Michael Somerville

CSIRO’s multiphase reaction models and their industrial applications

The status and ongoing work on a multiphase reaction model developed at the Commonwealth Scientific & Industrial Research Organization are outlined in this article. The package enables metallurgists to simulate reactions in pyrometallurgical processes with respect to equilibrium between various phases and to calculate slag viscosity at elevated temperatures. The models have been validated against measurements on physico-chemical properties of melts and solid phases produced in industrial processes. A number of examples of the application of the package to ferrous and non-ferrous smelting and refining processes are presented.

Current Status and Future Direction of Low-Emission Integrated Steelmaking Process

In 2006 the Australian steel industry and CSIRO initiated an R&D program to reduce the industry’s net greenhouse emission by at least 50%. Given that most of the CO2 emissions in steel production occur during the reduction of iron ore to hot metal through use of coal and coke, a key focus of this program has been to substitute these with renewable carbon (charcoal) sourced from sustainable sources such as plantations of biomass species. Another key component of the program has been to recover the waste heat from molten slags and produce a by-product that could be substituted for Portland cement.

Utilization of biomass as an alternative fuel in ironmaking

Abstract Raw biomass is unsuitable for ironmaking applications. However, after pyrolysis, the resultant chars can substitute for conventional nonrenewable fuels and reductants. Provided that the renewable fuels are produced sustainably, they have great potential to lower net CO2 emissions from an integrated steel plant without the need for significant capital expenditure. Charcoal properties can be tailored for optimal performance, and applications in cokemaking, sintering, and the blast furnace are presented. Potential applicability to alternate and emerging ironmaking processes is discussed. This chapter discusses recent R&D for the 10 applications identified and also presents progress toward a versatile large-scale pyrolysis process.

Fluxing Strategies for the Direct to Blister Smelting of High Silica and Low Iron Copper Concentrates

Copper concentrates which have high silica but low iron contents are difficult to smelt using conventional two stage smelting processes. Direct to blister smelting is possible using either iron oxide fluxes to produce a fayalite type slag or silica and lime fluxes to produce a lime-silica-iron oxide slag. The benefits of lime and silica fluxing option, have been quantified using both thermodynamic modelling and a campaign of pilot scale TSL (Sirosmelt) direct to blister smelting.

Direct-to-Blister Copper Smelting with the ISASMELT™ Process

To date, many types of primary concentrate have been smelted using the ISASMELT™ technology, with annual smelting of copper concentrate alone exceeding 7 million tonnes. Most of this material could best be described as chalcopyrite concentrate, owing to the predominance of copper attributable to this single mineral. Chalcopyrite concentrates lend themselves readily to smelting with a fayalite slag, and producing a matte containing 55–65 wt% Cu. However, the ISASMELT™ technology also stands ready to meet future copper demand through the treatment of new types of concentrates containing relatively low iron and high silica levels. Various slag systems have been considered for direct-to-blister smelting. They have been evaluated computationally, using the MPE thermodynamic modelling package, and practically, at pilot scale. The lime-silica-iron oxide slag was found to have the lowest slag make, lower dissolved copper and hence lowest copper losses. Based on the outcomes of the modelling and pilot scale testwork a future smelter flowsheet has been defined, comprising a single ISASMELT™ direct-to-blister furnace, an electric slag cleaning furnace, and appropriately designed anode furnaces.

High Temperature Characterisation and Techno-Economics of E-Waste Processing

The elemental composition of selected e-waste materials has been determined through fusion in a metal and slag bath. During this process the elemental components of the inhomogeneous pulverized material distributed to the copper, slag and fume process streams. Through the analysis and mass of these streams the composition of the original e-waste was calculated.