Thesis (MScEng (Process Engineering))--Stellenbosch University, 2008. / The electric smelting furnace is found at the heart of the platinum recovery process where the power input from the electrodes produces a complex interplay between heat transfer and fluid flow. A fundamental knowledge of the dynamic system hosted by the electric furnace is valuable for maintaining stable and optimum operation. However, describing the character of the system hosted by the electric furnace poses great difficulty due to its aggressive environment. A full-scale threedimensional Computational Fluid Dynamics (CFD) model was therefore developed for the circular, three-electrode Lonmin smelting furnace. The model was solved as time dependent to incorporate the effect of the three-phase AC current, which was supplied by means of volume sources representing the electrodes. The slag and matte layers were both modelled as fluid continuums in contact with each other through a dynamic interface made possible by the Volume of Fluid (VOF) multi-phase model. CO-gas bubbles forming at electrode surfaces and interacting with the surrounding fluid slag were modelled through the Discrete Phase Model (DPM). To account for the effect of concentrate melting, distinctive smelting zones were identified within the concentrate as assigned a portion of the melting heat based on the assumption of a radially decreasing smelting rate from the centre of the furnace. The tapping of slag and matte was neglected in the current modelling approach but compensation was made for the heating-up of descending material by means of an energy sink based on enthalpy differences. Model cases with and without CO-gas bubbles were investigated as well as the incorporation of a third phase between the slag and matte for representing the ‘mushy’ chromite/highly viscous slag commonly found in this region. These models were allowed to iterate until steady state conditions has been achieved, which for most of the cases involved several weeks of simulation time. The results that were obtained provided good insight into the electrical, heat and flow behaviour present within the molten bath. The current density profiles showed a large portion of the current to flow via the matte layer between the electrodes. Distributions for the electric potential and Joule heat within the melt was also developed and showed the highest power to be generated within the immediate vicinity of the electrodes and 98% of the resistive heat to be generated within the slag. Heat was found to be uniformly distributed due the slag layer being well mixed. The CO-gas bubbles was shown to be an important contributor to flow within the slag, resulting in a order of magnitude difference in average flow magnitude compared to the case where only natural buoyancy is at play. The highest flow activity was observed halfway between electrodes where the flow streams from the electrodes meet. Consequently, the highest temperatures are also observed in these regions. The temperature distribution within the matte and concentrate layers can be characterized as stratified. Low flow regions were identified within the matte and bottom slag layer which is where chromite and magnitite deposits are prone to accumulate. The model results were partially validated through good agreement to published results where actual measurements were done while also falling within the typical operating range for the actual furnace. The modelling of the electric furnace has been valuably furthered, however for complete confidence in the model results, further validation is strongly recommended.

There are three major problems affecting efficiency in the catalytic oxidation of ammonia for obtaining nitric acid in an industrial plant: the limited life of gauzes, the low efficiency of the catalyst after a few months of operation, and finally, the necessity of recovering as much quantity of precious metals as possible. The first point to study in order to control the process and extend the useful life of the catalyst should be the correct characterization of the deactivated system. Therefore, this research is a systematic study about the performance of the catalytic recovering systems in nitric acid plants for all industrial pressures. In addition, it intends to cover the need of updating the knowledge in this field. The results obtained in this study with the support of SEM, EDX, XPS and AAS techniques, allow us to reach the following conclusions: The extremely critical conditions in which the activation pretreatment takes place cause important structural variations in the material surface. Beyond that, significant PtO2 losses and subsequent enrichment in RhO2 occur in a campaign in a high pressure plant, and mean while a continuous surface reconstruction is taking place. In contrast, an enrichment in Rh0 occurs in a lower pressure plant. In all situations, the deactivation is associated to a decrease in the Platinum content, more active than Rhodium. The getter mechanism in the recovering gauzes is directional and consists in the absorption of PtO2 (or Pt0) on the surface of the Palladium-based wires. Next, the PtO2 reduces itself to Pt0 and forms the Pt-Pd alloy. The part of volatile Platinum and Palladium oxides which gest through the recovering pack, as well as the particles of Rh2O3 carried away mechanically, settle in the heat exchangers line and in the Platinum filter of the high pressure plant. The most part of impurities are associated to Fe, Ni, Cr, Cu and Mn,probably forming oxides. Finally, from the comparative analysis made between the diversity of plants studied, we can conclude that their different operating conditions have an extremely important influence in the performance of the catalytic and recovering systems used.