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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Materials Processing Fundamentals: Towards Sustainable Process Modeling, Design, and Operation
Presentation Title A New Thermodynamic Process-Simulation Tool for Sustainable Metallurgy Integrating LCA and Optimization With FactFlow
Author(s) Kentaro Oishi, Kyota Poëti, Daniel Wei, Khloé Le Boulanger, Patrice Chartrand, Jean-Philippe Harvey
On-Site Speaker (Planned) Kentaro Oishi
Abstract Scope This work presents a computational framework for evaluating and optimizing primary and secondary production routes of strategic metals using FactFlow, a process simulation tool integrated within FactSage. The methodology couples computational thermochemistry with Life Cycle Assessment (LCA) to assess cradle-to-gate environmental impacts, including energy use and CO₂ emissions. A key feature of the framework is its ability to perform multi-criteria optimization based on user-defined performance indices. Among these, the Energy Processing Performance Index (EPPI) and the CO₂ Processing Performance Index (CPPI) serve as illustrative examples that link thermodynamic feasibility with energy and environmental efficiency. FactFlow provides detailed mass and energy balances, while upstream environmental impacts are captured using data from Ecoinvent and complementary literature. This integrated and customizable approach supports informed decision-making and flexible process screening across diverse scenarios, offering a robust digital tool for improving the sustainability of strategic metal production.
Proceedings Inclusion? Planned:
Keywords Pyrometallurgy, Extraction and Processing, Modeling and Simulation

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A New Thermodynamic Process-Simulation Tool for Sustainable Metallurgy Integrating LCA and Optimization With FactFlow
Advancements in Friction Stir Welding of Copper Using Diamond Tooling
Applications of Machine Learning and AI in HPC4EI-Funded Projects for Manufacturing and Materials Research
CFD Modelling of Iron Concentrate Reduction in a Rotary Kiln Furnace
Crystal Nucleation and Growth in FluoroZirconate (ZBLAN) Glasses: Mesoscopic Study of the Effect of Shear Rate and Viscosity
HPC/AI Based Methodology for Flashback Detection in Hydrogen Blended Natural Gas Combustors
Influence of the Argon Gas Injection Position in a Metallurgical Ladle Using a Twisted Channels Nozzle on Slag Layer Opening and Mixing Times
Introduction to the High-Performance Computing for Energy Innovation Program
Investigating In-Situ Material Flow and Thermomechanical Conditions in Friction Extrusion With Varying Die Geometries Using SPH Method
Material Flow Optimization for Sustainable Aluminum Manufacturing
Modeling, Design, and Operation Maintenance for Long Campaign Life Blast Furnace Hearth
Molecular Simulation Study on Kinetics of CO2 Adsorption in Mg-MOF Decorated With Amine Groups
Multi-Physics Simulation of Inclusion Composition in the Continuous Casting Bloom: Effects of Element Segregation and Inclusion Diameter
Numerical Modeling of Solidification Structure and Macrosegregation in Large Bloom Continuous Casting With MEMS and FEMS: A Three-Phase Volume Average Approach
Optimization of Vacuum Induction Melting Ultrasonic Atomization Through Improved Process Monitoring
Probabilistic Spot-Melting Scan Strategy for Microstructure Engineering in Electron Beam Additive Manufacturing
PUMA: Simulating Powder Post-Processing for Advanced Manufacturing
Quench Process Modeling and Simulation in the Heat-Treatment of Critical Aerospace Components
Recovery and Re-Use of Metal Feedstock Powder in Cold Spray Deposition: Reducing Material Waste Through Powder Reclamation
Scale-up Electrodeposition of Ti-Al Alloys in AlCl3:BMIC Ionic Liquid Electrolyte
Syntheses of Ceramic Composites by Chemical Vapor Infiltration Using Microwave Heating
Three-Dimensional Multiphase Numerical Modeling of Gas Injection in the Anode Furnace for Copper Refining
Two-Phase Internal Cooling Correlations for High-Pressure Die Casting

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