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InsPyro - Inspiring metallurgy

S
Sander Arnout

The document discusses the vision for a sustainable future of metallurgy in Europe using secondary resources and zero-waste processes. It proposes that InsPyro can help metallurgical companies by providing process improvement, innovation, and focusing on flexible problem solving using materials characterization, thermodynamic modeling, and high-temperature experimental setups. InsPyro aims to cover companies' needs on a case-by-case basis and help drive process innovation required for metallurgy to have a future in Europe.

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Inspiring metallurgy1st Inspiration day, December 3rd 2010
Global metallurgy landscapeMetallurgy in Europe?No primary resources in EuropeExpensive labourEnvironmental restrictionsClimate change laws still rather dormantPeak metal: some metal resources depleting fast... and even speeding up as world material intensity is expected to triple by 2050Primary production also leads to ecological rucksack in other continentsHowever, metals are recyclable and huge amounts of waste are available in the West
Our vision on metallurgyMetallurgy is changing drastically, and ever fasterProcesses of the future use secondary resources produce zero waste are low energy and low CO2This is the only sustainable approach, not only in EuropeMetallurgy has a future in EuropeSecondary resources availableTechnology and knowledge availableGovernment push to cleantechTo get there, process innovation & research are key!3
Our vision for InsPyroProcess improvement and innovation: whats so new about that?Universities do it (but are only interested in the big stories)Equipment suppliers do it (but want to sell equipment)Optimization companies do it (but forget a metallurgical process is not a black box)Processing companies do it themselves (but often lack right tools and people)There is a need for flexible and focused helpThere is a need for more insight 4
Based on technology5MaterialscharacterizationSEMEPMAXRDICPLOMThermodynamicModellingLiquidusSolidificationReactionsEquilibriumProcess modellingScientific LiteratureJournalsProceedingReportsPatentsHigh temperatureexperimental set-upsTube furnacesInduction furnaceCSLMDSCSolidification
The offering of InsPyroCovering all forms of needs using our specialtiesCase by case definition of optimal strategy6
Current issues (1/2)Slag practiceLooking for the optimal fluxing strategySeveral issues need to be considered simultaneously:Metal yieldMetal quality (impurities)Metal cleanliness (non-metallic inclusions)Refractory lifetimeFurnace behaviourSlag valorizationRefractory protectionDetermining cause of accelerated wearSteel, ferroalloys, cast iron...7
Current issues (2/2)Process developmentUsing thermodynamic calculations as a first estimation for new processesContinuous need in non-ferrous metals sectorProduct developmentUsing calculations to predict phases and propertiesIn ceramics, iron, steel...8
References9
Thermodynamic modelling with a low thresholdInteractive all-round program:10Phase description databases for oxides, steel, lead, ...Calculation engineProgrammable library:Standalone applications for our customersIntegration into customers platformExcelSQLScadaWebResults in a reportResults database
Excel-based standardized calculations11Company XIllustration only no actual result
New features in since 12/2010Optimization of the equilibrium:Optimal situation for the process or material propertye.g. Global minimum melting temperaturee.g. Maximum amount of precipitates...Viscosity calculationsOxide liquids (slags and glasses)Based on quasichemicalchain formation model12
ConclusionsMetallurgy has a future in Europe, but not without process innovation With InsPyro:Add professional metallurgists to your teamComplement R&D with missing toolsHave the state of the art at your fingertipsSpeed up innovation within your organisation13

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InsPyro - Inspiring metallurgy

  • 1. Inspiring metallurgy1st Inspiration day, December 3rd 2010
  • 2. Global metallurgy landscapeMetallurgy in Europe?No primary resources in EuropeExpensive labourEnvironmental restrictionsClimate change laws still rather dormantPeak metal: some metal resources depleting fast... and even speeding up as world material intensity is expected to triple by 2050Primary production also leads to ecological rucksack in other continentsHowever, metals are recyclable and huge amounts of waste are available in the West
  • 3. Our vision on metallurgyMetallurgy is changing drastically, and ever fasterProcesses of the future use secondary resources produce zero waste are low energy and low CO2This is the only sustainable approach, not only in EuropeMetallurgy has a future in EuropeSecondary resources availableTechnology and knowledge availableGovernment push to cleantechTo get there, process innovation & research are key!3
  • 4. Our vision for InsPyroProcess improvement and innovation: whats so new about that?Universities do it (but are only interested in the big stories)Equipment suppliers do it (but want to sell equipment)Optimization companies do it (but forget a metallurgical process is not a black box)Processing companies do it themselves (but often lack right tools and people)There is a need for flexible and focused helpThere is a need for more insight 4
  • 5. Based on technology5MaterialscharacterizationSEMEPMAXRDICPLOMThermodynamicModellingLiquidusSolidificationReactionsEquilibriumProcess modellingScientific LiteratureJournalsProceedingReportsPatentsHigh temperatureexperimental set-upsTube furnacesInduction furnaceCSLMDSCSolidification
  • 6. The offering of InsPyroCovering all forms of needs using our specialtiesCase by case definition of optimal strategy6
  • 7. Current issues (1/2)Slag practiceLooking for the optimal fluxing strategySeveral issues need to be considered simultaneously:Metal yieldMetal quality (impurities)Metal cleanliness (non-metallic inclusions)Refractory lifetimeFurnace behaviourSlag valorizationRefractory protectionDetermining cause of accelerated wearSteel, ferroalloys, cast iron...7
  • 8. Current issues (2/2)Process developmentUsing thermodynamic calculations as a first estimation for new processesContinuous need in non-ferrous metals sectorProduct developmentUsing calculations to predict phases and propertiesIn ceramics, iron, steel...8
  • 10. Thermodynamic modelling with a low thresholdInteractive all-round program:10Phase description databases for oxides, steel, lead, ...Calculation engineProgrammable library:Standalone applications for our customersIntegration into customers platformExcelSQLScadaWebResults in a reportResults database
  • 11. Excel-based standardized calculations11Company XIllustration only no actual result
  • 12. New features in since 12/2010Optimization of the equilibrium:Optimal situation for the process or material propertye.g. Global minimum melting temperaturee.g. Maximum amount of precipitates...Viscosity calculationsOxide liquids (slags and glasses)Based on quasichemicalchain formation model12
  • 13. ConclusionsMetallurgy has a future in Europe, but not without process innovation With InsPyro:Add professional metallurgists to your teamComplement R&D with missing toolsHave the state of the art at your fingertipsSpeed up innovation within your organisation13