Process Modeling in Non-Ferrous Metallurgy

Abstract

Section 2.4.1 describes the general principles involved in developing quantitative models for complex processes.Section 2.4.2 describes models of processes operated at or near equilibrium conditions in which thermodynamic relations determine the overall process performance. The emphasis is placed on the behavior of minor element distribution to gas, slag, and matte or metal in nonferrous sulfide matte smelting and converting steps in batch and continuous operations under various conditions. Model predictions are compared with industrial data, which show satisfactory results. Finally, an example of modeling a system in which combined equilibrium and fluid flow must be considered is discussed.Section 2.4.3 describes mathematical models for individual process steps within overall metallurgical production systems, typically taking into account heterogeneous chemical reactions and rate phenomena that incorporate chemical kinetics and mass transfer. Such models form basic building blocks for models for an overall process, which in turn are a component of process models for an entire plant.Section 2.4.4 discusses the principles involved in computational fluid dynamic (CFD) modeling and presents examples of metallurgical process models based on CFD. This tool allows the simulation of multiphase fluid flow in complicated geometric systems, to which other subprocesses such as heat and mass transfer and chemical reactions can be incorporated. It is shown that real, industrial processes have become amenable to more detailed analysis and simulation, thanks to this versatile and useful technique. Its availability has also resulted in the merging of the basic principles of various previously independent sub-disciplines such as chemical reaction engineering, transport phenomena, and unit operations to formulate comprehensive and increasingly more realistic descriptions of complex processes. © 2014 Elsevier Ltd. All rights reserved.