Model studies of Australian lump ore applied to blast furnace ironmaking. Ore lump use in ironmaking blast furnaces (BFs) requires no preprocessing and has a lower carbon footprint. However, it suffers various technical problems. This project aims to understand and optimize the conditions for such operations. This will be achieved by means of a combined theoretical and experimental program, involving the use of state-of-the-art multiscale computer modelling and simulation techniques. The researc ....Model studies of Australian lump ore applied to blast furnace ironmaking. Ore lump use in ironmaking blast furnaces (BFs) requires no preprocessing and has a lower carbon footprint. However, it suffers various technical problems. This project aims to understand and optimize the conditions for such operations. This will be achieved by means of a combined theoretical and experimental program, involving the use of state-of-the-art multiscale computer modelling and simulation techniques. The research outcomes will be tested in the design and control of lump charging operations in practice through collaboration with the industrial partner. This will ultimately increase Australian ore lump usage in BFs, leading to significant financial and environmental benefits to Australia and the entire steel industry worldwide.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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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
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
Nanoarchitectured anti-corrosion coatings for zinc-plated steel. Zinc-plated steel is widely used in buildings, households and vehicles, but the long-term performance is limited due to corrosion resulting from exposure to high humidity or alkaline conditions. Currently, available chromium coatings are toxic, while polymeric coatings lack durability. This project aims to use nanotechnology to develop highly effective, multifunctional anti-corrosive coatings in which long-term protection is achiev ....Nanoarchitectured anti-corrosion coatings for zinc-plated steel. Zinc-plated steel is widely used in buildings, households and vehicles, but the long-term performance is limited due to corrosion resulting from exposure to high humidity or alkaline conditions. Currently, available chromium coatings are toxic, while polymeric coatings lack durability. This project aims to use nanotechnology to develop highly effective, multifunctional anti-corrosive coatings in which long-term protection is achieved by controlling the wettability and self-healing properties. The project is excepted to generate new knowledge in coating materials that limit corrosion and address environmental problems. This advanced manufacturing technology should be of high-value benefit to manufacturers and consumers of zinc-plated steel.Read moreRead less
Low emission iron and steelmaking using hydrogen to pre-reduce lump ore. This project aims to develop and apply a new route of lump iron ore pre-reduction with hydrogen or H2-enriched gases for ironmaking to minimise CO2 emission from steel production. The route will be built up on the base of H2 reduction kinetics of iron ore and with novel technologies such as CO2 recycle and H2-heating using hot blast, underpinning the hydrogen economy by addressing the environmental concerns in mineral and s ....Low emission iron and steelmaking using hydrogen to pre-reduce lump ore. This project aims to develop and apply a new route of lump iron ore pre-reduction with hydrogen or H2-enriched gases for ironmaking to minimise CO2 emission from steel production. The route will be built up on the base of H2 reduction kinetics of iron ore and with novel technologies such as CO2 recycle and H2-heating using hot blast, underpinning the hydrogen economy by addressing the environmental concerns in mineral and steel industries. It is not only significant for low-carbon steel production, but also for better fundamental understanding to develop the future zero-emission iron and steelmaking with hydrogen. The project will be very beneficent because it increases the use of lump iron ore and expends Australian export of iron ores.Read moreRead less
Microstructure control of hot-dip coated Al-Zn based alloy layers on steel . The process of hot-dip metal coating of steel has evolved to provide reliable products that find widespread application in many industries, including building and construction. This project aims to address and understand an intermittent processing problem using innovative approaches involving characterisation by synchrotron techniques and state-of-the art microscopy. Expected outcomes include increased manufacturing e ....Microstructure control of hot-dip coated Al-Zn based alloy layers on steel . The process of hot-dip metal coating of steel has evolved to provide reliable products that find widespread application in many industries, including building and construction. This project aims to address and understand an intermittent processing problem using innovative approaches involving characterisation by synchrotron techniques and state-of-the art microscopy. Expected outcomes include increased manufacturing efficiencies by identifying the cause of an intermittent processing defect and implementing methods of controlling this defect. This will help BlueScope and Australia maintain a world-leading reputation for high-quality coating products for domestic and export markets.Read moreRead less
Mitigating the negative effects of process water on recovering gold. Low quality water has been used in the minerals industry to save fresh water but shows harmful effects on gold extraction. This project aims to understand the interactions of organic and inorganic components, existing in process water, with gold and determine problematic components that inhibit gold extraction. Expected outcomes will be developed bio-sorbents, based on agriculture waste, that can remove the problematic componen ....Mitigating the negative effects of process water on recovering gold. Low quality water has been used in the minerals industry to save fresh water but shows harmful effects on gold extraction. This project aims to understand the interactions of organic and inorganic components, existing in process water, with gold and determine problematic components that inhibit gold extraction. Expected outcomes will be developed bio-sorbents, based on agriculture waste, that can remove the problematic components in process water efficiently and economically. This will provide major benefits for the minerals industry by providing options to respond and adapt to the impacts of water quality change, leading to increases in yield, revenue and growth of the precious metal sector whilst cutting poisonous chemical consumptions.Read moreRead less
Safe Emulsion Explosives for High Temperature Deep Level Mining. This project aims to develop a new class of emulsion explosives, which are not susceptible to hot and reactive rock conditions in very deep-level ore mines. These emulsions will contain a tuneable polymer network to prevent collapsing of the emulsion columns in hot upholes in high temperature mines, along with additives to eliminate the exothermic reaction with the rocks. If not prevented the reaction can cause premature detonation ....Safe Emulsion Explosives for High Temperature Deep Level Mining. This project aims to develop a new class of emulsion explosives, which are not susceptible to hot and reactive rock conditions in very deep-level ore mines. These emulsions will contain a tuneable polymer network to prevent collapsing of the emulsion columns in hot upholes in high temperature mines, along with additives to eliminate the exothermic reaction with the rocks. If not prevented the reaction can cause premature detonation or deflagration of the emulsion causing fatal injuries and generation of toxic NOx gases. Increase in economically and safely extractable deep-level ore volume that generates greater export earnings and more jobs are expected project outcomes, as is reduced atmospheric pollution.Read moreRead less
Improving the processing of low-grade copper ores . The project aims to investigate the electrochemical interaction occurring during the grinding of low-grade copper ores and understand how the interaction affects the recovery of copper minerals and rejection of waste minerals in the subsequent separation process. This project expects to generate new knowledge in the area of minerals processing and materials engineering using interdisciplinary approaches. Expected outcomes of this project includ ....Improving the processing of low-grade copper ores . The project aims to investigate the electrochemical interaction occurring during the grinding of low-grade copper ores and understand how the interaction affects the recovery of copper minerals and rejection of waste minerals in the subsequent separation process. This project expects to generate new knowledge in the area of minerals processing and materials engineering using interdisciplinary approaches. Expected outcomes of this project include cost-effective new steel products used for grinding copper ores and new chemical solutions to selectively reject waste minerals during mineral separation. This should significantly reduce the operating costs in copper processing plants and increase the copper production from low-grade copper ores.Read moreRead less