No pyrometallurgical smelter can operate without some form of tapping system. It is the one thing all smelters have in common. This collection discusses this meeting point of the science, technology, and skill involved in this process.
The tap-hole design process includes a set of design criteria, which need to be revised as the results of laboratory, computational fluid dynamics (CFD), and time-and-motion studies become available. The tap-hole life cycle is considered in this volume, with authors addressing the requirements for installation and operability as well as for maintenance. Matters such as online monitoring of the tap-hole wear, handling of liquid products, and extraction of fumes are all discussed.
Although much has been done to make the tapping process as automatic as possible, tapping of smelters cannot be done without labor. Tap floor operators work in harsh environments where safety is of utmost importance. Selection of suitable personnel and intensive training is required and is discussed in this collection.
Author(s): Joalet D. Steenkamp, Dean Gregurek, Quinn G. Reynolds, Gerardo Alvear Flores, Hugo Joubert, Phillip J. Mackey
Series: The Minerals, Metals & Materials Series
Publisher: Springer
Year: 2022
Language: English
Pages: 407
City: Cham
Preface
Contents
About the Editors
Part I Session I
1 Controlled Tapping—The Research Project
2 MIRS Robotic Tapping and Plugging of Non-ferrous Smelting Furnaces
3 Theoretical Framework and Practical Recommendations for Proper Thermal Lance Use and Selection
4 Data Analysis to Assess Carry-Over Slag
5 An Overview of Submerged Arc Furnaces Tapping Operations and Tap-Hole Management at Assmang Manganese Cato Ridge Works
6 Aluminium Tapping and Molten Metal Handling in Primary Smelters
Part II Session II
8 Furnace Tapping 101
9 CFD Study on Continuous Tapping of Silicon
10 Reduced-Order Models of Furnace Tapping Systems—A Case Study from a Submerged Arc Furnace Producing Silicomanganese
11 Tapped Alloy Mass Prediction Using Data-Driven Models with an Application to Silicomanganese Production
12 Slag Reduction and Viscosities Interaction in Ferromanganese Process
13 Lab-Scale Physical Model Experiments to Understand the Effect of Particle Bed on Tapping Flow Rates
14 The Interaction of Slag and Carbon on the Electrical Properties
15
Electrical Resistivity of Transformed Carbon Materials in the Silicon Furnace
Part III Session III
16 PGM, Nickel, and Copper Tapping: An Updated Industry Survey
17 Kansanshi Copper Smelter ISACONVERT™ Furnace Tapping System Design, Operation, and Improvements
18 Successful Development and Optimisation of Lead ISASMELT™ Furnace Slag Tapping System at Kazzinc Ltd.
19 Simulation-Based Approaches for Optimized Tap-Hole Design
Part IV Session IV
20 Tap-Hole Refractory Issues and Remedies
21 Sensor Technologies for Optimized Tapping Procedures
22 The Evaluation of Chemical Wear of Carbon-Based Tap-Hole Refractories in Ferrochrome Production
23 Investigation of Melting Behavior and Viscosity of Slags from Secondary Ferromanganese Production
24 Metal and Slag Extraction from Different Zones of a Submerged Arc Furnace with Non-uniform Porous Bed Using CFD
25 Tapblock Refractory Wear Monitoring and Hearth Refractory Design Optimization in Metallurgical Furnaces
26 Slide Gate Technology for Slag Tapping
27 Tap-Hole Clay Technologies for Ferroalloy Reduction Furnaces
28 Health-Friendly Plugging Repair Pastes
Author Index
Subject Index
