The mathematical modeling revolution in extractive metallurgy
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The Mathematical Modeling Revolution in Extractive Metallurgy
JULIAN SZEKELY
A brief review is presented of the current state of extractive metallurgy, and it is shown that it is still a significant part of the national economy. Then a definition is given of mathematical models, and the general philosophy of modeling is discussed, together with the cost of models, hardware, and software options. Several illustrative examples are given, drawn from aluminum electrolysis, flash smelting, tundish operations, and plasma systems. The paper is concluded with the future modeling tasks facing us; these include the more widespread applications of models to represent both existing and new processing operations. It is stressed that models can play a major role in developing a holistic approach to metals and materials processing, where the primary extraction and refining operations are combined with the final processing steps.
The Extractive Metallurgy Lecture was authorized in 1959 to provide an outstanding man in the field of nonferrous metallurgy as a lecturer at the annual AIME meeting. JULIAN SZEKELY is Professor of Materials Engineering at the Massachusetts Institute of Technology, a position he has held since 1975. A native of Hungary, he received the B.Sc., Ph.D., and D.Sc. degrees from Imperial College, London, England. His main research interests are in the mathematical modeling of metals and materials processing operations, with emphasis on new technologies, and he has written numerous books and over three hundred journal articles on this subject. His most recent and forthcoming books include The Mathematical and Physical Modeling of Primary Metals Processing Operations, with J. W. Evans and J. K. Brimacombe (Wiley, 1988); Ladle Metallurgy: Theory and Practice, with G. Carlsson and L. Helle (Springer, 1988); and Mathematical Modelling Strategies in Materials Processing, with W. Wahnsiedler (Wiley, to appear in 1989). His work has been recognized by many national and international awards, including the Mathewson Gold Medal (1973), the Extractive Metallurgy Science Award (1973), and the Howe Memorial Lectureship (1979) of the AIME. He received the Sir George Beilby Gold Medal of the British Institution of Chemical Engineers in 1974. In 1982 he was elected to the United States National Academy of Engineering. METALLURGICALTRANSACTIONS B
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INTRODUCTION
T O be chosen as the 1987 Extractive Metallurgy Lecturer is a great honor, which is amplified by the many distinguished colleagues and friends of mine who have been so recognized in the past. These include mentors like the late Denys Richardson E~1and colleagues including John Elliott, t2J Herb Kellogg, E31Nick Themelis, t4J Noel Jarrett, f51 and Milt Wadsworth. [6] Noel Jarrett's lecture, given last year, may serve as an excellent model, because it has dealt with both the economic and societal, as well as the technological, aspects of extractive metallurgy, that of aluminum. Noel has interpreted the term "extractive metallurgy" broadly to include recycling, and has
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