FeCr-SAF Digital Twin

Interactive Reactor Cross-Section — live process state

Hover a zone for detail. Values below update live from the model. Click Static Model or Dynamic Model to drive them.

Live Furnace State

Electrical & Geometry

Charge / Burden (per hour basis)

Chromite ore

Ore feed (kg/h) Cr2O3 (wt%) FeO (wt%) Fe2O3 (wt%) SiO2 (wt%) MgO (wt%) Al2O3 (wt%) CaO (wt%) MnO (wt%)

Reductant & flux

Coke (kg/h) Coke fixed-C (wt%) Quartzite flux (kg/h) Dolomite flux (kg/h)

Reduction extents

Cr recovery Fe recovery Si (SiO2→Si) Mn recovery Target alloy C

Furnace, Refractory & Electrical

Bath tap temp (°C) Roof/off-gas temp (°C) Hearth dia (m) Bath dia (m) Active height (m) Electrode dia (m)

Working lining (mm) Working lining k Safety lining (mm) Insulation (mm) Current density (A/cm²) Elec. efficiency

Key Steady-State Results

Alloy — final composition

Plant / measured slag (wt%) — editable

SiO2 Cr2O3 Al2O3 MgO CaO FeO

Type your assayed slag here — the table below compares it against the model.

Slag composition — model vs measured plant

Energy demand breakdown (MWh / t alloy)

Mass balance — inputs vs outputs (kg/h)

Shell heat loss by surface (kW)

Transient Operating Schedule

Duration (h) Time step (s) Nominal power (MW) Feed rate (t/h)

Charge pre-heat (°C) Start bath (°C) Set-point (°C) Power control

Tap interval (h) Tap fraction Alloy heel (t) Slag heel (t)

Uses the same charge as the Static tab

End-of-Campaign Result

Final alloy (wt%)

Final slag (wt%)

Bath temperature & controlled power

Alloy composition trajectory (wt%)

Bath temperature & power

Cumulative alloy & slag output (t)

Alloy composition (wt%)

Residual reducible oxides in slag (wt%)

Chromium recovery (%)

Off-gas evolution (Nm³/h)

Specific energy (MWh/t)

Slag liquidus & viscosity

Full slag composition (wt%)

Shell heat loss (kW)

Process Event Log — additions, milestones & taps (timed)

Campaign Summary

The event log captures every discrete action the model takes each time step: energising, reaction onset, thermal milestones, recovery targets and every tap (with the alloy grade tapped). In a plant deployment this stream is written to the historian / SCADA tag database.

Validation against literature & Industry-X envelope

Calibrated to an actual plant HC-FeCr material-balance sheet (Industry-X, high-grade charge). Each metric shows the model, the plant point value, and the industrial HC-FeCr range from the literature (slag FeO 0.5–6, Cr2O3 4–14, SiO2 25–45, Al2O3 15–40, MgO 15–33, CaO 1–15 wt%; Rennie 1972, FactSage/Pyrosim review, Sahu 2024). Alloy grade, all six slag oxides, slag/metal, basicity and Cr recovery are reproduced. Specific energy and current density have no sheet value and are shown against an engineering band.

Model vs Industry-X — metal production parity

Slag liquidus response (MgO sweep)

FeCr-SAF Digital Twin v1.0