The scheduling of the converter aisle of a nickel smelting plant is a non-trivial task with significant consequences to plant profitability and production. An optimization-based scheduling formulation is developed using a continuous-time paradigm to accurately represent event timings. The formulation accounts for environmental restrictions on sulfur dioxide emissions using event timing constraints. The formulation includes novel semi-continuous modeling to represent flash furnaces which operate with a continuous inlet flow and intermittent discrete material removal, as well as, a novel sequencing and symmetry-breaking scheme to account for identical units operating in parallel. A rolling horizon feature is included in the formulation to accommodate multi-period optimization. Tightening constraints are developed and used to improve the computational performance of the optimization and demonstrate the capacity of the proposed methodology to function as a real-time decision-support tool. A solution procedure is presented where an aggregate model is used to bound the objective function of the master problem in a two layer optimization scheme. Finally, a novel multi-tiered procedure is presented to enhance the optimization solution by re-optimizing for objectives of decreasing priority in order to minimize task start times and penalize deviations in the furnace flow rate. To address the closed-loop properties of scheduling, a reactive scheduling mechanism is included to allow for rescheduling to account the impact of process disturbances on the operating schedule. A methodology for reducing radical scheduling changes due to the optimization during reactive scheduling is presented. The reactive scheduling algorithm utilizes a tiered optimization approach that progressively increases the degrees of freedom available, as required, in order to achieve a feasible production schedule. The use of the reactive scheduling algorithm demonstrates the ability to reject disturbances and transition plant operation in an agile manner. / Thesis / Master of Applied Science (MASc)

No description available.

Thesis (MScEng (Process Engineering))--University of Stellenbosch, 2011. / ENGLISH ABSTRACT: A mineral concentrate drying process consisting of a hot gas generator, a flash dryer and a feeding section is found to be the bottleneck in the platinum concentrate smelting process. This operation is used as a case study for system identification and model-based control of dryers. Based on the availability of a month's worth of dryer data obtained from a historian, a third party modelling and control software vendor is interested in the use of this data for data driven model construction and options for dryer control. The aimed contribution of this research is to use only data driven techniques and attempt an SID experiment and use of this model in a controller found in literature to be applicable to the dryer process. No first principle model was available for simulation or interpretation of results. Data were obtained for the operation from the plant historian, reduced, cleaned and investigated for deterministic information through surrogate data comparison – resulting in usable timeseries from the plant data. The best datasets were used for modelling of the flash dryer and hot gas generator operations individually, with the hot gas generator providing usable results. The dynamic, nonlinear autoregressive models with exogenous inputs were identified by means of a genetic programming with orthogonal least squares toolbox. The timeseries were reconstructed as a latent variable set, or “pseudo-embedding”, using the delay parameters as identified by average mutual information, autocorrelation and false nearest neighbours. The latent variable reconstruction resulted in a large solution space, which need to be investigated for an unknown model structure. Genetic Programming is capable of identifying unknown structures. Freerun prediction stability and sensitivity analysis were used to assess the identified best models for use in model based control. The best two models for the hot gas generator were used in a basic model predictive controller in an attempt to only track set point changes. One step ahead modelling of the flash dryer outlet air temperature was unsuccessful with the best model obtaining a validation R2 = 43%. The lack of process information contained in the available process variables are to blame for the poor model identification. One-step ahead prediction of the hot gas generator resulted in a top model with validation R2 = 77.1%. The best two hot gas generator models were implemented in a model predictive controller constructed in a real time plant data flow simulation. This controller's performance was measured against set point tracking ability. The MPC implementation was unsuccessful due to the poor freerun prediction ability of the models. The controller was found to be unable to optimise the control moves using the model. This is assigned to poor model freerun prediction ability in one of the models and a too complex freerun model structure required. It is expected that the number of degrees of freedom in the freerun model is too much for the optimiser to handle. A successful real time simulation architecture for the plant dataflow could however be constructed in the supplied software. It is recommended that further process measurements, specifically feed moisture content, feed temperature and air humidity, be included for the flash dryer; closed loop system identification be investigated for the hot gas generator; and a simpler model structure with smaller reconstructed latent variable regressor set be used for the model predictive controller. / AFRIKAANSE OPSOMMING: 'n Drogings proses vir mineraal konsentraat bestaan uit drie eenhede: 'n lug verwarmer-, 'n blitsdroeër- en konsentraat toevoer eenheid. Hierdie droeër is geïdentifiseer as die bottelnek in die platinum konsentraat smeltingsproses. Die droeër word gebruik as 'n gevallestudie vir sisteem identifikasie asook model-gebasseerder beheer van droeërs. 'n Maand se data verkry vanaf die proses databasis, het gelei tot 'n derde party industriële sagteware en beheerstelsel maatskappy se belangstelling in data gedrewe modelering en beheer opsies vir die drogings proses. Die doelwit van hierdie studie is om data gedrewe modeleringstegnieke te gebruik en die model in 'n droeër-literatuur relevante beheerder te gebruik. Geen eerste beginsel model is beskikbaar vir simulasie of interpretasie van resultate nie. Die verkrygde data is gereduseer, skoon gemaak en bestudeer om te identifiseer of die tydreeks deterministiese inligting bevat. Dit is gedoen deur die tydreeks met stochastiese surrogaat data te vergelyk. Die mees gepaste datastelle is gebruik vir modellering van die blitsdroeër en lugverwarmer afsonderlik. Die nie-liniêre, dinamiese nie-linieêre outeregressie modelle met eksogene insette was deur 'n genetiese programmering algoritme, met ortogonale minimum kwadrate, identifiseer. Die betrokke tydreeks is omskep in 'n hulp-veranderlike stel deur gebruik te maak van vertragings-parameters wat deur gemiddelde gemeenskaplike inligting, outokorrelasie en vals naaste buurman metodes verkry is. Die GP algoritme is daartoe in staat om the groot oplossings ruimte wat deur hierdie hulp-veranderlike rekonstruksie geskep word, te bestudeer vir 'n onbekende model struktuur. Die vrye vooruitskattings vermoë, asook die model sensitiwiteit is inag geneem tydens die analiese van die resultate. Die beste modelle se gepastheid tot model voorspellende beheer is gemeet deur die uitkomste van 'n sensitiwiteits analise, asook 'n vrylopende voorspelling, in oënskou te neem. Die een-stap vooruit voorspellende model van die droeër was onsusksesvol met die beste model wat slegs 'n validasie R2 = 43% kon behaal. Die gebrekkige meet instrumente in die droeër is te blameer vir die swak resultate. Die een-stap vooruit voorspellende model van die lug verwarmer wat die beste gevaar het, het 'n validasie R2 = 77.1% gehad. 'n Basiese model voorspellende beheerder is gebou deur die 2 beste modelle van slegs die lugverwarmer te gebruik in 'n intydse simulasie van die raffinadery data vloei struktuur. Hierdie beheerder se vermoë om toepaslike beheer uit te oefen, is gemeet deur die slegs die stelpunt te verander. Die beheerder was egter nie daartoe in staat om die insette te optimeer, en so die stelpunt te volg nie. Hierdie onvermoë is as gevolg van die kompleks vrylopende model struktuur wat oor die voorspellingsvenster optimeer moet word, asook die onstabiele vryvooruitspellings vermoë van die modelle. Die vermoede is dat die loslopende voorspelling te veel vryheids grade het om die insette maklik genoeg te optimeer. Die intydse simulasie van die raffinadery se datavloei struktuur was egter suksesvol. Beter meting van noodsaaklike veranderlikes vir die droër, o.a. voginhoud van die voer, voer temperatuur, asook lug humiditeit; geslotelus sisteem identifikasie vir die lugverwarmer; asook meer eenvoudige model struktuur vir gebruik in voorspellende beheer moontlik vermag deur 'n kleiner hulp veranderlike rekonstruksie te gebruik.

Made available in DSpace on 2017-07-21T20:42:28Z (GMT). No. of bitstreams: 1 Eduardo Prestes.pdf: 9360031 bytes, checksum: cf81ac633030e28b561a09650cf7105a (MD5) Previous issue date: 2007-12-14 / The recycled lead obtained mainly from the recovery of lead from lead-acid batteries is named secondary lead. The process of lead scrap smelting and reduction is carried out in short rotary furnaces and the standard refractory lining is the burned magnesia-chromite bricks. The employment of refractory castables is not found in the literature for this type of application. Therefore, this research provides an evaluation by slag attack of commercial castable refractories selected for short rotary furnace application of secondary lead smelting in confrontation with commercial burned magnesia-chromite bricks. After the scorification tests, statics and dynamics, the wear and slag penetration area in each sample was measured using the analysis image software “Image- Pro Plus 5.1”. For the best performance products was realized the corrosion study by analysis of the refractory-slag interface by Scanning Electronic Microscopy (SEM), Energy Dispersive Scanning (EDS) and X-Ray Diffractometry. Sintered magnesia-chrome spinel bricks showed the best slag attack resistance and the evaluated castable refractories showed inferior performance than the standards refractory bricks. Nevertheless, a low cement alumina-chrome castable based on white fused alumina was similar to performance of the direct bonded magnesia-chromite bricks. This result shows that the employment of castable refractory in short rotary furnace of secondary lead smelting is very promising. The analysis of the refractory products after the static and dynamic slag attack showed that the FeO is the main corrosive agent of the slag, due to its reaction with components of refractory and formation of low melting compounds. / O chumbo reciclado produzido principalmente a partir da recuperação do chumbo de sucatas de baterias automotivas é denominado chumbo secundário. O processo de fusão e redução da sucata metálica de chumbo é realizado em pequenos fornos rotativos e o revestimento refratário normalmente empregado é composto por produtos formados a base de magnésia-cromo. O emprego de concretos refratários para este tipo de aplicação praticamente não é encontrado na literatura. Por isso, este trabalho apresenta uma avaliação, pelo ataque por escória, de concretos refratários comerciais selecionados para aplicação em fornos rotativos d e redução de chumbo secundário em comparação com os refratários formados de magnésiacromo. Após os testes de escorificação, estáticos e dinâmicos, os produtos refratários foram avaliados pela área do perfil de desgaste e de infiltração dos corpos de prova. A área foi obtida pelo emprego do software de análise de imagem “Image-Pro Plus 5.1”. Para os produtos de melhor desempenho nos ensaios de escorificação foi realizado o estudo da corrosão pela análise da interface refratário-escória, utilizando as técnicas de microscopia eletrônica de varredura (MEV), espectroscopia por dispersão de energia (EDS) e difratometria de raios X. Os refratários formados de magnésia-cromo apresentaram melhor resistência ao ataque por escória em relação aos concretos refratários avaliados. No entanto, um concreto refratário de aluminacromo de baixo teor de cimento, a base coríndon branco, apresentou desempenho próximo dos produtos formados de magnésia-cromo. Este resultado mostra que o emprego de concretos refratários em fornos rotativos de redução de chumbo secundário é muito promissor. A análise dos produtos refratários após o ataque por escória estático e dinâmico mostrou que o FeO é o principal agente corrosivo da escória, devido a sua reação com os componentes do refratário e formação de compostos de baixo ponto de fusão.

Aluminium smelting is a high temperature electrometallurgical process, which suffers considerable inefficiencies in power utilization and equipment maintenance. Aluminium smelting cell works in the extreme environments that contain extraordinarily aggressive gases, such as HF, CO and SO2. Mild steel used as a structural material in the aluminium industry, can be catastrophically corroded or oxidized in these conditions. This project was mainly concerned with extending the lifetime of metal structures installed immediately above the aluminium smelting cells. An aluminium-rich coating was developed on low carbon steel A06 using pack cementation technique. Yttria (Y2O3) was also used to improve the corrosion resistance of coating. Kinetics of the coating formation were studied. XRD, FESEM and FIB were employed to investigate the phase constitution and the surface morphology. Together with other potentially competitive materials, aluminium-rich coating was evaluated in simulated plant environments. Results from the long time (up to 2500h) isothermal oxidation of materials at high temperature (800??C) in air showed that the oxidation resistance of coated A06 is close to that of stainless steel 304 and even better than SS304 in cyclic oxidation tests. Coated A06 was also found to have the best sulfidation resistance among the materials tested in the gas mixture contains SO2 at 800??C. Related kinetics and mechanisms were also studied. The superior corrosion resistance of the coated A06 is attributed to the slow growing alpha-Al2O3 formed. Low temperature corrosion tests were undertaken in the gas mixtures containing air, H2O, HCl and SO2 at 400??C. Together with SS304 and 253MA, coated A06 showed excellent corrosion resistance in all the conditions. The ranking of the top three materials for corrosion resistance is: 253MA, coated A06 and SS304. It is believed that aluminised A06 is an ideal and economical replacement material in the severe corrosive aluminium smelting cell environment.

Employing a technological approach derived from the 'Anthropology of Technology' theoretical literature, this thesis concerns the identifi cation and explanation of change in prehistoric extractive metallurgical behaviour in the Khao Wong Prachan Valley of central Thailand. The 'Valley' metallurgical complex, amongst the largest in Eurasia, constitutes Southeast Asia's only documented industrial-scale copper-smelting evidence. The two smelting sites investigated, Non Pa Wai and Nil Kham Haeng, provide an interrupted but analytically useful sequence of metallurgical consumption and production evidence spanning c. 1450 BCE to c. 300 CE. The enormous quantity of industrial waste at these sites suggests they were probably major copper supply nodes within ancient Southeast Asian metal exchange networks. Excavated samples of mineral, technical ceramic, and slag from Non Pa Wai and Nil Kham Haeng were analysed in hand specimen, microstructurally by refl ected-light microscopy and scanning electron microscopy (SEM), and chemically by polarising energy dispersive x-ray fl uorescence spectrometry ([P]ED-XRF) and scanning electron microscopy with energy dispersive x-ray fl uorescence spectrometry (SEM-EDS). Resulting analytical data were used to generate detailed technological reconstructions of copper smelting behaviour at the two sites, which were refi ned by a programme of fi eld experimentation. Results indicate a long-term improvement in the technical profi ciency of Valley metalworkers, accompanied by an increase in the human effort of copper production. This shift in local 'metallurgical ethos' is interpreted as a response to rising regional demand for copper in late prehistory.

Aluminium smelting is a high temperature electrometallurgical process, which suffers considerable inefficiencies in power utilization and equipment maintenance. Aluminium smelting cell works in the extreme environments that contain extraordinarily aggressive gases, such as HF, CO and SO2. Mild steel used as a structural material in the aluminium industry, can be catastrophically corroded or oxidized in these conditions. This project was mainly concerned with extending the lifetime of metal structures installed immediately above the aluminium smelting cells. An aluminium-rich coating was developed on low carbon steel A06 using pack cementation technique. Yttria (Y2O3) was also used to improve the corrosion resistance of coating. Kinetics of the coating formation were studied. XRD, FESEM and FIB were employed to investigate the phase constitution and the surface morphology. Together with other potentially competitive materials, aluminium-rich coating was evaluated in simulated plant environments. Results from the long time (up to 2500h) isothermal oxidation of materials at high temperature (800??C) in air showed that the oxidation resistance of coated A06 is close to that of stainless steel 304 and even better than SS304 in cyclic oxidation tests. Coated A06 was also found to have the best sulfidation resistance among the materials tested in the gas mixture contains SO2 at 800??C. Related kinetics and mechanisms were also studied. The superior corrosion resistance of the coated A06 is attributed to the slow growing alpha-Al2O3 formed. Low temperature corrosion tests were undertaken in the gas mixtures containing air, H2O, HCl and SO2 at 400??C. Together with SS304 and 253MA, coated A06 showed excellent corrosion resistance in all the conditions. The ranking of the top three materials for corrosion resistance is: 253MA, coated A06 and SS304. It is believed that aluminised A06 is an ideal and economical replacement material in the severe corrosive aluminium smelting cell environment.

Le Sahel, milieu compris entre le Sahara et la forêt soudanienne, subit actuellement de grands bouleversements environnementaux. Depuis les sécheresses des années 1970-1980 et la forte croissance démographique, le couvert végétal s’est considérablement dégradé, contribuant à l’augmentation du ruissellement et à l’érosion des sols. À partir de ce constat, nous avons entrepris l’étude des sociétés passées de la région de Niamey afin d’évaluer leur impact sur le milieu. Le manque de données archéologiques a nécessité de recenser les principaux indices d’occupation au cours du Néolithique et de l’Âge du fer. Outre l’apport de nouvelles datations pour le site de Kirkissoy, une étude sédimentaire a été réalisée sur un paléo-chenal du fleuve Niger et de nouveaux sites ont été identifiés. Pour l’Âge du fer, des sites d’habitat et plus de 5000 bas fourneaux à usage unique ont été cartographiés. Ils témoignent d’une activité métallurgique comprise entre le 4e et le 14e siècles AD. Les études typologique et spatiale des structures de réduction ont révélé l’existence de différents types de bas fourneaux et d’une répartition spatiale liée au contexte géomorphologique et à la gestion de l’espace de travail. L’étude d’un parcellaire sur les plateaux, associé à ces bas fourneaux, a mis en évidence une activité agricole autour de l’an mil. Le bilan de ces données archéologiques a été mis en parallèle avec les données environnementales acquises par l’étude d’un remplissage sédimentaire. Au cours des quatre derniers millénaires, la région de Niamey et le Sud-ouest du Niger ont été marqués par des changements environnementaux et sociétaux qui ont provoqué une discontinuité de l’occupation humaine. / The Sahel, a zone between the Sahara Desert and the Sudan forests, is currently experiencing major environmental changes. Since the droughts in 1970s and 1980s, and with the high population growth rate, vegetation cover has deteriorated considerably, contributing to increased runoff and soil erosion. Starting from this observation, we undertook the study of past societies in the Niamey region, to assess their impact on the environment. The lack of archaeological data meant that it was necessary to identify key indicators of occupation during the Neolithic and the Iron Age. In addition to providing new evidence to date the Neolithic site of Kirkissoy, a sedimentary study was conducted on a palaeochannel of the River Niger and new sites were discovered on the left bank. For the Iron Age, several habitat sites were identified and more than 5,000 single use bloomery furnaces were mapped. They provide evidence of metallurgical activity from the 4th to 14th centuries AD. Typological and spatial analysis show the existence of several types of furnaces and their spatial distribution is linked to workspace management and the geomorphological context. As well as these bloomery furnaces, an agricultural system with plot boundaries was identified and studied on the lateritic plateaus of Louguel. It shows intensive agricultural activity around the year one thousand. These archaeological data are compared with environmental data obtained by the study of the sedimentary record. Over the past four thousand years, the Niamey region and southwestern Niger have been marked by environmental and societal changes, resulting in discontinuous human occupation.

Copper is an essential metal in today’s economy, due to its superior electrical and thermal conductivities, alloying properties, and chemical uses. Most copper is produced viamining and refining, and most copper is found in the earth’s crust as chalcopyrite, CuFeS2. Typically, chalcopyrite is concentrated and fed to a high temperature pyrometallurgical process which produces >99.99% purity copper cathodes. Recently, Freeport-McMoRan Inc. has implemented a hydrometallurgical autoclave-leaching process that takes chalcopyrite concentrate and produces copper cathodes. It is imperative that these pyrometallurgical and hydrometallurgical processes be modeled and compared so that the extraction industry can best decide which technology to apply in the future. This work presents transient, reduced-order models for the comparison of the two processes using exergy balances. Exergy is typically thought of as the maximum work extractable from a system as it spontaneously reacts to the state of the surrounding environment; for extractive processes, it is also helpful to think of exergy as the minimum work required to effect a concentration, e.g. of copper. Exergy balances are thus similar to first law balances, but they comment on the location and magnitude of usefulenergy flows, instead of energy flows in general. For the baseline case, this work found that the pyrometallurgical process up to 99.5% copper anode stored 54% of the fed exergy in product, lost 20% of the fed exergy, and destroyed the remaining 26%. In contrast, the hydrometallurgical process up to 30 grams-per-liter copper pregnant-leach-solution stored 5% of the fed exergy in product, lost 9% of the fed exergy, and destroyed the remaining 86%. The effects of process variations are also looked at. It is recommended that this work be incorporated in whole-plant exergy balances to more precisely examine the tradeoffs between the pyrometallurgical and hydrometallurgical routes of copper extraction from chalcopyrite concentrates.

This thesis found that the three communities of Midvale, Murray, and Sandy were the center of the smelting industry in the Salt Lake Valley. These communities became the center of smelting because of their central location, the readily available water supply, and the availability of an inexpensive, efficient transportation system to ship the bullion. The smelters were surrounded by two major mountain ranges which provided a ready supply of good lead, silver, and copper ore.The development of the smelting industry followed three separate phases or periods. The first phase was one of experimentation or period of discovery, in which the smelters operated without the technological skill necessary to be financially successful. The second phase was highlighted by the emergence of skilled German mining engineers who enabled the smelters to be financially successful. Phase three was ushered in during the late nineteenth century by the industrialists who consolidated the smaller smelters and built larger, more efficient plants.