Flash Smelting: Analysis, Control and Optimization deals with the analysis, control, and optimization of flash smelting. This book explores flash smelting in general and Outokumpu and Inco flash smelting in particular, and also presents a mathematical description for the flash smelting process. A set of mass and heat balance equations that can be used to describe steady state smelting under autogenous or nearautogenous smelting conditions is developed.
This text has 20 chapters and begins with an overview of flash smelting and its products; the main raw materials of copper flash smelting; chemical reactions in the flash furnace; impurities in the concentrates that are fed to the flash furnace; and the operation of industrial flash furnaces. Attention then turns to Outokumpu flash smelting, Inço flash smelting, and mathematical representation of flash smelting. The chapters that follow focus on the effects of blast preheat on flash smelting; the combustion of fossil fuel in the flash furnace; and the effect of matte grade on the fossil fuel, industrial oxygen, and blast preheat requirements of flash smelting. Equations are used to determine the effects of such factors as concentrate composition, blast temperature, and dust carryout, and as the basis for optimizing and controlling the flash smelting process.
This book will be of interest to both mathematicians and metallurgists.
Autorentext
Professor William George Davenport is a graduate of the University of British Columbia and the Royal School of Mines, London. Prior to his academic career he worked with the Linde Division of Union Carbide in Tonawanda, New York. He spent a combined 43 years of teaching at McGill University and the University of Arizona.
His Union Carbide days are recounted in the book Iron Blast Furnace, Analysis, Control and Optimization (English, Chinese, Japanese, Russian and Spanish editions).
During the early years of his academic career he spent his summers working in many of Noranda Mines Company's metallurgical plants, which led quickly to the book Extractive Metallurgy of Copper. This book has gone into five English language editions (with several printings) and Chinese, Farsi and Spanish language editions.
He also had the good fortune to work in Phelps Dodge's Playas flash smelter soon after coming to the University of Arizona. This experience contributed to the book Flash Smelting, with two English language editions and a Russian language edition and eventually to the book Sulfuric Acid Manufacture (2006), 2nd edition 2013.
In 2013 co-authored Extractive Metallurgy of Nickel, Cobalt and Platinum Group Metals, which took him to all the continents except Antarctica.
He and four co-authors are just finishing up the book Rare Earths: Science, Technology, Production and Use, which has taken him around the United States, Canada and France, visiting rare earth mines, smelters, manufacturing plants, laboratories and recycling facilities.
Professor Davenport's teaching has centered on ferrous and non-ferrous extractive metallurgy. He has visited (and continues to visit) about 10 metallurgical plants per year around the world to determine the relationships between theory and industrial practice. He has also taught plant design and economics throughout his career and has found this aspect of his work particularly rewarding. The delight of his life at the university has, however, always been academic advising of students on a one-on-one basis.
Professor Davenport is a Fellow (and life member) of the Canadian Institute of Mining, Metallurgy and Petroleum and a twenty-five year member of the (U.S.) Society of Mining, Metallurgy and Exploration. He is recipient of the CIM Alcan Award, the TMS Extractive Metallurgy Lecture Award, the AusIMM Sir George Fisher Award, the AIME Mineral Industry Education Award, the American Mining Hall of Fame Medal of Merit and the SME Milton E. Wadsworth award. In September 2014 he will be honored by the Conference of Metallurgists' Bill Davenport Honorary Symposium in Vancouver, British Columbia (his home town).
Inhalt
Preface
Acknowledgments
1 Flash Smelting
1.1 Products
1.2 Raw Materials
1.3 Chemical Reactions
1.4 Impurity Behavior
1.5 Industrial Flash Furnaces and Their Operation
1.6 Recent Trends in Flash Smelting
1.7 The Competitive Position of Flash Smelting
1.8 Summary
Suggested Reading
References
Problems
2 Outokumpu Flash Smelting
2.1 The Outokumpu Furnace
2.2 Peripheral Equipment
2.3 Operation
2.4 Control Strategies
2.5 Major 1980s Trends in Outokumpu Smelting
2.6 Other Trends
2.7 Summary
Suggested Reading
References
Problems
3 Inco Flash Smelting
3.1 Construction Details
3.2 Auxiliary Equipment
3.3 Operation
3.4 Inco Control Strategy
3.5 1980s Trends in Inco Smelting
3.6 Summary
Suggested Reading
References
Problems
4 Mathematical Description of Flash Smelting
4.1 Fundamental Equations-Mass and Heat Balances
4.2 Feed and Product Specifications
4.3 Adaptation of Mass and Heat Balances to Flash Smelting, Illustrative
Problem
4.4 Useful Forms of Equations (4.2) to (4.7)
4.5 Solving the Section 4.3 Illustrative Problem
4.6 Discussion
4.7 Summary
Suggested Reading
References
Problems
5 Mixed Mineralogy in Concentrate Feed-Copper-Iron-Sulphur-Oxygen-Silica Minerals
5.1 Illustrative Problem
5.2 Representing Mineralogy in Mass and Enthalpy Balances
5.3 Calculation Matrix and Results
5.4 Discussion
5.5 Summary: General Treatment of Cu-Fe-S-O-SiO2 Materials
Problems
6 Outokumpu Flash Smelting-Effects of Nitrogen in Flash Furnace Blast
6.1 Illustrative Problem
6.2 Nitrogen Equations
6.3 Enthalpy Balance Modification
6.4 Nitrogen in the Calculation Matrix
6.5 Calculation and Results
6.6 Discussion
6.7 Summary
Problems
7 Preheating the Flash Furnace Blast
7.1 Illustrative Problem
7.2 Results
7.3 Blast Preheat Energy-An Alternative Representation of Hot Blast
7.4 Illustrative Problem and Calculation Matrix
7.5 Discussion
7.6 Summary
Problems
8 Combustion of Fossil Fuel in the Flash Furnace
8.1 Illustrative Fossil Fuel Combustion Problem
8.2 New Carbon and Hydrogen Balance Equations
8.3 Mass Fossil Fuel Specification
8.4 Oxygen Balance Modifications
8.5 Enthalpy Balance Modifications
8.6 Calculation Matrix and Results
8.7 Discussion
8.8 Summary
Reference
Problems
9 Alternative Strategies For Producing Matte of a Specified Grade-60% Cu
9.1 Objective of Chapter
9.2 Calculations
9.3 Results
9.4 Discussion
9.5 Off-Gas Volume
9.6 Maximum Flash Furnace Smelting Rate
9.7 Summary
Problems
10 Energy and Industrial Oxygen Requirements for Producing Matte of a Specified Grade-60% Cu
10.1 Modifications to the Calculation Matrix
10.2 Results
10.3 Energy Minimization
10.4 Calculation of Energy Consumption
10.5 Minimum Energy Requirement, 60% Cu Matte
10.6 Discussion
10.7 Summary
Reference
Problems
11 Influence of Matte Grade on Energy and Industrial Oxygen Requirements for Steady-State Smelting
11.1 Calculations and Results
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