Metallurgical Processing in Motion: Embracing Digital Twins and Dynamic Simulations

In a recent feature published by African Mining, Samantha Edwards of SKEmet shared insights on how digital twins and dynamic simulations are reshaping metallurgical processing. The article, titled “Metallurgical processing through digital twins and simulations”, explores the shift from traditional steady-state models to time-dependent, real-world simulations that reflect the true complexity of plant operations.

Why Steady-State Isn’t Enough

Historically, metallurgical processes relied on steady-state mass and energy balances—useful for initial design but limited in capturing the nuances of fluctuating conditions. These models assume constant feed rates, temperatures, and pressures, which rarely hold true in practice. As Samantha noted, “Steady-state models can’t account for start-ups, shutdowns, or disturbances that impact process behaviour.”

The Power of Dynamic Simulations

Dynamic simulations introduce time as a critical variable. They model how systems respond to changes in feed composition, reagent dosing, and operational conditions. For example:

• Simulating temperature profiles in a roaster furnace under variable fuel supply

• Predicting slag formation and tapping schedules in copper smelting

• Optimizing leaching reactor performance based on real-time reagent addition

These simulations enable smarter equipment sizing, better control strategies, and reduced operational costs through predictive maintenance and energy optimization.

Digital Twins: A Mirror of Reality

Digital twins go a step further by integrating real-time sensor data, historical trends, and simulation models into a living digital replica of the plant. This allows operators to:

• Run “what-if” scenarios without disrupting production

• Train staff in a virtual environment

• Detect faults early by comparing live data with expected behaviour

• Adapt control systems to changing conditions

As Samantha emphasized, “Digital twins powered by dynamic simulations transform a reactive plant into a proactive one—capable of evolving with its environment.”

Real-World Impact

SKEmet’s approach is already making waves. In copper smelting, dynamic simulations help optimize feed blends and charging strategies, improving product consistency and reducing energy use. In hydrometallurgy, they enhance metal recovery and minimize environmental impact by simulating precipitation circuits and leaching kinetics.

Looking Ahead

The fusion of digital twins and dynamic simulations marks a new era in metallurgical processing—one where data drives decisions, and adaptability becomes a competitive advantage. As the industry pushes toward sustainability and efficiency, SKEmet stands at the forefront, turning complexity into clarity.

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Thank you to Nicolaas C. Steenkamp and the African Mining Publication team for the feature. Read the full article here: https://lnkd.in/dQiuKfSf