Leoben, Austria


Leoben, Austria
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Konetschnik S.,METTOP GmbH | Anzinger A.,Montanwerke Brixlegg AG | Preiss R.,Holding AG
World of Metallurgy - ERZMETALL | Year: 2014

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.

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 | Year: 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.

Wenzl C.,METTOP GmbH | Stibich R.,Montanwerke Brixlegg AG | Pesl J.,Montanwerke Brixlegg AG
World of Metallurgy - ERZMETALL | Year: 2011

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.

Filzwieser A.,METTOP GmbH | Siegmund A.,Mettop United States LLC | Filzwieser I.,METTOP GmbH | Hanel M.B.,METTOP GmbH
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2016

The intensification of metallurgical furnace reactions requires more effective cooling in order to achieve low refractory wear and good furnace longevity, making cooling technology an important aspect of furnace operation. In addition, increased awareness of safety for personnel and equipment is becoming more and more a focal topic for commercial plants. The use of water - today's standard cooling medium - has some disadvantages, as it can cause problems during furnace start up and operation, namely refractory hydration, corrosion, and explosions. Beside these detrimental effects, the energy removed by extensive water cooling cannot be captured and is normally lost in cooling towers. Not to forget the severe personnel as well as economical damage in case of a malfunctioning water cooling system. With Mettop's new patented cooling technology (ILTEC) it is possible to overcome the disadvantages of water by using an alternative cooling medium based on an ionic liquid named IL-B2001. The main advantage of this ionic liquid is the fact that no explosion occurs when it comes in contact with molten metal. Furthermore, the ionic liquid is non-toxic and can be used at higher temperatures than water - up to 200°C (392 F). This relatively high cooling medium temperature avoids hydration and corrosion problems and allows recovery of energy, for example, by combining the ILTEC system with an organic ranking cycle (ORC) technology. The fact that no explosion occurs when IL-B2001 gets in contact with molten metal results in a revolutionary solution for the metallurgical industry in terms of safety. New safety standards can be achieved as described in this paper on two examples: a tap hole cooling and a wall cooling at a shaft furnace. © 2016 by AIST.

Kubin M.,INTECO Special Melting Technologies GmbH | Ofner B.,INTECO Special Melting Technologies GmbH | Holzgruber H.,INTECO Special Melting Technologies GmbH | Schneider R.,Upper Austria University of Applied Sciences | And 3 more authors.
IOP Conference Series: Materials Science and Engineering | Year: 2016

One of the main benefits of the ESR process is to obtain an ingot surface which is smooth and allows a subsequent forging operation without any surface dressing. The main influencing factor on surface quality is the precise controlling of the process such as melt rate and electrode immersion depth. However, the relatively strong cooling effect of water as a cooling medium can result in the solidification of the meniscus of the liquid steel on the boundary liquid steel and slag which is most likely the origin of surface defects. The usage of different cooling media like ionic liquids, a salt solution which can be heated up to 250°C operating temperature might diminish the meniscus solidification phenomenon. This paper shows the first results of the usage of an ionic liquid as a mould cooling medium. In doing so, 210mm diameter ESR ingots were produced with the laboratory scale ESR furnace at the university of applied science using an ionic liquid cooling device developed by the company METTOP. For each trial melt different inlet and outlet temperatures of the ionic liquid were chosen and the impact on the surface appearance and internal quality were analyzed. Furthermore the influence on the energy balance is also briefly highlighted. Ultimately, an effect of the usage of ionic liquids as a cooling medium could be determined and these results will be described in detail within the scope of this paper. © Published under licence by IOP Publishing Ltd.

Filzwieser A.,METTOP GmbH | Filzwieser I.,METTOP GmbH | Konetschnik S.,METTOP GmbH
JOM | Year: 2012

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.

Koncik L.,METTOP GmbH | Konetschnik S.,METTOP GmbH | Wenzl C.,METTOP GmbH | Ruhs S.,METTOP GmbH
Proceedings - European Metallurgical Conference, EMC 2011 | Year: 2011

Gas purging improves metallurgical work and can result in a significant reduction of process time. While it is already used in anode furnaces, there are only a few converters, which are equipped with a purging system. Reason is that for the installation of porous plugs, it is necessary to cut openings in the steel shell of the furnace. Well thought-out purging systems are designed to prevent a metal leakage or run through by various construction details, but this hazard cannot be eliminated completely; defect sources are an insufficient walling around the purging plugs or problems with the refractory quality for example. The present publication deals with the two possibilities of piping installation. The first opportunity - the external piping - is one opening with the gas supply for every single plug; this includes the possibility of plug changing, also in hot conditions. Alternatively, using internal piping, the piping can be done between steel shell and refractory lining so that fewer and smaller openings in the furnace are required; this increases the safety. The main part of the paper shows the differences and possibilities of both systems. The benefits and possible defect sources are pointed out and illustrated in detail on the base of two practical examples. The first one is the installation of a conventional external system in a drum-type anode furnace with expansion joints in the refractory lining. As a second example, the installation of porous plugs in a tilting furnace with spring mounted walls is described. Here, the piping from the front side of the furnace to the porous plugs is done on the inner side of the steel shell.

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

Hanel M.,Mettop GmbH | Filzwieser A.,Mettop GmbH | Ruhs S.,Mettop GmbH
World of Metallurgy - ERZMETALL | Year: 2016

It is the increasing demand for an economic and cost saving operation mode that requires effective cooling in order to achieve low refractory wear and good furnace lifetime, which is making cooling technology an important aspect of furnace operation. In addition, safety awareness is becoming more and more a focal point of the operating philosophy. However, the use of water - today's standard cooling medium - has major drawbacks as it can cause problems during furnace start up and operation, namely hydration problems, corrosion and explosion. Not to forget the severe personal as well as economical damage in case of a malfunctioning water cooling system. With the new patented cooling technology ILTEC it is possible to overcome the disadvantages of water by using an alternative cooling medium, namely the ionic liquid IL-B2001. The main characteristics, which make IL-B2001 so favourable, are a neglectable vapour pressure, the absence of explosion, the wide liquidus range and the operation temperature from 50 to 200 °C and the non-flammable, non-corrosive and atoxic behaviour. All those properties lead to many areas of application, which can contribute to accomplishing a water-free production route for the entire metal processing industry.

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