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Celebrating the Megascale: Proceedings of the Extraction and Processing Division Symposium on Pyrometallurgy in Honor of David G.C. Robertson / Edition 1

Celebrating the Megascale: Proceedings of the Extraction and Processing Division Symposium on Pyrometallurgy in Honor of David G.C. Robertson / Edition 1


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Product Details

ISBN-13: 9781118889619
Publisher: Wiley
Publication date: 02/17/2014
Pages: 664
Product dimensions: 6.10(w) x 9.00(h) x 1.70(d)

About the Author

The Minerals, Metals & Materials Society (TMS) is a member-driven international professional society dedicated to fostering the exchange of learning and ideas across the entire range of materials science and engineering, from minerals processing and primary metals production, to basic research and the advanced applications of materials. Included among its nearly 13,000 professional and student members are metallurgical and materials engineers, scientists, researchers, educators, and administrators from more than 70 countries on six continents. For more information on TMS, visit

Table of Contents

Preface xiii

About the Editors xv

About the Organizers xix

Technical Reviewers xxi

Session Chairs xxiii

Keynote Session

David Gordon Campbell Robertson: A Biographical Sketch 3
J. See

Evolution of the Large Copper Smelter - 1800s to 2013 17
P. Mackey

Evolution of the Mega-Scale in Ferro-Alloy Electric FurnaceSmelting 39
L. Nelson

From Sulfide Flash Smelting to a Novel Flash IronmakingTechnology 69
H. Sohn

Fostering Minerals Workforce Skills of Tomorrow throughEducation and Training Partnerships 77
G. Lind

Modeling of Ladle Metallurgy in Steelmaking 85
G. Irons, K. Krishnapisharody, and K. Graham

Process Metallurgy an Enabler of Resouce Efficiency: LinkingProduct Design to Metallurgy in Product Centric Recycling 93
M. Reuter and A. van Schaik

Horizontal Single Belt Casting (HSBC) of Ca-Based, Bulk MetallicGlass (BMG) Strips 105
R. Guthrie, M. Isac, D. Li, and L. Calzado


Developments in Manganese Ferroalloy Research and Production inthe Last 25 Years 121
M. Tangstad and R. Tronstad

DC Arc Furnaces - Past, Present, and Future 129
R. Jones

Recent Developments in FactSage Thermochemical Software andDatabases 141
C. Bale, E. Belisle, P. Chartrand, S. Decterov, G. Eriksson, A.Gheribi, K. Hack, I. Jung, J. Melançon, A. Pelton, S.Peterson, and C. Robelin

Reduction of Agglomerated Manganese Ores in a 150 kW Pilot ScaleFurnace 149
M. Tangstad, T. Brynjulfsen, and E. Ringdalen

Arc Detection in DC Arc Furnaces 157
Q. Reynolds, C. Hockaday, D. Jordan, and I. Barker

An Electromagnetically Stirred Slurry Model for the SmeltingZone of a Ferroalloy Furnace 169
B. Bowman

Roles of Mn Carbides in Carbothermic Processes for Mn Alloys179
B. Lee, H. Shin, and Y. Lee

Non-Ferrous Smelting, Converting, and Refining

Redoubling Platinum Group Metal Smelting Intensity - OperationalChallenges and Solutions 189
R. Hundermark, L. Nelson, B. de Villiers, J. Ndlovu, D. Mokwena,P. Mukumbe, B. Pieterse, W. Seyanund, and P. van Manen

Pyrometallurgical Processing Technologies for Treating HighArsenic Copper Concentrates 197
P. Taylor and T. Putra

Arsenic and Antimony Capacities in Ni-Cu Mattes and Slags213
R. Reddy and J. Font

Quartz-Cristobalite Transformation and Its Effect on Reactionsin Si Production: Initial Studies 225
E. Ringdalen, D. Adisty, and L. Kolbeinsen

Modifications to a Smelter to Accommodate Recycled Materials237
G. Roset, D. Flynn, and K. Schumacher

Removal of Pb from Molten Copper by FetO-SiO2 (-CaO, Al2O3) SlagTreatment 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 FreezeLinings – The Development of Techniques for the Analysis ofComplex Slag Systems 259
A. Mehrjardi, P. Hayes, and E. Jak

Modelling Simulation and Comparison of Refractory Corrosion atRHI's Technology Center 267
D. Gregurek, A. Ressler, A. Franzkowiak, and A. Spanring

Iron and Steel Production

Sustainability in Ironmaking: The Rise of Direct Reduction277
T. Battle

Kinetics of Reaction Important in Oxygen Steelmaking 289
K. Coley, E. Chen, and M. Pomeroy

Current Status and Future Direction of Low-Emission IntegratedSteelmaking Process 303
S. Jahanshahi, A. Deev, N. Haque, L. Lu, J. Mathieson, T.Norgate, Y. Pan, P. Ridgeway, H. Rogers, M. Somerville, D. Xie, andP. Zulli

Analysis of Steelmaking Reactions by Coupled Reaction Model317
S. Kitamura

Cold Modelling of Splashing Phenomena in Oxygen Steelmaking325
S. Sabah and G. Brooks

Lean Operations Strategy to Combat Uncertainties in Temperatureat BOF End Point, Tapping, Deoxidation, Alloy Addition and ThermalHistory 333
I. Shukla, G. Rajesh, P. Agarwal, A. Shukla, and D.Philip

Ladle Metallurgy Kinetics: Inclusion-Inclusion Reactions341
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: Achievementsand Challenges 359
M. Cross, D. McBride, and N. Croft

Metallurgical Plant Optimization through the Use of FlowsheetSimulation Modelling 367
M. Kennedy

ChemSheet as a Simulation Platform for PyrometallurgicalProcesses 377
K. Penttilä, J. Salminen, N. Tripathi, and P.Koukkari

A Computational Fluid Dynamic Model for a Novel Flash IronmakingProcess 385
S. Perez-Fontes, H. Sohn, and M. Olivas-Martinez

Application of the Combined Reactors Method for Analysis ofSteelmaking Process 393
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

Electrochemical Characterization and Modeling of a Solid OxideMembrane-Based Electrolyzer for Production of Magnesium and Oxygen417
X. Guan, U. Pal, S. Gopalan, and A. Powell

Phenomenological Models and Animations of Welding and TheirImpact 425
T. DebRoy

Metallurgical Education

Current and Suggested Focus on Sustainability in Pyrometallurgy429
J. See, D. Robertson, and P. Mackey

Teaching Process Simulation in Eleven Easy Lessons Using Exceland Its Tools 447
A. Morris

Enhancement of Pyrometallurgical Teaching Using Excel SimulationModels 455
E. Grimsey

The Engineering Design Sequence and Materials Development: 990Gold-Titanium as a Case Study 465
M. Schlesinger

The Challenges for Professional Metallurgical Education473
B. Hannah and P. Hayes

Sustainability Education for Minerals and Materials IndustryProfessionals 481
W. Rankin

Delivering a National Process Design Unit with Industry Support489
D. Ibana

The MetSkill Program - Rapidly Developing Effective YoungEngineers in the Workplace 499
D. Drinkwater and N. Bianco

Pyrometallurgy Process Fundamentals I

Oxidation of Flash Reduced Iron Particles in Various GasMixtures Under the Conditions of a Novel Flash Ironmaking Process509
Z. Yuan, H. Sohn, and M. Olivas-Martinez

A New Approach to Investigating Coke Reactivity 519
B. Monaghan, R. Longbottom, M. Reid, O. Aladejebi, A.Jayasekara, and M. Panhuis

The Use of Natural Gas for Reduction of Metal Oxides:Constraints and Prospects 529
O. Ostrovski

Decomposition of Methane during Oxide Reduction with Natural Gas537
H. Dalaker and P. Tetlie

Reduction of Mixtures of Ni-Oxide and Ti-Oxide Powder in aNatural Gas Containing Atmosphere 547
C. van der Eijk and K. Tang

Kinetic and Thermodynamic Analysis of the Reduction of Oxides ofCu and Co in a SiO2-CaO-(Al,Fe)2O3 Slag 553
Y. Hara and A. Jha

Carbothermic Reduction of Ilmenite Concentrate with CokeAssisted by High Energy Ball Milling 563
B. Song, K. Zhang, F. Xi, and X. Lv

Pyrometallurgy Process Fundamentals II

Electricity-Independent Generation of Silicon Based on the Useof Rice Husk: A Concept Process 575
M. Barati

Electrically Enhanced Metal Purification Using Slag 587
M. Islam, M. Rhamdhani, and G. Brooks

Crystallization Behavior of Molten Blast Furnace Slag UsingConfocal Scanning Laser Microscope 597
L. Lu, H. Meilong, and B. Chenguang

Viscosity-Structure Relationship in the CaO-SiO2-MnO-CaF2 Slagfor the Production of Manganese Ferroalloys 605
J. Park and K. Ko

Recovery of Vanadium from a High Ca/V Ratio Vanadium Slag UsingSodium Roasting and Ammonia Leaching 613
S. Xu, M. Long, D. Chen, H. Fan, Y. Chen, and X. Sun

Sintering Process for Limonitic Nickel Laterite 623
E. Guo, M. Liu, C. Pan, Q. Yuan, and X. Lv

Pyrometallurgy Process Fundamentals III

Development of a Thermodynamic Database for Mold FluxApplications to the Continuous Casting Process for Steelmaking633
M. Van Ende and I. Jung

Thermodynamic Optimization of Mn-Si-C System 641
M. Paek, Y. Kang, and J. Pak

Removal of Non-Metallic Inclusions from Molten Steel Using aHigh Frequency Magnetic Field 651
S. Wang, L. Zhang, and Y. Tian

Fluid Flow, Alloy Dispersion and Inclusion Motion inArgon-Stirred Steel Ladles 659
Y. Li, L. Zhang, and Y. Ren

Poster Session

Nitrogen Solubility in Liquid Mn-Fe-Si-C Alloys 669
J. Eom, J. Jang, M. Paek, and J. Pak

Study of Dezincification and De-Lead of Blast Furnace Dust byFluidized Reduction Experiment 675
S. Yang, C. Liu, X. Gao, and J. Li

Author Index 685

Subject Index 689

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