simulation tools. Automated testing with the continuous delivery paradigm ensure a stable, maintained and documented code base.

Area 4 houses five more projects on various scales and application groups in multiphase flow modelling in metallurgical process flows. In particular, the focus is on comprehensive modelling and simulation of key elements of the iron making process. Examples include modelling of raceway dynamics in a blast furnace, particle dynamics in reactive moving beds, iron reduction in fluidised bed reactors, and liquid melt models in RH plants and ladle furnaces. Several computational tools are further developed or extended to include models for reactive particles, droplets, and carier phases. These computational tools include both open source codes, as well as proprietary packages. The main open source tools are the Discrete Element Model (DEM) code LIGGGHTS®, CFD codes OpenFOAM® (finite volume) and Palabos® (Lattice-Boltzmann). These codes are also coupled to handle simulation of dense multiphase flows. Furthermore, Area 4 contains two projects on a larger spatial and temporal scale. A set of quality control parameters is investigated to improve continuous casting and flowsheet modelling tool gPROMS® is used to model and improve the iron making route.