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Sankt Stefan ob Leoben, Austria

Konetschnik S.,METTOP GmbH | Anzinger A.,Montanwerke Brixlegg AG | Preiss R.,Holding AG
World of Metallurgy - ERZMETALL

METTOP understands itself as a think tank for the metallurgical industry. Existing problems and challenges are taken up from the industry and - based on them - solutions will be worked out. These solutions need to be sophisticated and advantageous from the technical side of view. However, a market penetration will only be successful, if there are economic benefits as well. This is the topic of the present paper - it demonstrates the economic advantages of three technologies and products on the base of an example each. The first part deals with the METTOP-BRX-Technology, which was developed for upgrading copper electrolyses. A brownfield project with an existing capacity of 200,000 metric tons of cathode copper is assumed as an example. In this case, the economic benefit arises from an increased productivity of the modified tankhouse. For the second technology and product, respectively, a water cooled tap-hole is considered, which is upgraded with the "Ionic Liquid Cooling Technology" (ILTEC). This technology improves process safety and reduces downtime and repair costs in case of leakage of the cooling medium. On the basis of a risk assessment, the economic advantage is estimated. The last presented product is METTOP's 3D-refractory engineering. As an independent company, it is possible to design lining concepts without any limitation in respect of brick qualities or certain company's corporate philosophy.The economic benefit arises from savings of the refractory procurement as well as increased furnace uptime due to an optimized lining concept. Source

Wenzl C.,METTOP GmbH | Stibich R.,Montanwerke Brixlegg AG | Pesl J.,Montanwerke Brixlegg AG
World of Metallurgy - ERZMETALL

Over the last years, several development and optimisation projects have been carried out at Montanwerke Brixlegg AG, the main project in the tankhouse being the development of the METTOP-BRX-Technology together with METTOP and the subsequent conversion to a high current density tankhouse. Already in October 2007 the refining capacity had been increased to 108,0001 cathodes per year by enlarging the tankhouse, and will now in autumn 2011 be further increased to 118,0001 cathodes per year by using high current density. In order to enable high current density, half of the tankhouse has been equipped with a new transformer and the METTOP-BRX-Technology, namely a manifold electrolyte inlet for parallel flow that allows using high current densities while maintaining a high current efficiency and good cathode quality. A current density of more than 400 A/m 2 can be used in the high current density tankhouse part. Source

Konetschnik S.,METTOP GmbH | Wenzl C.,METTOP GmbH | Koncik L.,METTOP GmbH | Pesl J.,Montanwerke Brixlegg AG | Antrekowitsch H.,University of Leoben
Proceedings - European Metallurgical Conference, EMC 2011

The present paper deals with the process modelling of a state-of-the-art recycling process for low grade copper scrap, containing complex materials. The process itself is described shortly; the major part of the publication shows the possibilities and advantages of a well-reasoned model. A recycling process for low grade material needs a reducing or neutral smelting as well as two to three refining steps. Due to the presence of harmful elements, the off-gas treatment of the py-rometallurgical processes has major importance. Heart of the presented and modelled process is a bath smelting reactor, which can be operated in batchwise or continuous mode; this has significant influence on the whole recycling route and necessary capacity of all vessels. For designing the overall process and showing the influence of parameter variation, a thermody-namic process model was developed. By iterative calculation rounds for single process steps as well as for the whole process route, the mass and energy balances and material flows are determined. Special attention is put on the recycling of high organics containing raw materials. By the use of the model, an optimized addition time and amount of each kind of raw material can be calculated. A well-reasoned model is an interaction of thermodynamic software packages and empiric data. The software allows an easy mass and energy balancing based on a Gibbs minimization module. However, an essential step is the adjustment of the calculated values due to kinetic influences and/or insufficient thermodynamic data; this has to be done by empiric data and based on experience. Source

Filzwieser A.,METTOP GmbH | Filzwieser I.,METTOP GmbH | Konetschnik S.,METTOP GmbH

New electrorefining technology utilizes a novel manifold electrolyte inlet, which allows improving productivity and production in new and existing tankhouses at high current efficiency and very good cathode quality. Two installation examples-Montanwerke Brixlegg AG, Brixlegg, Austria (upgrade existing tankhouse) and Xiangguang Copper, Yanggu, China (new tankhouse)- demonstrate the use of current densities above 400 A/m2 at very high current efficiency in electrorefining. © 2012 TMS. Source

Wenzl C.,METTOP GmbH | Filzwieser A.,METTOP GmbH | Raaber E.,METTOP GmbH
Proceedings - European Metallurgical Conference, EMC 2011

Cooling technology is an important aspect of furnace operations: more intense furnace operations require effective cooling in order to achieve low refractory wear and good furnace lifetimes. This requires cooling solutions for the most critical furnace regions. However, the use of water - today's standard cooling medium - has some disadvantages, as it can cause problems both during furnace start up and operation, namely hydration problems, corrosion, and explosions. To overcome the disadvantages of water, the use of ionic liquids (ILs) as alternative cooling medium was investigated, and patented by METTOP. The big advantage of ILs is the fact that they can be used at higher temperatures than water (hence avoiding hydration and corrosion) and do not lead to explosions when contacting molten copper. Consequently, prolonged refractory life and hence furnace campaigns, as well as improved work safety are achieved. Different ILs were tested thoroughly regarding contact with liquid copper, corrosion, and heat transfer. Furthermore, CFD calculations were made to investigate and the heat transfer. These were verified by experiments in a test stand. The good results of the test lead to the design of first industrial cooling solutions. Source

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