CELEBRATING THE MEGASCALE Proceedings of the Extraction and Processing Division Symposium on Pyrometallurgy in Honor of David G.C. Robertson Cover Photographs: Images on front cover, clockwise from top: (1) Ladle pouring. Photo courtesy of Rodney Jones, Mintek; (2) Photo of David G.C. Robertson; (3) Metal tapping. Photo courtesy ofIsabel Geldenhuys, Mintek; (4) Molten silver cast from a levitation coil (1961). Photo courtesy of School of Materials Science and Engineering, University of New South Wales; (5) Slag tapping. Photo courtesy of Anglo American Platinum. Additional image on back cover; (6) Metallurgical plant near green countryside at the Polokwane Smelter. Photo courtesy of Anglo American Platinum. TMS2014 143rd Annual Meeting & Exhibition CELEBRATING THE MEGASCALE Proceedings of the Extraction and Processing Division Symposium on Pyrometallurgy in Honor of David G.C. Robertson Proceedings of a symposium sponsored by the Extraction and Processing Division of The Minerals, Metals & Materials Society (TMS) held during 1 143,d Annual Meeting & Exhibition February 16-20,2014 San Diego Convention Center San Diego, California, USA Edited by: I Phillip J. Mackey Eric J. Grimsey I Rodney T. Jones Geoffrey A. Brooks Editors Phillip l. Mackey Rodney T. lones Eric l. Grimsey Geoffrey A. Brooks ISBN 978-3-319-48591-1 ISBN 978-3-319-48234-7 (eBook) DOI 10.1007/978-3-319-48234-7 Chemistry and Materials Science: Professional Copyright IQ 2016 by The Minerals, Metals & Materials Society Published by Springer International Publishers, Switzerland, 2016 Reprint of the original edition published by John Wiley & Sons, Inc., 2014, 978-1-118-88961-9 This work is subject to copyright. 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Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper This Springer imprint is published by Springer Nature The registered company is Springer International Publishing AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland TABLE OF CONTENTS Celebrating the Megascale: Proceedings of the Extraction and Processing Division Symposium on Pyrometallurgy in Honor of David G.C. Robertson Preface X 111 About the Editors About the Organizers ........................................................................................ xix Technical Reviewers ......................................................................................... xxi Session Chairs ................................................................................................. xxiii Keynote Session David Gordon Campbell Robertson: A Biographical Sketch J See Evolution of the Large Copper Smelter - IS00s to 2013 17 P. Mackey Evolution of the Mega-Scale in Ferro-Alloy Electric Furnace Smelting ............ 39 L. Nelson From Sulfide Flash Smelting to a Novel Flash Ironmaking Technology ............ 69 H. Sohn Fostering Minerals Workforce Skills of Tomorrow through Education and Training Partnerships G. Lind Modeling of Ladle Metallurgy in Steelmaking ................................................... S5 G. Irons, K. Krishnapisharody, and K. Graham v Process Metallurgy an Enabler of Resouce Efficiency: Linking Product Design to Metallurgy in Product Centric Recycling ........................................... 93 M Reuter and A. van Schaik Horizontal Single Belt Casting (HSBC) of Ca-Based, Bulk Metallic Glass (BMG) Strips .................................................................................................... 105 R. Guthrie, M !sac, D. Li, and L. Calzado Ferro-Alloys Developments in Manganese Ferroalloy Research and Production in the Last 25 years .................................................................................................... 121 M. Tangstad and R. Tronstad DC Arc Furnaces - Past, Present, and Future .................................................... 129 R. lanes Recent Developments in FactSage Thermochemical Software and Databases ................................................................................................... 141 C. Bale, E. Belisle, P. Chartrand, S. Decterov, G. Eriksson, A. Gheribi, K. Hack, 1. Jung, J Melam;on, A. Pelton, S. Peterson, and C. Robelin Reduction of Agglomerated Manganese Ores in a 150 kW Pilot Scale Furnace .................................................................................................... 149 M. Tangstad, T Brynjulfsen, and E. Ringdalen Arc Detection in DC Arc Furnaces 157 Q. Reynolds, C. Hockaday, D. Jordan, and 1. Barker An Electromagnetically Stirred Slurry Model for the Smelting Zone ofa Ferroalloy Furnace ..................................................................................... 169 B. Bowman Roles of Mn Carbides in Carbothermic Processes for Mn Alloys 179 B. Lee, H. Shin, and Y. Lee Non-Ferrous Smelting, Converting, and Refining Redoubling Platinum Group Metal Smelting Intensity -Operational Challenges and Solutions .................................................................................. 189 R. Hundermark, L. Nelson, B. de Villiers, J Ndlovu, D. Mokwena, P. Mukumbe, B. Pieterse, W. Seyanund, and P. van Manen VI Pyrometallurgical Processing Technologies for Treating High Arsenic Copper Concentrates ......................................................................................... 197 P. Taylor and T Putra Arsenic and Antimony Capacities in Ni-Cu Mattes and Slags 13 R. Reddy and J Font Quartz-Cristobalite Transformation and Its Effect on Reactions in Si Production: Initial Studies ............................................................................ 225 E. Ringdalen, D. Adisty, and L. Kolbeinsen Modifications to a Smelter to Accommodate Recycled Materials .................... 237 G. Roset, D. Flynn, and K. Schumacher Removal ofPb from Molten Copper by FeO-Si0 (-CaO, Ab03) Slag t 2 Treatment in Mitsubishi Process ....................................................................... 243 S. Park and J Park Simulation of the Gas Flow in a Peirce-Smith Converter.. ............................... 251 W. Silva, B. Ribeiro, and F. Elias From Phase Equilibrium and Thermodynamic Modeling to Freeze Linings The Development of Techniques for the Analysis of Complex Slag Systems ..................................................................................................... 259 A. Mehrjardi, P. Hayes, and E. Jak Modelling Simulation and Comparison of Refractory Corrosion at RHI's Technology Center ............................................................................................ 267 D. Gregurek, A. Ressler, A. Franzkowiak, and A. Spanring Iron and Steel Production Sustainability in Ironmaking: The Rise of Direct Reduction ............................ 277 T. Battle Kinetics of Reaction Important in Oxygen Steelmaking .................................. 289 K. Coley, E. Ch en, and M Pomeroy Current Status and Future Direction of Low-Emission Integrated Steehnaking Process S. Jahanshahi, A. Deev, N. Haque, L. Lu, J Mathieson, T. Norgate, Y. Pan, P. Ridgeway, H. Rogers, M. Somerville, D. Xie, and P. Zulli VII Analysis of Steelmaking Reactions by Coupled Reaction Model... .................. 317 S. Kitamura Cold Modelling of Splashing Phenomena in Oxygen Steelmaking .................. 325 S. Sabah and G. Brooks Lean Operations Strategy to Combat Uncertainties in Temperature at BOF End Point, Tapping, Deoxidation, Alloy Addition and Thermal History ......... 333 I. Shukla, G. Rajesh, P. Agarwal, A. Shukla, and D. Philip Ladle Metallurgy Kinetics: Inclusion-Inclusion Reactions ............................... 341 P. Pistorius Valorization of Electrical Arc Furnace Oxidizing Slag .................................... 347 J Lee, S. An, M Shin, and K. Sim Process Modeling and Simulation Computational Modelling of Metallurgical Processes: Achievements and Challenges .................................................................................................. 359 M Cross, D. McBride, and N. Croft Metallurgical Plant Optimization through the Use of Flowsheet Simulation Modelling .......................................................................................................... 367 M. Kennedy ChemSheet as a Simulation Platform for Pyrometallurgical Processes ............ 377 K. Penttila, J Salminen, N. Tripathi, and P. Koukkari A Computational Fluid Dynamic Model for a Novel Flash Ironmaking Process .......................................................................................... 385 S. Perez-Fontes, H. Sohn, and M. Olivas-Martinez Application of the Combined Reactors Method for Analysis of Steelmaking Process S. Lekakh and D. Robertson Modelling of Slag Foaming Coupled with Decarburisation ............................ .401 M Sattar, J Naser, and G. Brooks A Methodology for Modeling Electromagnetic Confinement Systems: Application to Levitation Melting .................................................................... 409 N. El-Kaddah and T. Natarajan VIII Electrochemical Characterization and Modeling of a Solid Oxide Membrane-Based Electrolyzer for Production of Magnesium and Oxygen .... .417 X Guan, U Pal, S. Gopalan, and A. Powell Phenomenological Models and Animations of Welding and Their Impact ..... .425 T. DebRoy Metallurgical Education Current and Suggested Focus on Sustainability in Pyrometallurgy ................. .429 J See, D. Robertson, and P. Mackey Teaching Process Simulation in Eleven Easy Lessons Using Excel and Its Tools .................................................................................................... .447 A. Morris Enhancement of Pyrometallurgical Teaching Using Excel Simulation Models E. Grimsey The Engineering Design Sequence and Materials Development: 990 Gold- Titanium as a Case Study ................................................................................. .465 M Schlesinger The Challenges for Professional Metallurgical Education ............................... .473 B. Hannah and P. Hayes Sustainability Education for Minerals and Materials Industry Professionals .. .481 W Rankin Delivering a National Process Design Unit with Industry Support ................. .489 D.lbana The MetSkill Program - Rapidly Developing Effective Young Engineers in the Workplace .............................................................................................. .499 D. Drinkwater and N. Bianco Pyrometallurgy Process Fundamentals I Oxidation of Flash Reduced Iron Particles in Various Gas Mixtures Under the Conditions of a Novel Flash Ironmaking Process ....................................... 509 Z. Yuan, H. Sohn, and M Olivas-Martinez IX