Applications of Process Engineering Principles in Materials Processing, Energy and Environmental Technologies: An EPD Symposium in Honor of Professor Ramana G. Reddy: Plenary Session
Sponsored by: TMS Extraction and Processing Division, TMS Light Metals Division, TMS: Energy Committee, TMS: Hydrometallurgy and Electrometallurgy Committee
Program Organizers: Shijie Wang, Rio Tinto Kennecott Utah Copper; Michael Free, University of Utah; Shafiq Alam, University of Saskatchewan; Mingming Zhang, Arcelor Mittal; Patrick Taylor, Colorado School of Mines

Monday 9:20 AM
February 27, 2017
Room: 15B
Location: San Diego Convention Ctr

Session Chair: Hong Yong Sohn, University of Utah

9:20 AM  
Applications of Process Engineering Principles in Materials Processing, Energy and Environmental Technologies-Contributions of Professor Ramana Reddy: Shijie Wang1; 1Rio Tinto Kennecott Utah Copper
    Life time achievements of Professor Reddy’s teaching, research and scholarship in the field of chemical and materials science and engineering are briefly described. He has devoted his entire career in the introduction and application of process engineering principles to the quantitative description of materials processing reactions, and industrial operations. He has formulated quantitative methodologies based on first principles of thermodynamics, phase equilibria and kinetics to: design of slags and fluxes for production and purification of metals and alloys; development of Reddy-Blander model for a priori prediction of impurities capacities of melts; development of novel ionic liquid electrolytes for materials processing; design materials for fuel cells and capacitors; use of thermodynamic approaches to predict physical properties of materials; industrial energy waste separation and remediation; and thermal energy storage. He is a scholar and mentor, and has made numerous scientific and service contributions to the society and metallurgical and materials engineering education.

9:50 AM  
Towards the Innovation Economy: An Industry Perspective on Radical Innovation: Tom Hennebel1; Isabel Vermeulen1; Karolien Vasseur1; Lennart Scheunis1; Christina Meskers1; Marleen Esprit1; Maurits Van Camp1; 1Umicore
    Umicore strongly believes in a circular economy as pathway towards a resource resilient society. This pathway firstly requires a transition from an industrial to a knowledge economy, which is obtained by the implementation of quality and knowledge management, and by communication and computing technologies. The next step towards the circular economy includes the transition into an innovation economy and can solely be taken by providing systemic solutions that require (i) deep knowledge and expertise, (ii) a highly collaborative approach and (iii) radical changes, in which design is of utmost importance. Especially these radical changes are complex for industry when their current operations, technologies, processes or products are successful. In this presentation, we will elaborate on how Umicore participates in the transition towards the innovation economy by working towards and implementing radical changes in their flowsheets. Examples include case studies on furnace integrity and on the treatment of secondary industrial residues.

10:20 AM Break

10:35 AM  
Status of the Development of Flash Ironmaking Technology: H.Y. Sohn1; Yousef Mohassab1; Mohamed Elzohiery1; De Qiu Fan1; Amr Abdelghany1; 1University of Utah
    The flash ironmaking process being developed at the University of Utah is aimed at producing iron directly from iron oxide concentrate. In this process, the concentrate is reduced by H₂ and CO gas mixture produced from the partial oxidation of natural gas in a flash reactor. Natural gas represents an economically viable reductant/fuel for the flash ironmaking. The rate equations for the reduction kinetics by H₂, CO and H₂+CO gas mixtures were determined in the temperature range 1150-1600 °C. These rate equations were applied to experimental results from a laboratory flash reactor using CFD simulation. A new mini pilot reactor, which is capable of operating at 1250-1550 °C with a concentrate feeding rate of 2-5 kg/h, has been installed. Commissioning of the reactor with an emphasis on preheating of the reactor, production of reducing gas mixtures and the feeding and collection of iron ore concentrate particles has been completed.

11:05 AM  
Innovations and Insights in Fluid Flow and Slime Adhesion for Improved Copper Electrorefining: Weizhi Zeng1; Michael Free1; Shijie Wang2; 1University of Utah; 2Rio Tinto Kennecott Utah Copper
    Copper electrorefining is an old technique that is generally performed in electrolytic cells with a bottom inlet and top outlet that are convenient for electrolyte flow control. Nevertheless, this configuration cannot effectively direct electrolyte flow to the regions between electrodes, which results in weak convection and inadequate delivery of chemical species and additives. Innovations in electrorefining cell design can improve electrolyte flow for improved cathode quality as will be discussed in this paper, along with associated current distribution, species transport, fluid flow field, and particle movements that were simulated based on finite element modeling. The resulting fluid flows in cells can transport suspended slime particles to the cathode where they can become incorporated as impurities. The concentration of suspended slime particles is inversely related to slime adhesion, which is strongly influenced by slime particle sintering, and sintering is related to temperature and slime particle composition. Thus, the combination of innovative fluid flow and slime particle sintering can play important roles in improving cathode quality as will be discussed in this paper.

11:35 AM  
Molten Flux Design for Solid Oxide Membrane-Based Electrolysis of Aluminum from Alumina: Shizhao Su1; Thomas Villalon1; Uday Pal1; 1Boston University
    Compared with the current Hall–He´roult process for smelting aluminum, the Solid Oxide Membrane (SOM)-Based electrolysis process brings various advantages such as simplified design, lower cost, lower energy use, and many other environmental benefits. However, the state-of-the-art SOM electrolysis process is limited by solid oxide membrane stability and its compatibility with molten salt and electrode materials. This work will identify cost-effective molten salt compositions and membrane materials/architecture along with electrodes and current collectors that are all chemically compatible and provide optimum electrochemical properties for efficient aluminum oxide electrolysis.

12:05 PM  
Effect of Slag Phase on Mixing and Mass Transfer in a Model Creusot Loire Uddeholm (CLU) Converter: Rauf Eric1; Admire Chaendera1; 1University of the Witwatersrand
    Gas jet was blown through bottom nozzles of a 1/5th scale CLU model in the presence and absence of slag. Kerosene and water were used to simulate the slag and metal phases respectively. Mixing time increased with increasing bath height and with a decrease in the gas flow rate. It was related to bath weight, bath height and gas flow rate. Slag increased mixing time by about 16% and the mass transfer values by about 32%. Mass transfer rates were higher near the bath surface and in the gas-liquid plume region. They increased with increasing gas flow rate and with a decrease in bath height. A relationship showing the dependence of derived mass transfer coefficient on the gas injection rate was established. Turbulence characteristics inside the bath liquid were established to vary with location, vessel geometry and gas injection rate.