Process control sensor systems for copper production, ProCuPro

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Sensors and process control technology are lacking in copper production, and indeed in most non-ferrous production processes, because many of these processes are pyrometallurgical, i.e. they occur at high temperatures and in corrosive environments. Stand-off sensors such as optical probes and spectrometric systems can provide an elegant solution to this measurement challenge. Funded in part by NSERC-Engage and OCE, first steps have been taken by Queen's University and KPM towards an all-optical temperature probe, which had been tested by Aurubis, Hamburg in May 2018 by a queen's graduate student. With the current proposal, we intend to expand the suite of optical technologies for in-line probing of high-temperature industrial processes. We will use particle scattering to obtain dust particle size distributions. We will use fiber probe technologies to measure atomic emission, and absorption spectroscopy for chemical analysis. These techniques will be validated using off-line analysis through, e.g. by gas chromatography, X-ray Photoelectron Spectroscopy (XPS) and X-ray Diffraction (XRD). By correlating optical online measurements and product yields to the adjustable input parameters (feed composition, SO2 and O2 concentration, fuel concentration) we will create a database of operating conditions that will allow the operator to target the process towards a desired product composition and yield. The proposed work aligns very well with the objectives of the initiative "Advanced Manufacturing-Industry 4.0" as it entails the digital transformation of metal manufacturing, through the interactions between a distributed and multi-parameter sensor system, a deep database and the machinery operators. By correlating online and off-line information with desired product yields one may expect to increase reliability, product quality while reducing energy costs and reducing the environmental footprint. Graduate students and postdoctoral fellows will be trained in research lab at Queen's and Potsdam University, at a pilot plant at KPM and eventually on the production floor of an industrial smelter in Germany. Interactions with German project partners UPPC and Loptek will require visits to their facilities.