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J.s. Truelove - One of the best experts on this subject based on the ideXlab platform.

  • Simulating radiative transfer in Flash Smelting furnaces
    Applied Mathematical Modelling, 1995
    Co-Authors: S. R. Varnas, J.s. Truelove
    Abstract:

    In this paper we examine the accuracy of three approximate solutions to the radiative transfer equation in the context of simulating a Flash Smelting furnace. We have built some one-phase models decoupled from flow and other means of heat transfer to validate them against the zone model solutions of the radiative transfer equation. The approximations have also been incorporated into an overall two-phase model of fluid flow and heat transfer in a particle-seeded gas jet enclosed within an axisymmetric cylindrical shaft with hot radiating walls. We have explored the sensitivity of the predictions of the overall model to the choice of the radiation approximation and some other model parameters.

S. R. Varnas - One of the best experts on this subject based on the ideXlab platform.

  • Evaluation of nickel Flash Smelting through piloting and simulation
    Metallurgical and Materials Transactions B, 1998
    Co-Authors: S. R. Varnas, P. T. L. Koh, N. Kemori
    Abstract:

    An extensive study of the nickel Flash Smelting process has been undertaken. It is aimed at the optimization of the burner design to improve the Smelting performance and to increase the throughput of the rebuilt furnace. A design-based mathematical model was developed to simulate the operation of the four burners and the reaction shaft of the Flash furnace at Western Mining Corporation Ltd.’s Kalgoorlie Nickel Smelter. A modified single burner version of the model was validated against data obtained from the pilot plant at the Pyrometallurgical Research Centre (PRC) of the Sumitomo Metal Mining Co.’s Toyo Smelter. The approach taken involved experimental measurements of key process parameters in the pilot plant and detailed numerical simulation of the fluid flow, heat transfer, and combustion in the entire burner-shaft complex. Several burner designs have been tested experimentally at the pilot plant and theoretically through computer simulation. The main outcome of the study was the development of an experimentally validated mathematical model of the Flash smelter providing a new powerful design tool. The insight gained about the process from the application of this tool led to the design of a more efficient nickel Flash Smelting process.

  • Simulating radiative transfer in Flash Smelting furnaces
    Applied Mathematical Modelling, 1995
    Co-Authors: S. R. Varnas, J.s. Truelove
    Abstract:

    In this paper we examine the accuracy of three approximate solutions to the radiative transfer equation in the context of simulating a Flash Smelting furnace. We have built some one-phase models decoupled from flow and other means of heat transfer to validate them against the zone model solutions of the radiative transfer equation. The approximations have also been incorporated into an overall two-phase model of fluid flow and heat transfer in a particle-seeded gas jet enclosed within an axisymmetric cylindrical shaft with hot radiating walls. We have explored the sensitivity of the predictions of the overall model to the choice of the radiation approximation and some other model parameters.

Wang Ling-yun - One of the best experts on this subject based on the ideXlab platform.

J. Poijärvi - One of the best experts on this subject based on the ideXlab platform.

  • oxygen pressure in the outokumpu Flash Smelting furnace part 2 the don process
    Mineral Processing and Extractive Metallurgy, 2001
    Co-Authors: P. Taskinen, K. Seppälä, J. Laulumaa, J. Poijärvi
    Abstract:

    AbstractOxygen-activity measurements and sampling for chemical assay were carried out in a nickel Flash Smelting furnace and slag-cleaning electric furnace during industrial operation. In the primary Direct Outokumpu Nickel (DON) Smelting furnace, which produces high-grade nickel matte, the oxygen activity and chemical compositions of the slag and matte were quite uniform throughout the settler and no differences in oxygen potential were found across the slag-matte interface. In the course of batch slag reduction by surface coke a clear oxygen-activity gradient developed in the slag layer, but chemical gradients in the non-foamy bath were small. The distribution coefficients of selected impurity elements in DON Smelting are reported.

  • oxygen pressure in the outokumpu Flash Smelting furnace part 1 copper Flash Smelting settler
    Mineral Processing and Extractive Metallurgy, 2001
    Co-Authors: P. Taskinen, K. Seppälä, J. Laulumaa, J. Poijärvi
    Abstract:

    AbstractOxygen activities in an industrial copper Flash Smelting furnace were measured by disposable oxygen probes to which a sampling device was attached. The chemical composition of the phase in the vicinity of the oxygen probe was determined with the aim of obtaining a detailed analysis of the mechanisms of slag and matte formation in suspension Smelting. The results show clearly that no significant oxygen-activity gradients exist in the settler products as a function of either the area or the depth of the settler. The observations indicate that the majority of the slag and matte formation processes are completed just below the reaction shaft area. Data on the distribution of minority elements were also derived.

  • Oxygen pressure in the Outokumpu Flash Smelting furnace—Part 1: copper Flash Smelting settler
    Mineral Processing and Extractive Metallurgy, 2001
    Co-Authors: P. Taskinen, K. Seppälä, J. Laulumaa, J. Poijärvi
    Abstract:

    AbstractOxygen activities in an industrial copper Flash Smelting furnace were measured by disposable oxygen probes to which a sampling device was attached. The chemical composition of the phase in the vicinity of the oxygen probe was determined with the aim of obtaining a detailed analysis of the mechanisms of slag and matte formation in suspension Smelting. The results show clearly that no significant oxygen-activity gradients exist in the settler products as a function of either the area or the depth of the settler. The observations indicate that the majority of the slag and matte formation processes are completed just below the reaction shaft area. Data on the distribution of minority elements were also derived.

William G. Davenport - One of the best experts on this subject based on the ideXlab platform.

  • Flash Smelting of Nickel Sulfide Concentrates
    Extractive Metallurgy of Nickel Cobalt and Platinum Group Metals, 2011
    Co-Authors: Frank K. Crundwell, Michael S. Moats, Venkoba Ramachandran, Timothy G. Robinson, William G. Davenport
    Abstract:

    Flash Smelting oxidizes and melts pentlandite concentrates. The principal product is a molten Ni-Fe-S matte that is considerably richer in nickel (20%-60% Ni) than the concentrate feed (12%-20% Ni). This matte product is transferred to converting (

  • direct to copper Flash Smelting
    Extractive Metallurgy of Copper (Fifth Edition), 2011
    Co-Authors: William G. Davenport, Matthew J. King, M. Schlesinger, Asit K. Biswas
    Abstract:

    This chapter discusses the process of direct-to-copper Smelting that is the Smelting of concentrate directly to molten copper in one furnace. In 2011, it was practiced in three smelters: Olympic Dam (Australia), Glogo´w II (Poland), and Chingola (Zambia). All of these plants use an Outotec Flash furnace. The main advantage of the process is its restriction of SO 2 evolution to a single, continuous source of high SO 2 -strength gas. In principal, the energy, operating, and capital costs of producing metallic copper are also minimized by the single-furnace process. Metallic copper is obtained in a Flash furnace by setting the ratio of oxygen input in the blast to concentrate feed rate to the point where all the Fe and S in the input concentrate are oxidized. The ratio must be precisely controlled to avoid the production of Cu 2 S or Cu 2 O. Avoiding formation of a molten Cu 2 S layer in the furnace is critical. Reactions between Cu 2 S layers and oxidizing slag may cause rapid SO 2 evolution and slag foaming. Direct-to-copper Flash Smelting has proven effective for SO 2 capture. However, about 25% of the Cu in the input concentrate is oxidized, ending up as copper oxide dissolved in slag. This copper oxide must be reduced back to metallic copper, usually with coke. The expense of recovering Cu from slag will probably restrict future direct-to-copper Smelting to concentrates that produce little slag. Chalcopyrite concentrates will probably continue to be treated by multi-furnace processes, either by conventional Smelting and converting or by continuous multi-furnace processing.

  • Flash Smelting—Outokumpu Process
    Extractive Metallurgy of Copper, 2002
    Co-Authors: William G. Davenport, Matthew J. King, M. Schlesinger, Asit K. Biswas
    Abstract:

    This chapter discusses the Outokumpu Flash Smelting process for copper. It is used for more than half of copper matte Smelting. It is used in two locations for direct-to-copper Smelting and in one location for continuous converting. It blows oxygen, air, dried concentrate, flux, and particulate recycle material as a well-dispersed mixture into a hot reaction shaft. It results in controlled oxidation of the concentrate's iron and sulfur, large evolution of heat, and melting of the solids. Smelting reactions are extremely fast under these conditions. Outokumpu Flash furnaces smelt up to 3000 tons of new concentrate per day. Outokumpu Flash furnaces vary considerably in size and shape and have five main features. A list of required equipment, dimensions, and production details is provided. Modern Outokumpu Flash furnaces operate with high oxygen blast and very little hydrocarbon fuel. They are operated under automatic control to give constant temperature and constant composition products at a rapid rate with minimum energy consumption. Outokumpu Flash Smelting has been widely adopted due to its efficient capture of sulfur dioxide, rapid production rate, and small energy requirement. The inability to smelt scrap is the only limitation of this process. The chapter summarizes the products and goals of Flash Smelting.

  • Flash Smelting outokumpu process
    Extractive Metallurgy of Copper, 2002
    Co-Authors: William G. Davenport, Matthew J. King, M. Schlesinger, Asit K. Biswas
    Abstract:

    This chapter discusses the Outokumpu Flash Smelting process for copper. It is used for more than half of copper matte Smelting. It is used in two locations for direct-to-copper Smelting and in one location for continuous converting. It blows oxygen, air, dried concentrate, flux, and particulate recycle material as a well-dispersed mixture into a hot reaction shaft. It results in controlled oxidation of the concentrate's iron and sulfur, large evolution of heat, and melting of the solids. Smelting reactions are extremely fast under these conditions. Outokumpu Flash furnaces smelt up to 3000 tons of new concentrate per day. Outokumpu Flash furnaces vary considerably in size and shape and have five main features. A list of required equipment, dimensions, and production details is provided. Modern Outokumpu Flash furnaces operate with high oxygen blast and very little hydrocarbon fuel. They are operated under automatic control to give constant temperature and constant composition products at a rapid rate with minimum energy consumption. Outokumpu Flash Smelting has been widely adopted due to its efficient capture of sulfur dioxide, rapid production rate, and small energy requirement. The inability to smelt scrap is the only limitation of this process. The chapter summarizes the products and goals of Flash Smelting.

  • Inco Flash Smelting
    Extractive Metallurgy of Copper, 2002
    Co-Authors: William G. Davenport, Matthew J. King, M. Schlesinger, Asit K. Biswas
    Abstract:

    This chapter discusses the Inco Flash Smelting process. It uses industrial oxygen blast to smelt copper–iron–sulfur concentrates. It introduces dry feed and industrial oxygen through four horizontal burners and removes sulfur dioxide offgas through a central gas uptake. The offgas is water-quenched and sent to a sulfuric acid plant to capture its sulfur dioxide. As very little nitrogen enters the Inco furnace, its blast and offgas handling systems are small. The offgas is 60 to 75% of the volume in sulfur dioxide. Because the process slag contains less than 1% copper, it can be discarded without copper-recovery treatment. A detailed structure of the Inco Flash Smelting process is discussed in the chapter. Inco Flash gives a cost advantage over most of the other modern Smelting techniques. The converter slag can also be recycled through the furnace for copper recovery. But still, there are many more Outokumpu Flash furnaces than Inco Flash furnaces for several reasons such as Outokumpu's engineering and operational support.