The goal of the COMET Module PlasmArc4Green is to develop numerical modelling and experimental monitoring tools for the accurate performance prediction of plasma-based metal production processes.

Thematic focuses

• Modelling the state of plasma outside of thermodynamic equilibrium, at near-electrode regions and plasma fringes at very high current densities

• Development of reliable theoretical models describing the effects of collisions and species drifts on the plasma properties

• Theoretical and experimental study of surface-plasma interactions, including electromagnetic and chemical phenomena occurring inside the near electrode region

• Development of novel in-situ measurement techniques for better process control

• Validation of simulations through metallurgical lab and pilot scale experiments

• Implementation of a Data Management Platform following FAIR data principles

Description

The metals industry is a major contributor to greenhouse gas emissions, making the development of sustainable and CO₂-neutral production processes essential to meet growing global demand while maintaining competitiveness.

Arc plasma-based processes offer significant potential to replace conventional fuel-based technologies, improving energy efficiency and reducing CO₂ emissions. However, many of the underlying physical phenomena remain insufficiently understood, creating a growing need for advanced modelling, simulation, and measurement techniques.

K1-MET aims to develop simulation, modelling, and monitoring tools to better understand and optimize arc plasma-based metal production. Particular focus is placed on phenomena such as high-current arc interactions with graphite electrodes and refractories, as well as melt evaporation and its influence on hydrogen plasma-based smelting. These challenges will be addressed through fundamental physics-based modelling combined with advanced sensor technologies for harsh process environments.

The resulting insights will support the development of more efficient and sustainable metal production technologies and contribute to the transition toward climate neutrality by 2050 and beyond.

At our Chair, Project 2 – Plasma-Solid Interaction is a key focus. The project aims to improve the understanding and modelling of high-current arc plasmas and their interaction with metal baths, electrodes, and refractories in green metal production.

By combining advanced 2D and 3D simulations with experimental investigations, the project addresses the complex and dynamic behaviour of industrial arcs, including different arc regimes, arc splitting, and the interaction between plasma and solid surfaces. The developed models incorporate fluid dynamics, plasma chemistry, radiation, and electrode interactions and are validated against experimental measurements.

The results will provide deeper insight into arc behaviour and enable more accurate prediction and control of plasma processes, ultimately contributing to more energy-efficient and sustainable metal production.