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Mathematical modelling of materials processing operations
Book Reviows
263
Nathematlcal ~ e 1 1 i n g of Naterlale Processing Operations J.Szekely, H.Henein, I.Samarsekera, N.Jarrett, L.B.Hales, K.RaJamani (Eds.) The Metals Society, Warrendale, 1987. Price US$128 (members $80). 920 pps. ISBN 0-87339-071-7 This book contains the papers presented at the fifth Extractive and Process Metallurgy Fall Meeting at Palm Springs, C a l i f o r n i a . A total of 68 papers (nearly 1200 pages} are divided into the following section headings: Plenary (3 papers}, Grinding Circuit Simulation (4), Flotation Cell Simulation (5), C o l u m n F l o t a t i o n (4), Sensors and Instrumentation (5), Hydrometallurgy (6), Ferrous (I0), Nonferrous (11), Reactor Technology (5), Casting (6), Reheat and Deformation (4) and Economics (5}. The aim of the organising committee was to give a broad o v e r v i e w of the s t a t e - o f - t h e - a r t of m o d e l l i n g of m e t a l s p r o c e s s i n g o p e r a t i o n s r a n g i n g from m i n e r a l processing, through extractive metallurgy to the finished metal. This is reflected in the large n u m b e r of diverse topic tltles and they have clearly achieved their objective in this mighty tome. Anyone involved in the minerals industry who has an interest in mathematical modelllng will find something of use in this book. With the need to look for process improvements in order to stay economical and improve profitability, a b e t t e r u n d e r s t a n d i n g of p r o c e s s b e h a v l o u r under c h a n g i n g c o n d i t i o n s is required. The d e v e l o p m e n t of mathematical models which relate controllable variables to efficiency and product properties allows the i n v e s t i g a t i o n of c o n t r o l s t r a t e g i e s and the optimisation of plant performance. Although the reader may only have a direct interest in two or three sections, a glance at the modelling approach adopted by some of the other disciplines may well prove inspirational. The two p l e n a r y lectures by Evans and H e r b s t give contrasting reviews of mathematical modelllng and make excellent reading. The next four sections are d e v o t e d to m i n e r a l processing. The papers on grinding circuits show that circuit control is of prime importance, using dynamic simulation and expert systems. The continued i n t e r e s t in the p r o c e s s of froth f l o t a t i o n is demonstrated in the next section. Kinetic models in various forms are used to compare reagents and predict plant performance. No symposium would be complete without a section on column flotation. Unfortunately two of the papers in this section consist only of an abstract. The population balance model in one of the papers seems to be the more advanced of the two presented. Finally, some developments in sensors for p r o c e s s i n g plants are o u t l i n e d in the last section. Hydrometallurgy is r e p r e s e n t e d by a v a r i e t y of papers. These range from solution mining, to cobalt sorption in a continuous ion-exchange column and zinc pressure leach modelling. A computer controlled instrumentation and data analysis laboratory is described and the advantages evaluated. Finally, two p a p e r s on mass b a l a n c e m o d e l l i n g are presented, one on the general use of spreadsheets for process simulation and the other for the process design of plants in Zambia. Two sections are devoted to pyrometallurgy. Under the Ferrous heading there are seven papers concerning flow modelling of various operations and three of these include heat and mass transfer phenomena. The remaining papers present models for iron ore induration systems, iron oxide pellet reduction and the c a l c u l a t i o n of multicomponent multlphase equilibria. The Non Ferrous papers include two on modelling of the carbomethal reduction of alumina and another two on flow modelling in cells for aluminlum production. There are a further two on m o d e l l i n g g a s / p a r t i c l e reactions, one c o n s i d e r e d the p r o b l e m of irregular particles and the other the specific case of CuS reactions. Several copper furnaces were modelled: the reverberatory, two on flash smelting and another of f l a s h c o n v e r t i n g . The final paper deals with free-energy minimisation techniques for complete sulphide smelting modelling. This book by anyone references reading to
offers a very wide coverage of the subject and should be consulted interested in mathematical modelling in the minerals industry. The alone offer a good starting point for follow up work. Recommended obtain an appreciation of the current mathematlcal modelling scene. R.W. Barley
263
Nathematlcal ~ e 1 1 i n g of Naterlale Processing Operations J.Szekely, H.Henein, I.Samarsekera, N.Jarrett, L.B.Hales, K.RaJamani (Eds.) The Metals Society, Warrendale, 1987. Price US$128 (members $80). 920 pps. ISBN 0-87339-071-7 This book contains the papers presented at the fifth Extractive and Process Metallurgy Fall Meeting at Palm Springs, C a l i f o r n i a . A total of 68 papers (nearly 1200 pages} are divided into the following section headings: Plenary (3 papers}, Grinding Circuit Simulation (4), Flotation Cell Simulation (5), C o l u m n F l o t a t i o n (4), Sensors and Instrumentation (5), Hydrometallurgy (6), Ferrous (I0), Nonferrous (11), Reactor Technology (5), Casting (6), Reheat and Deformation (4) and Economics (5}. The aim of the organising committee was to give a broad o v e r v i e w of the s t a t e - o f - t h e - a r t of m o d e l l i n g of m e t a l s p r o c e s s i n g o p e r a t i o n s r a n g i n g from m i n e r a l processing, through extractive metallurgy to the finished metal. This is reflected in the large n u m b e r of diverse topic tltles and they have clearly achieved their objective in this mighty tome. Anyone involved in the minerals industry who has an interest in mathematical modelllng will find something of use in this book. With the need to look for process improvements in order to stay economical and improve profitability, a b e t t e r u n d e r s t a n d i n g of p r o c e s s b e h a v l o u r under c h a n g i n g c o n d i t i o n s is required. The d e v e l o p m e n t of mathematical models which relate controllable variables to efficiency and product properties allows the i n v e s t i g a t i o n of c o n t r o l s t r a t e g i e s and the optimisation of plant performance. Although the reader may only have a direct interest in two or three sections, a glance at the modelling approach adopted by some of the other disciplines may well prove inspirational. The two p l e n a r y lectures by Evans and H e r b s t give contrasting reviews of mathematical modelllng and make excellent reading. The next four sections are d e v o t e d to m i n e r a l processing. The papers on grinding circuits show that circuit control is of prime importance, using dynamic simulation and expert systems. The continued i n t e r e s t in the p r o c e s s of froth f l o t a t i o n is demonstrated in the next section. Kinetic models in various forms are used to compare reagents and predict plant performance. No symposium would be complete without a section on column flotation. Unfortunately two of the papers in this section consist only of an abstract. The population balance model in one of the papers seems to be the more advanced of the two presented. Finally, some developments in sensors for p r o c e s s i n g plants are o u t l i n e d in the last section. Hydrometallurgy is r e p r e s e n t e d by a v a r i e t y of papers. These range from solution mining, to cobalt sorption in a continuous ion-exchange column and zinc pressure leach modelling. A computer controlled instrumentation and data analysis laboratory is described and the advantages evaluated. Finally, two p a p e r s on mass b a l a n c e m o d e l l i n g are presented, one on the general use of spreadsheets for process simulation and the other for the process design of plants in Zambia. Two sections are devoted to pyrometallurgy. Under the Ferrous heading there are seven papers concerning flow modelling of various operations and three of these include heat and mass transfer phenomena. The remaining papers present models for iron ore induration systems, iron oxide pellet reduction and the c a l c u l a t i o n of multicomponent multlphase equilibria. The Non Ferrous papers include two on modelling of the carbomethal reduction of alumina and another two on flow modelling in cells for aluminlum production. There are a further two on m o d e l l i n g g a s / p a r t i c l e reactions, one c o n s i d e r e d the p r o b l e m of irregular particles and the other the specific case of CuS reactions. Several copper furnaces were modelled: the reverberatory, two on flash smelting and another of f l a s h c o n v e r t i n g . The final paper deals with free-energy minimisation techniques for complete sulphide smelting modelling. This book by anyone references reading to
offers a very wide coverage of the subject and should be consulted interested in mathematical modelling in the minerals industry. The alone offer a good starting point for follow up work. Recommended obtain an appreciation of the current mathematlcal modelling scene. R.W. Barley