Modeling of RTFT water atomization steel powder production process

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The production of metal powders by water atomization is a well established process, which can be used to produce a wide range of particle sizes. A careful control of the particle size distribution is necessary, to atomize powders with a high quality and at a low production cost. Rio Tinto is one of the major suppliers of high-quality iron, steel and specialty metal powders. Ilmenite ore from RTFT's Canadian mines is transformed into advanced products at their metallurgical complex in Sorel-Tracy, Quebec, Canada. The proposed CRD research program will identify solution strategies enabling the increase of saleable product yield, which is currently impacted by up to 8% of oversize product fraction (particles larger than 210 microns). Reducing this fraction by 50% would result in approx. $0.8 million annual production cost savings.The possibility of producing particles with more controlled morphology is expected to enable the development of new metal powder grades, including potentially those suitable for the emerging additive manufacturing industry. The project will encompass the development of a computational fluid dynamics model covering all aspects related to molten metal flow, nozzles and atomization vessel geometry, interaction between the high-pressure water jets and the molten metal stream, and metal particles formation. The study will establish a basis for improvements that benefits not only the Canadian but also the global powder metal industry in terms of product cleanliness, quality and particle size control. Several highly qualified personnel (HQP) will be trained in the course of the project in the area of metal powder production, who will eventually enter the powder manufacturing industry or academia in Canada