The Metso Geminex platform was developed in-house by Metso and is used for digitally replicating mining and refining processes. It is a digital twin that combines operational data with Metso process expertise, providing insight-driven performance in the metallurgical industry. An accurate functional digital model of the whole metallurgical process is based on combining real data from both internal and external data sources, resulting in better recoveries, transparency and overall optimization of the process.
How Geminex creates value for DRI Smelting
Metso’s innovative DRI smelting furnace has been designed to replace traditional blast furnaces whilst significantly reducing carbon dioxide emissions, a crucial step for the steel industry that accounts for about 8% of global CO2 emissions [1]. This process also enhances energy efficiency and reduces operational costs, making it a vital technology for the future of sustainable steel production [2].
As a novel process, significant benefits can be achieved by utilizing all available data from theory and practice, such as pilot tests, to form the basis for the DRI Smelting digital twin. This way, the planet positive investment can be de-risked. The tools are also created to improve operational efficiency, sustainability and economic value at a much larger industrial scale.
At the same time, as with any new technology, operators need training and support. This is where the Geminex digital twin provides a safe and effective platform to simulate your process entirely offline, and gives the operators an understanding of the dynamics involved in the operation of the plant.
Enhancing operational efficiency and sustainability
Metso’s Geminex for DRI Smelting enhances operational efficiency by providing accurate process simulations and predictions. By integrating real-time data and the detailed digital model of the entire metallurgical process, the model allows operators to simulate and compare different scenarios. As a result, they can make informed decisions to optimize the production process, reduce variability and improve recovery rates. The ability to test and refine processes virtually means that improvements can be explored without disrupting actual operations, leading to smoother and more efficient production cycles.
Geminex significantly contributes to sustainability by minimizing the carbon footprint through optimizing the use of resources such as energy and reductants. The digital twin technology enables precise recipe matching to variable DRI feed types, which ensures that resources are used efficiently. These support the industry’s move towards more sustainable and environmentally friendly operations. This not only aligns with science-based global sustainability targets, but also enhances the overall environmental performance of metallurgical plants. Further, we should not forget the economic advantage Geminex delivers by improving resource management and operational efficiency, which results in reduced costs and increased profitability.
