Recent Studies in Ironmaking Process Modeling: 2023-Early 2026

This review summarizes representative studies on numerical simulations of ironmaking processes published between 2023 and early 2026, with emphasis on recent methodological developments, target phenomena, and engineering applications. It covers the major modeling frameworks used in ironmaking, including continuum multifluid models; computational fluid dynamics-discrete element method (CFD-DEM); interface-resolving methods, such as the volume of fluid method (VOF); mesh-free approaches, such as smoothed particle hydrodynamics (SPH); and hybrid- or data driven models, for prediction, monitoring, and optimization. This review is structured around distinct reactor regions and their underlying process phenomena, including burden distribution and gas–solid interaction in the shaft, raceway dynamics, softening–melting behavior in the cohesive zone, liquid flow in the dripping zone and hearth, low-carbon operational dynamics, and modeling of hydrogen based direct reduced iron shaft furnaces. The literature indicates that recent studies have shifted from simplified reactor scale descriptions to increasingly detailed multiscale and multiphysics representations. Moreover, the focus of the studies is also shifting from mechanistic interpretation to predictive and design-oriented simulation, supported by high-performance computing, surrogate-assisted modeling, and digital twin-oriented frameworks. Overall, recent progress in ironmaking processes suggests that numerical simulation is becoming an essential design and decision-support tool not only for conventional blast furnace analysis but also for developing low-carbon, hydrogen-based, and electrified ironmaking systems.