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Introduction

Model development, numerical simulations, and the analyses of complex (big) data sets represents the central topic within K1-MET competence centre. Area 4 – Simulation and Analyses unites the major developments concerning digital aspects and combines the knowledge from a wide range of industrial and academic applications.

Contact person

Magdalena Schatzl
Management Area 4

 +43 732 6989 2838
magdalena.schatzl[at]k1-met.com

Objectives & Motivation

  • Comprehensive modelling tools for metallurgical processes
  • High quality simulation tools from particle scale to plant scale
  • Novel methodology development for high resolution AND high speed simulations
  • Continuous, discrete and coupled simulation engines
  • Fusion of process expert knowledge and data scientist to provide applicable data analyses tools and prediction schemes.
  • Individualised problem solutions 

Results and application

During several years of development K1-MET was able to build up and maintain a substantial library of numerical models, improvements, and methodologies to investigate the complex nature of multi flow and multi scale processes. These developments enjoy extensive international success and rank on the leading edge of research. The Fast simulations project incorporates novel methodologies to reduce the calculation times of complex situations by the order of >100 and might enable near real time calculations within a limited parameter space.

Area 4 is hosting several more projects on various scales and application groups in multiphase and multiphysic flow modelling in metallurgical process flows. In particular, the focus is on comprehensive modelling and simulation of key elements of the iron and steel making processes. Examples include modelling of raceway dynamics in a shaft furnaces, particle dynamics in reactive moving beds, chemical coupling in fluidised bed reactors, liquid melt models (in converters, RH plants, ladle furnaces, etc.), and electromagnetic flow control within mould flow. Several computational tools are further developed or extended to include models for reactive particles, droplets, and carrier phases as well as interfacial flows. 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). These codes are also coupled to handle simulation of dense multiphase flows. 

Furthermore, Area 4 is dedicated to acquire, process, and analyse (big) datasets originating from simulations and/or process measurements. Digitalisation and big data aspects are becoming a wide field of ideas, but industrial implementation still require expert knowledge to turn the data streams into applicable/interpretable results. The close cooperation with industrial and academic partners as well as the interdisciplinary approaches within Area 4 enables best possible results. Consequently, the united know-how is transformed into algorithms and methods emphasizing useful information for the process operators.