Mining and Minerals

Smelting and Pyrometallurgical Operations

A smelter converts energy and reductant into metal and slag, and the difference between a good and a bad operation is usually control of the slag rather than anything done to the metal. This course concentrates there. Delegates work through the thermodynamic basis in practical terms: oxidation states, reduction and the conditions under which a metal reports to matte, metal or slag. Furnace types are covered across submerged arc, blast, flash and converter operations, with the duties each suits. Feed preparation, blending and moisture control follow. Slag chemistry is addressed in detail, including basicity, viscosity, liquidus and the tapping behaviour each produces. Refractory wear and furnace integrity are covered, since a run out is the worst outcome available. Tapping, casting and handling of molten material are addressed with their specific hazards. Off gas, dust and sulphur capture follow. Energy consumption per tonne is treated as the central economic measure. The course closes on recovery accounting and on furnace shutdown and relining.