Future copper metallurgy for the age of e-mobility and the circular economy. Copper, nickel, cobalt, chromium and tin metals are essential for the manufacture of new battery materials, electrical and electronic devices and technologies that will enable the global transition to sustainable energy systems. There are major technical challenges associated with the industrial scale high temperature production, separation and recycling of these metals. The aim of the present study is develop advanced ....Future copper metallurgy for the age of e-mobility and the circular economy. Copper, nickel, cobalt, chromium and tin metals are essential for the manufacture of new battery materials, electrical and electronic devices and technologies that will enable the global transition to sustainable energy systems. There are major technical challenges associated with the industrial scale high temperature production, separation and recycling of these metals. The aim of the present study is develop advanced chemical thermodynamic databases and models that can be used to predict the outcomes of these complex chemical reactions, and in doing so provide the industry with the vital fundamental scientific information and tools needed to be able to design and improve new, more efficient metal production and recycling technologies. Read moreRead less
Multiscale study of raceway operations for low-cost and stable ironmaking. This project aims to optimise blast furnace operations and to assess the performance of Australian brown coals in ironmaking. Pulverised coal injection is a cost-effective technology in blast furnace ironmaking, particularly if low-grade coal is used. This project aims to develop control strategies for stable and low-cost operation and to assess and optimise the combustion of brown coal and its blends in this process. The ....Multiscale study of raceway operations for low-cost and stable ironmaking. This project aims to optimise blast furnace operations and to assess the performance of Australian brown coals in ironmaking. Pulverised coal injection is a cost-effective technology in blast furnace ironmaking, particularly if low-grade coal is used. This project aims to develop control strategies for stable and low-cost operation and to assess and optimise the combustion of brown coal and its blends in this process. The project aims will be achieved via multiscale modelling and simulation, supported by laboratory and plant experiments. The outcomes of the project are intended to open a new market for brown coal.Read moreRead less
Thermodynamic basis for ironmaking and slag recycling in circular economy. This project aims to develop new, powerful state-of-the-art computer-based tools to predict the outcomes of complex chemical reactions, high-temperature ironmaking and slag recycling processes. Globally, over 1 billion tonnes of iron are produced each year consuming 30 billion billion (Quintillion) Joules energy! and creating over 300 million tonnes of molten oxides (slags). Our industry partners need new advanced thermod ....Thermodynamic basis for ironmaking and slag recycling in circular economy. This project aims to develop new, powerful state-of-the-art computer-based tools to predict the outcomes of complex chemical reactions, high-temperature ironmaking and slag recycling processes. Globally, over 1 billion tonnes of iron are produced each year consuming 30 billion billion (Quintillion) Joules energy! and creating over 300 million tonnes of molten oxides (slags). Our industry partners need new advanced thermodynamic databases and computer models with which to optimise their major industrial processes and develop new technologies. By delivering these tools, this project expects to benefit both industry and the community through improved process efficiencies, and reductions in energy usage, pollutants, and environmental impacts.
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Differential solidification of steel slag to create a fertiliser co-product. The project aims to develop a process to separate phosphorus from steelmaking slag while the slag is still molten. Changing iron ore grades in Australia, especially increasing phosphorus content, places Australian iron ore products at a competitive disadvantage and attracts a significant financial penalty. The separation process is intended to facilitate recycling of an iron rich stream within the steelworks and product ....Differential solidification of steel slag to create a fertiliser co-product. The project aims to develop a process to separate phosphorus from steelmaking slag while the slag is still molten. Changing iron ore grades in Australia, especially increasing phosphorus content, places Australian iron ore products at a competitive disadvantage and attracts a significant financial penalty. The separation process is intended to facilitate recycling of an iron rich stream within the steelworks and production of a phosphorus rich co-product for agriculture. Benefits are anticipated to include increased utilisation of steel slag, creation of a valuable fertiliser co-product, decreased greenhouse gas emissions, and a reduction in the penalty applied to Australian iron ores.Read moreRead less
Phosphorous and iron recovery from steelmaking slag for effective recycling. This project aims to understand the principles that control phosphorus (P) partitioning in steel plant slags and to optimise the treatment process to produce P- and Fe-rich streams for recycling. Changing ore grades in Australia, especially increasing P content, are placing a substantial proportion of these ore products at a competitive disadvantage. The project will use an integrated approach to demonstrate, experiment ....Phosphorous and iron recovery from steelmaking slag for effective recycling. This project aims to understand the principles that control phosphorus (P) partitioning in steel plant slags and to optimise the treatment process to produce P- and Fe-rich streams for recycling. Changing ore grades in Australia, especially increasing P content, are placing a substantial proportion of these ore products at a competitive disadvantage. The project will use an integrated approach to demonstrate, experimentally and theoretically, how key properties of slags can be manipulated to enhance partitioning and couple this analysis with fluid dynamics to model the kinetics of the separation process. The expected outcomes of this research are to: first, provide possible solutions to address the increasing P content in Australian iron ores, which could place future ore products at a competitive disadvantage within the global iron ore market; and second, to identify treatment methods and practices which would promote higher recycling rates of steelmaking slag, significantly reducing the volume of material stockpiled or sent to landfill.Read moreRead less
Data-driven monitoring of raceway dynamics in ironmaking blast furnaces. Raceway dynamics in ironmaking blast furnaces affect operational stability and cost considerably, yet their dynamic behaviour has not been well monitored online. The project aims to develop a data-driven model for monitoring the internal state of gas-solid-powder reacting flow in the raceway and predicting raceway anomalies online. It will be achieved by combining particle-fluid numerical simulations with data processing an ....Data-driven monitoring of raceway dynamics in ironmaking blast furnaces. Raceway dynamics in ironmaking blast furnaces affect operational stability and cost considerably, yet their dynamic behaviour has not been well monitored online. The project aims to develop a data-driven model for monitoring the internal state of gas-solid-powder reacting flow in the raceway and predicting raceway anomalies online. It will be achieved by combining particle-fluid numerical simulations with data processing and reduced-order state observer, supported by lab/plant experiments, and collaborating with two industry partners from coal and steel industries. The project outcomes including codes, models and raceway control strategies can help promote Australian metallurgical coal's global markets and ultimately the Australian economy.Read moreRead less
Micromechanical analysis of size segregation and its prediction in granular free-surface flows. Industries often suffer from size segregation in the handling and processing of granular materials, leading to significant economic consequences. This project aims to develop a fundamental understanding of size segregation and prediction models, enabling industries to eliminate, minimise, or manage the effects to an acceptable level.
Preparation and use of lignite-iron ore composite briquettes for ironmaking. Preparation and use of lignite-iron ore composite briquettes for ironmaking. This project aims to study the briquetting processes of fine powders, and the preparation and utilization of new brown coal (lignite)–iron ore composite briquettes in a blast furnace. Lignite is a low-cost and abundant resource, and could be used in an emerging carbon-iron ore composite briquette for low-cost ironmaking. This project will perfo ....Preparation and use of lignite-iron ore composite briquettes for ironmaking. Preparation and use of lignite-iron ore composite briquettes for ironmaking. This project aims to study the briquetting processes of fine powders, and the preparation and utilization of new brown coal (lignite)–iron ore composite briquettes in a blast furnace. Lignite is a low-cost and abundant resource, and could be used in an emerging carbon-iron ore composite briquette for low-cost ironmaking. This project will perform multi-scale numerical studies, supported by lab/industry-scale experiments, to produce models and control strategies. Anticipated outcomes include better design and control of briquette's preparation and utilization in ironmaking for further cost-cutting; a new market for brown coal; and a more competitive Australian economy.Read moreRead less
Development and application of a virtue experimental blast furnace. This project aims to develop a virtual experimental blast furnace based on advanced discrete particle simulation technique. It is intended that the model furnace will be used to study the flow and thermochemical behaviour in iron making, quantify the effects of key variables related to raw material and operational conditions, and formulate strategies for optimum process design and control under different conditions. The findings ....Development and application of a virtue experimental blast furnace. This project aims to develop a virtual experimental blast furnace based on advanced discrete particle simulation technique. It is intended that the model furnace will be used to study the flow and thermochemical behaviour in iron making, quantify the effects of key variables related to raw material and operational conditions, and formulate strategies for optimum process design and control under different conditions. The findings aim to be very useful to comprehensively assess the performance of Australian minerals in iron making, improve the energy efficiency and reduce carbon dioxide emission in the steel industry, and enhance the competitiveness of the Australian economy.Read moreRead less
Improvements in Australia’s iron ore resource utilisation . This project aims to support improved extraction and utilisation of Australia’s iron ore resources through providing new technical information on the behaviour of the ores during iron ore sintering. The project will measure the rates of chemical reactions taking place between the minerals and high temperature melts encountered in iron ore sintering. These reactions are critical in determining the microstructures formed and the resulting ....Improvements in Australia’s iron ore resource utilisation . This project aims to support improved extraction and utilisation of Australia’s iron ore resources through providing new technical information on the behaviour of the ores during iron ore sintering. The project will measure the rates of chemical reactions taking place between the minerals and high temperature melts encountered in iron ore sintering. These reactions are critical in determining the microstructures formed and the resulting physical properties of the iron ore sinter. Understanding the effect of these properties on subsequent iron -making process efficiency will support companies to efficiently use, market, and sell different iron ores.Read moreRead less