5 results on '"Hundermark, R.J"'
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2. Challenges and solutions in PGM furnace operation: high matte temperature and copper cooler corrosion
- Author
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Shaw, A, de Villiers, L.P.vS, Hundermark, R.J, Ndlovu, J, Nelson, L.R, Pieterse, B, Sullivan, R, Voermann, N, Walker, C, Stober, F, and McKenzie, A.D
- Subjects
corrosion ,copper cooler ,PGM smelting ,matte temperature ,chloride-accelerated sulphidation - Abstract
The key aspects of process metallurgy that distinguish platinum group metal (PGM) concentrate smelting from that of other base metal sulphide concentrates are presented. These differences include considerably higher input chrome and magnesia contents that directly raise the slag liquidus temperature and have the potential to increase accumulations of refractory spinels. Most importantly, the higher processing temperature required for PGM smelting and the resulting very high matte superheat lead to considerably more onerous smelting conditions than those typical of other smelting operations. This has presented challenges to furnace design and integrity, especially when coupled with the progressive intensification of smelting, involving doubling, and then redoubling, of furnace power inputs over the past 20 years. These power increases have been enabled by increasingly more advanced furnace cooling and structural technologies. Key technologies include strong constant-force spring-loaded bindings acting in three dimensions to minimize infiltration of superheated matte into brick joints, and robust well-cooled tapholes for reliably tapping the superheated matte. The result has been substantially improved productivity, and reduced smelting capital cost outlay per unit of production. A significant challenge, which was not anticipated, presented itself in the form of insidious corrosion of the furnace lining, and especially high-intensity copper cooling elements. Investigation of corrosion in related industries eventually identified 'chloride-accelerated sulphidation', and this term has been retained as it generically describes the most pertinent aspects of the accelerated low-temperature wear of copper coolers observed in PGM smelting. In addition to discussing the corrosion mechanism, this paper describes a number of solutions that were developed jointly by Anglo American Platinum and Hatch to address the copper corrosion problem. First, new monitoring technologies allowed furnaces to be operated more safely for a longer period of time. Second, a system for replacing corroded coolers from outside the furnace during a fast 'hot' shutdown minimized the impact on furnace operating factor and hearth life. Finally, a corrosion-resistant graphite-protected cooler design significantly improved furnace campaign life, and heralds a more lasting solution to cooler corrosion in PGM furnaces.
- Published
- 2013
3. The tap-hole - key to furnace performance
- Author
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Nelson, L.R., primary and Hundermark, R.J., additional
- Published
- 2016
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4. Converter processing of platinum group metals.
- Author
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Nelson L.R., Georgalli G.A., Hines K.L., Hundermark R.J., Nelson L.R., Georgalli G.A., Hines K.L., and Hundermark R.J.
- Abstract
The history and variety of commercial Platinum Group Metal (PGM) matte converting processes are explored. Aspects unique to pneumatic converting of high iron, lower grade mattes (typically up to 30% NiCuCo), often containing chrome (0.5-2% Cr2O3), to PGM-enriched (1 500-25 000 g/t PGM) converter mattes, to endpoints specific to promote downstream refining to final metal are described. The range of converter vessels, involving batch, to staged, to continuous converting processes are presented, along with some of the operating requirements and challenges. (Authors.), The history and variety of commercial Platinum Group Metal (PGM) matte converting processes are explored. Aspects unique to pneumatic converting of high iron, lower grade mattes (typically up to 30% NiCuCo), often containing chrome (0.5-2% Cr2O3), to PGM-enriched (1 500-25 000 g/t PGM) converter mattes, to endpoints specific to promote downstream refining to final metal are described. The range of converter vessels, involving batch, to staged, to continuous converting processes are presented, along with some of the operating requirements and challenges. (Authors.)
5. Considerations for scale-up of ferronickel electric smelting furnaces.
- Author
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Hundermark R.J., Nelson L.R., Hundermark R.J., and Nelson L.R.
- Abstract
With progression to shielded arc operation in ferronickel smelting, the power dissipated in the arc zone partially offsets the power dissipated in the slag zone, thus reducing sidewall heat fluxes and metal temperatures. The liquid zone of the crucibles are subjected to less arduous conditions, but the intensity of the furnace operation is shifted to the electrodes. Closer attention should therefore be paid to factors such as the local electrode gas fluxes (or superficial gas velocities), freeboard and off-gas temperatures, for any given calcine feed quality, to optimise electric furnace reduction and its resultant alloy nickel grade and overall recovery. An approach to quantifying the electrode gas flux is suggested which provides an improved link between ferronickel calcine feed characteristics, the product alloy Ni grade and the electrode power density metric, as a means to define conditions capable of giving stable shielded arc operation. Further understanding of the local electrode conditions is needed to assist with scale-up of processes to over 100 MW., With progression to shielded arc operation in ferronickel smelting, the power dissipated in the arc zone partially offsets the power dissipated in the slag zone, thus reducing sidewall heat fluxes and metal temperatures. The liquid zone of the crucibles are subjected to less arduous conditions, but the intensity of the furnace operation is shifted to the electrodes. Closer attention should therefore be paid to factors such as the local electrode gas fluxes (or superficial gas velocities), freeboard and off-gas temperatures, for any given calcine feed quality, to optimise electric furnace reduction and its resultant alloy nickel grade and overall recovery. An approach to quantifying the electrode gas flux is suggested which provides an improved link between ferronickel calcine feed characteristics, the product alloy Ni grade and the electrode power density metric, as a means to define conditions capable of giving stable shielded arc operation. Further understanding of the local electrode conditions is needed to assist with scale-up of processes to over 100 MW.
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