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 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 77 G. Lind Modeling of Ladle Metallurgy in Steelmaking 85 G. Irons, K. Krishnapisharody, and K. Graham 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. Isac, 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. Jones Recent Developments in FactSage Thermochemical Software and Databases 141 C. Bale, E. Belisle, P. Chartrand, S. Decterov, G. Eriksson, A. Gheribi, K. Hack, I. Jung, J. Melancon, 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 I. Barker An Electromagnetically Stirred Slurry Model for the Smelting Zone of a 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 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 213 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 of Pb from Molten Copper by FetO-SiO2 (-CaO, Al2O3) Slag 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. Chen, and M. Pomeroy Current Status and Future Direction of Low-Emission Integrated Steelmaking Process 303 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 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 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 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 455 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. Ibana 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 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 Gas 537 H. Dalaker and P. Tetlie Reduction of Mixtures of Ni-Oxide and Ti-Oxide Powder in a Natural Gas Containing Atmosphere 547 C. van der Eijk and K. Tang Kinetic and Thermodynamic Analysis of the Reduction of Oxides of Cu and Co in a SiO2-CaO-(Al,Fe)2O3 Slag 553 Y. Hara and A. Jha Carbothermic Reduction of Ilmenite Concentrate with Coke Assisted 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 Use of 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 Using Confocal Scanning Laser Microscope 597 L. Lu, H. Meilong, and B. Chenguang Viscosity-Structure Relationship in the CaO-SiO2-MnO-CaF2 Slag for the Production of Manganese Ferroalloys 605 J. Park and K. Ko Recovery of Vanadium from a High Ca/V Ratio Vanadium Slag Using Sodium 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 Flux Applications to the Continuous Casting Process for Steelmaking 633 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 a High Frequency Magnetic Field 651 S. Wang, L. Zhang, and Y. Tian Fluid Flow, Alloy Dispersion and Inclusion Motion in Argon-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 by Fluidized Reduction Experiment 675 S. Yang, C. Liu, X. Gao, and J. Li Author Index 685 Subject Index 689

About the Author

Phillip Mackey, P.J. Mackey Technology Inc., Montreal, Quebec, Canada.

Eric Grimsey, Curtin University, Kalgoorlie, Western Australia, Australia.

Rodney Jones, Mintek, Randburg, South Africa.

Geoffrey Brooks, Swinburne University of Technology, Melbourne, Victoria, Australia.