Integrated experimental and thermodynamic modelling research methodology for metallurgical slags with examples in the copper production field
Recent advances of coupled experimental and thermodynamic modelling research on phase equilibria, thermodynamics and viscosities of copper and other metallurgical slag systems, and experiences of implementation of the advanced research outcomes into industrial practice are summarised. An outline of key issues derived from many years experience in continuing development and application of both experimental, thermodynamic and viscosity modelling research is presented. Particular emphasis is given to the details of the research methodologies, analysis of reasons for uncertainties and the ways to continuously improve the accuracy of both studies. The ways how the advanced research tools can be implemented into industrial operations are presented with examples on copper production slag systems. Experimental part of the study involves high temperature equilibration in controlled gas atmospheres, rapid quenching and direct measurement of equilibrium phases with electron probe X-ray microanalysis (EPMA). Thermodynamic modelling undertaken using computer package FactSage with the quasi-chemical model for the liquid slag phase is closely integrated with the parallel experimental research. Experiments are planned to provide specific data for thermodynamic model development as well as for pseudo-ternary liquidus diagrams which can be used directly by process operators. Thermodynamic assessments are used to identify priorities for experiments. Experimental and modelling studies are combined into an integrated research program contributing to and enhancing outcomes of each other and of the overall program. The continuous development of experimental methodologies have brought significant advances. Importantly, these novel approaches enable measurements to be made in systems that could not previously be characterised, for example, due to uncontrollable reactions with container materials or changes in bulk composition due to vapour phase reactions. The approach, however, requires particular attention to ensure accurate information is obtained. An ongoing dedicated program of improving accuracy of all possible elements of the research revealed a number of possible sources of uncertainties and the ways developed to mitigate those shortcomings are systematically summarised in this paper. The thermodynamic modelling has progressed significantly, and achieved a level of prediction of phase equilibria and thermodynamics of complex multi-component multi-phase systems with improved accuracy. The adequate description of the systems however requires a combination of various types of data and still demands continuous further development. The outcomes of both experimental and modelling studies are applied to assist in improvements of the industrial copper production. High certainty of the predictions of the behaviour of complex industrial processes provides a strong basis for optimisation of operations. The stage of implementation of the outcomes of the laboratory experimental and theoretical thermodynamic modelling, however, is frequently overlooked, but requires high level of research expertise to establish the actual conditions in the real industrial process and relate them to the advanced laboratory and theoretical research tools. Examples of the applications are given in the paper.
copper smelting slag phase equilibria thermodynamic modelling liquidus minor elements distribution.
Evgueni Jak
PYROSEARCH, Pyrometallurgy Research Centre, School of Chemical Engineering,The University of Queensland, Brisbane, Queensland, 4072, Australia
国际会议
Ninth International Conference on Molten Slags,Fluxes and Salts(第九届国际熔渣、溶剂与熔盐学术会议 MOLTEN12)
北京
英文
1-28
2012-05-27（万方平台首次上网日期，不代表论文的发表时间）