Computer simulations enable installations like processing plants, oil refineries and power stations to assess plant upgrades without the need for costly experiments.

Predicting the performance of new plant and equipment is vitally important, but until recently engineers had to rely on costly and potentially disastrous trial-and-error procedures. However, CSIRO Minerals has developed computer simulations to enable installations like processing plants, oil refineries and power stations to assess plant upgrades without the need for costly experiments.

Instead, operators can use a technology called computational fluid dynamics (CFD), a sophisticated form of computer simulation that predicts equipment performance.

'This technology essentially tests potential modifications on a virtual plant before implementation', says CSIRO’s CFD group leader Dr Phil Schwarz.

Based on predicting how gas, liquid, particles or mixtures flow within a piece of equipment, CFD also calculates other complex phenomena such as reactions, particle breakage or wear on equipment surfaces. Its use can help companies reduce capital and operating costs, cut harmful gaseous and particulate emissions, lessen fuel requirements and improve product quality.

Dr Schwarz says: 'We helped BP Bulwer Island refinery save $5 million a year in operating costs through CFD modelling. We also helped Worsley Alumina double the throughput of its washers and settlers, saving them millions of dollars.'

Environmental improvements are also possible. The technology was used to help Zinifex reduce fugitive emissions from the slag fumer charge port at Port Pirie by 65 per cent, creating company and community benefits.

Although basic CFD techniques have been around for more than a decade, ongoing development has allowed it to be more successfully used in predicting complex mineral processing techniques. CSIRO Minerals is keen to see this work enhanced further.

It is currently working on two projects to develop CFD models to improve solvent extraction-electrowinning (SX-EW) and electro-refining plants.

Working with industry, the SX project has been under way for 18 months and aims to develop models to improve performance of solvent extraction systems, such as mixer-settlers and pulsed columns.

For further information contact:
CSIRO Enquiries
Email: Solve@csiro.au      Web: www.csiro.au
Tel: 1300 363 400       International: +61 3 9545 2176

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Last Updated: February 10, 2005
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