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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Uncertainty and Risk Quantifying Optimistion for Open Pit Mine Design and Production Scheduling. Open pit mine design and production scheduling (OPDPS) deals with the management of cash flows in the order of hundreds of millions of dollars, and is a critical aspect of mining ventures. To enhance decision-making under conditions of uncertainty, this proposal aims to develop a new methodology for OPDPS based on mathematical and statistical techniques which model uncertainty in key parameters, geol ....Uncertainty and Risk Quantifying Optimistion for Open Pit Mine Design and Production Scheduling. Open pit mine design and production scheduling (OPDPS) deals with the management of cash flows in the order of hundreds of millions of dollars, and is a critical aspect of mining ventures. To enhance decision-making under conditions of uncertainty, this proposal aims to develop a new methodology for OPDPS based on mathematical and statistical techniques which model uncertainty in key parameters, geological, mining and market/cost and their effects on economic forecasts. The new formulation is founded on stochastic integer programming, and its integration with spatial stochastic simulations of geological attributes. Methods developed are computerised and tested in field studies.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
Hot stage separation of non-ferrous fraction during iron ore reduction. The project aims to provide in-situ investigation of the behaviour and properties of the non-ferrous fraction in iron ore during reduction. The results aim to allow industry to: improve the quality of the final metallic iron product; economically separate and recover high-value non-ferrous impurities in the iron ore; reduce waste generated by ironmaking; and enable utilisation of, and add value to, iron ores that currently a ....Hot stage separation of non-ferrous fraction during iron ore reduction. The project aims to provide in-situ investigation of the behaviour and properties of the non-ferrous fraction in iron ore during reduction. The results aim to allow industry to: improve the quality of the final metallic iron product; economically separate and recover high-value non-ferrous impurities in the iron ore; reduce waste generated by ironmaking; and enable utilisation of, and add value to, iron ores that currently are not commercially viable due to their high impurity levels and low iron contents. The project aims to help expand the mining potential of the currently unviable iron ore deposits and enable industry to maintain the economic benefits from iron ore production in the years to come.Read moreRead less
A novel low-energy process route for primary copper production utilising synergistic hydro- and pyro-metallurgical processes. With increasing demand for copper metal, there is an urgent need to find new ways to efficiently treat lower grade ores. The new process offers a way of significantly reducing energy consumption and greenhouse gas emissions in primary copper production and making more efficient use of the world's copper resources.
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
Optimising non-explosive rock breaking technology. Non-explosive rock breaking technology has the potential to significantly improve safety and production in mining and construction industries. This project will quantify a non-explosive hydraulic rock breaking technology through innovative theoretical and numerical investigations. The influences of all the key factors on the efficiency of this technology will the examined. It is envisaged that the outcomes from this proposal will optimise the no ....Optimising non-explosive rock breaking technology. Non-explosive rock breaking technology has the potential to significantly improve safety and production in mining and construction industries. This project will quantify a non-explosive hydraulic rock breaking technology through innovative theoretical and numerical investigations. The influences of all the key factors on the efficiency of this technology will the examined. It is envisaged that the outcomes from this proposal will optimise the non-explosive rock breaking technology, greatly improve its application and guide our industry partner to develop reliable equipment.Read moreRead less
Three-dimensional flotation of fine particles. Three-dimensional flotation of fine particles. This project aims to research three-dimensional flotation of fine particles under both batch and continuous steady state conditions. In flotation, fine hydrophobic particles adhere to the two-dimensional surface of rising air bubbles, forming concentrate. In three-dimensional flotation, however, the particles adhere to and become embedded in a novel binder, forming a highly buoyant product. The process ....Three-dimensional flotation of fine particles. Three-dimensional flotation of fine particles. This project aims to research three-dimensional flotation of fine particles under both batch and continuous steady state conditions. In flotation, fine hydrophobic particles adhere to the two-dimensional surface of rising air bubbles, forming concentrate. In three-dimensional flotation, however, the particles adhere to and become embedded in a novel binder, forming a highly buoyant product. The process is very selective and arguably 1000 times faster than conventional flotation. The project is expected to provide the knowledge required to achieve scale-up, so the technology can be used to recover high value product from tailings waste, eliminating the capital impediment and possibly transforming the entire mining industry.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