Treatise on Process Metallurgy

Volume 4: Industrial Plant Design and Process Modeling

2nd Edition - August 23, 2024
Editors: Alexander McLean, Seshadri Seetharaman, Roderick Guthrie, Sridhar Seetharaman, H. Y. Sohn
Language: English
Hardback ISBN:
9 7 8 - 0 - 3 2 3 - 8 5 4 8 0 - 1
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 8 5 4 8 1 - 8

Treatise on Process Metallurgy: Volume Four, Industrial Production provides academics with the fundamentals of the manufacturing of metallic materials, from raw materials into fini… Read more

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Treatise on Process Metallurgy: Volume Four, Industrial Production provides academics with the fundamentals of the manufacturing of metallic materials, from raw materials into finished parts or products. In these fully updated volumes, coverage is expanded into four volumes, including Process Fundamentals, encompassing process fundamentals, structure and properties of matter; thermodynamic aspects of process metallurgy, and rate phenomena in process metallurgy; Processing Phenomena, encompassing interfacial phenomena in high temperature metallurgy, metallurgical process phenomena, and metallurgical process technology; Metallurgical Processes, encompassing mineral processing, aqueous processing, electrochemical material and energy processes, and iron and steel technology, non-ferrous process principles and production technologies, and more.

The work distills the combined academic experience from the principal editor and the multidisciplinary four-member editorial board.

Chapter 1: Metallurgical Production Technology

1. Industrial Production of metals and alloys: Introduction

1.1. Metallurgical Production Plant – Project stage

1.1.1 Conceptualisation

1.1.2 Site Readiness Assessment

1.1.3 Metallurgical Production Plant – Techno-Economics

1.1.4. Award of Contracts

1.1.5. Earth Work

1.1.6. Civil and Structural Work

1.1.7. Equipment Erection Work

1.1.8. Cold Commissioning

1.1.9. Hot Commissioning

1.1.10. Quality Control -- At Project Stage

1.2. Process Concepts for Upscaling

1.2.1. Introduction

1.2.2. Applications in Ironmaking

1.2.3. Applications in Steelmaking

1.3. Metallurgical Production Plant – Production stage

1.3.1 Iron making technologies – present and future

1.3.2. Steel Making technologies – present and future

1.4. Metallurgical Production Plant – Quality Control Systems

1.5. Metallurgical Production Plant – Utilities

1.5.1. Electric Power Supply

1.5.2. Water Supply System and Argon, Nitrogen and Compressed Air

1.5.3. Oxygen Supply

1.5.4. Pneumatic Systems

1.5.5. Hydraulic Systems

1.6. Metallurgical Production Plant – Artificial Intelligence / Machine Learning

1.6.1 Machine Learning, AI, Neural Network and Data Analytics

1.7. Metallurgical Production Plant – Gas Energy & Co Product

1.7.1.Gas & Energy management

1.7.2. Co-Products management

1.8. Start-up and functioning of a ferrous or non-ferrous metal production plant

Chapter 2: Modelling of Industrial Processes

2.1 Principles of and General Approach to Process Modeling

2.2 Modeling of unit processes

2.2.1 Thermodynamic Equilibrium Process Modeling

2.2.2 Reaction Engineering Models

2.2.3 CFD Modeling

2.2.4 AI/Neural Network Approach

2.3 Modeling of Mineral Processing Operations

2.3.1 Comminution processes

2.3.2 Flotation processes

2.4 Modeling of Ferrous production processes [Subsection]

2.4.1 Blast furnace

2.4.2 Modeling of the FINEX Process

2.4.3 Converters

2.4.4 Secondary steelmaking

2.4.4.1 modeling based on the thermodynamics

2.4.4.2 RH Process

2.4.4.3 Ladle Process

2.4.5 Ferroalloy production

2.4.6 Inclusion removal

2.4.7 Continuous casting

2.5 Modeling of Base-Metal Smelting Processes

2.5.1 Overall plant operation

2.5.2 Flash smelting

2.5.3 Flash converting

2.5.4 Bath smelting

2.6 Modeling of hydrometallurgical processes

2.6.1 Leaching

2.6.2 Electrolytic Processes

2.7 Modeling of light metal-production processes

2.7.1 Hall-Heroult Cells

Nomenclature

Alexander McLean

Alexander McLean works in the Department of Materials Science and Engineering at University of Toronto, Toronto, Ontario, Canada.

Affiliations and expertise

Department of Materials Science and Engineering, University of Toronto, Toronto, Ontario, Canada

Seshadri Seetharaman

Seshadri Seetharaman is Professor Emeritus at the Royal Institute of Technology in Stockholm. Professor Seetharaman has more than 320 publications in peer-reviewed journals, 130 conference presentations and 10 patents. He is the editor for the books, "Fundamentals of Metallurgy" and "Treatise on Process Metallurgy". He received the President’s award for teaching merits in 1994. He was nominated as the best teacher in Materials Science eight times and was chosen as the best teacher of the Royal Inst. of Technol. In 2004. He has been visiting professor at Kyushu Inst. Technol., Kyoto university, Japan and TU-Bergakademie, Freiberg, Germany. He was awarded the Brimacomb prize for the year 2010 Hon. Doctor at Aalto University, Finland in 2011 and Hon. Professor at the Ukrainian Metallurgical Academy, 2011. Prof. Seetharaman is an Hon. Member of the Iron and Steel Institute of Japan, 2011, He has been honoured as the Distinguished Alumni of the Indian Institute of Science, Bangalore, India in the year 2013. He is currently a visiting professor at TATA Steel, Jamshedpur, India

Affiliations and expertise

Professor Emeritus, Royal Institute of Technology, Stockholm, Sweden

Roderick Guthrie

Roderick Guthrie works in the Department of Mining and Materials Engineering at McGill Metals Processing Centre, Quebec, Canada.

Affiliations and expertise

Department of Mining and Materials Engineering, McGill Metals Processing Centre, Quebec, Canada

Sridhar Seetharaman

Sridhar Seetharaman is the Fulton Professor of Industrial Decarbonization at Arizona State University. He received his undergraduate degree from the Royal Institute of Technology and his PHD from MIT. He is a Distinguished Member and Fellow of the Association for Iron and Steel Technology.

Affiliations and expertise

Fulton Professor of Industrial Decarbonization at Arizona State University, USA

H. Y. Sohn

Hong Yong Sohn holds the rank of Distinguished Professor at the University of Utah, having joined the Department of Metallurgical Engineering in 1974. He received his B.S. degree in Chemical Engineering from Seoul National University in Korea and his Ph.D. degree in Chemical Engineering in 1970 from the University of California at Berkeley. He worked as a Research Engineer at Du Pont’s Engineering Technology Laboratory. Dr. Sohn has authored or co-authored 7 monographs, 19 edited books, 28 book chapters, 11 patents, some 600 papers, and 39 technical reports. He has served as a Director of TMS-AIME (The Minerals, Metals and Materials Society), was a U.S. DOE Fossil Energy Lecturer, 1978–81, and is an Advisor to LS-MnM (formerly LS-Nikko Copper Inc.) of Korea and also Korea Institute of Geoscience and Mineral Resources (KIGAM). He is an Honorary Professor of Metallurgy at the Kunming University of Science and Technology at the Anhui University of Technology, China. Professor Sohn’s work has been recognized through various awards, which include the 2014 Educator Award from TMS; the Distinguished Scholarly and Creative Research Award, 2012 from the University of Utah; Billiton Gold Medal, 2012 from The Institute of Materials, Minerals and Mining in the U.K.; the TMS 2009 Fellow Award “in recognition of outstanding contribution to the practice of metallurgical/materials science and technology” from The Minerals, Metals and Materials Society (TMS); the 2001 James Douglas Gold Medal Award (“for leadership and outstanding contributions in research and education of nonferrous extractive metallurgy and for work related to the modeling of gas-solid reactors and the development of novel solvent extraction systems”) from the American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME); Fellow Award from the Korean Academy of Science and Technology, 1998; the TMS Champion H. Mathewson Gold Medal Award (1993 “for the most notable contribution to Metallurgical Science in the 3–year period”); the TMS Extractive Metallurgy Lecturer Award (1990 “in recognition as an outstanding scientific leader in the field of nonferrous extraction and processing metallurgy”); the TMS Extraction and Processing Science Award (1990, 1994, 1999 and 2007, respectively, for analysis of flash furnace shaft; modeling of in situ solution mining operations; synthesis of ultrafine particles of intermetallic compounds; and analysis of the influence of chemical equilibrium on fluid-solid reaction rates and the falsification of activation energy); the Fulbright Distinguished Lecturer (1983); and the Camille and Henry Dreyfus Foundation Teacher-Scholar Award (1977). In 2006, TMS honored Dr. Sohn by holding the “Sohn International Symposium on Advanced Processing of Metals and Materials”. Professor Sohn’s research interests have covered a wide range of subjects, such as Development of a Novel Flash Ironmaking; Plasma-Assisted Chemical Synthesis of Inorganic and Ceramic Nanomaterials; Metallurgical Process Engineering including Computational Fluid Dynamics (CFD) Modeling; Nonferrous metal production (especially coppermaking at high temperatures); Fluid–Solid Reaction Engineering; Synthesis and Processing of Ceramic and Intermetallic Compounds; Hydrogen Storage Materials; Solvent Extraction. A major common theme through these research efforts has been the development and application of reaction kinetics theories, especially the engineering analysis of the reactions between solids and fluids. He coauthored a seminal monograph in the field, “Gas-Solid Reactions”, which had been a standard reference on the subject for more than 40 years: Professor Sohn recently updated and expanded the book as “Fluid-Solid Reactions” incorporating the massive amount of work he has continued on the topic since the publication of “Gas-Solid Reactions” and expanding the coverage to include reactions between a solid and a liquid. A major accomplishment by Professor Sohn in this field is the formulation of a rate law called “Sohn’s Law of Additive Reaction Times” that governs the reactions between solids and fluids that are affected by mass transfer processes. A new monograph entitled “Flash Ironmaking” he wrote at the request of Taylor & Francis Publishers has been released in March 2023. Among the numerous plenary and keynote lectures Professor Sohn has given, he delivered a talk on “Novel Ironmaking Technology with Low Energy Requirement and CO2 Emission” to the U.S. Congress on April 21, 2008. He has also served as a technical consultant to many industrial companies, government units, and research institutes, in addition to serving on a number of editorial/advisory boards of international journals.

Affiliations and expertise

Distinguished Professor, Metallurgical Engineering; Adjunct Professor, Chemical Engineering, University of Utah, USA

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Treatise on Process Metallurgy

Volume 4: Industrial Plant Design and Process Modeling

Purchase options

Institutional subscription on ScienceDirect

Alexander McLean

Seshadri Seetharaman

Roderick Guthrie

Sridhar Seetharaman

H. Y. Sohn