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JOM, Vol. 71, No. 2, 2019 https://doi.org/10.1007/s11837-018-03316-4 Ó 2019 The , & Society

The World Needs Metallurgical Process Peter C. Hayes

The Changing World On the face of it, the metallurgical development of new advanced materials industry looks stronger than at any time in and , creating its development. Primary production opportunities for new industries in a is at record levels, and continues to expand diverse range of applications. LQUHVSRQVHWRVLJQL¿FDQWSRSXODWLRQ The advent of computerization and new and consumption growth. The rapid technologies for generation and technological changes that are currently storage are already stimulating the need for underway are creating new markets for new process technologies to produce a wide metals. range of metallic elements—elements that, The industry response to this demand even in the recent past, have been regarded will be increased investment in exploration as being of no more than intellectual or and the discovery of new primary sources academic interest. Peter Hayes in the form of bodies. However, we Although small in volume, these are FDQH[SHFWWKDWDVWKHVH¿QLWHVRXUFHV high value products, critical for the are consumed, there will be further sustainability of our technologically Editor’s Note: This article declines in mean ore grades. Without advanced societies. Examples of these is based on the keynote lecture, “The Changing World major technological innovations this trend metals include, in photovoltaics—indium, of Metallurgical Education, means that, to maintain the same levels of gallium, germanium, silicon, silver; in delivered by Peter Hayes production, there will be increased energy electric vehicles and batteries—cobalt, at a joint session of the 7th usage, and with it increased costs and copper, lithium, rare elements, International Symposium on the potential for greater environmental vanadium; in —gold, palladium, Advances in Sulfide Smelting impacts. The problems will be most acute platinum, ruthenium; thermo- and opto- and the Peter Hayes Symposium for nonferrous metals and those metals that electrics—bismuth, antimony, arsenic, on Pyrometallurgical Processing are present in low concentrations in . gallium, selenium, tellurium. These metals at Extraction 2018 held in The use and treatment of polymetallic are needed in the form of pure metals, August 2018. Comments were ores will increase. Raw materials will compounds, and solutions to tight chemical provided by the following be of greater complexity in terms of DQGSK\VLFDOVSHFL¿FDWLRQVIRUHDFKRIWKHVH discussion panel: Bart Blanpain (Leuven ); Kenneth both microstructure and composition different manufacturing applications. Coley (McMaster University); over those that have been used in recent In , issues such as materials Mario Loebbus (Aurubis); Sari times. These factors will create a need scarcity and concerns over the supply of Muinonen (Glencore); and for further technological development critical metals have prompted strategic Maurits van Camp (Umicore). and metallurgical innovation to be able to moves involving both government and Extraction 2018 was organized HI¿FLHQWO\SURFHVVWKHVHPDWHULDOV industry towards creating a circular by The and Materials  7KHSUR¿OHRIWKHPHWDOOXUJLFDO economy; one in which waste and energy Society (MetSoc) of the industries in Europe and the United usage is minimized, and metal and materials Canadian Institute of Mining, 6WDWHVKDVFKDQJHGVLJQL¿FDQWO\IURP recycling are maximized. These initiatives, Metallurgy and Petroleum one of primary metal production and the need for industry, university, and (CIM); the Society for Mining, to manufacturing. Metallurgical JRYHUQPHQWFRRSHUDWLRQDUHH[HPSOL¿HGE\ Metallurgy & Exploration (SME); and TMS. engineers have played a key role in the the establishment of the European Institute

463 464 Hayes

of Innovation and (EIT). decline in teaching, and in research and Do You Within this Institute, “raw materials” was development capabilities in core aspects designated as one of the key Knowledge of metallurgical .6 Have a and Innovation Communities charged with Metallurgical process engineering has assisting the drive towards the circular been reduced to a minor component of Perspective economy.1 most of these MSE teaching and learning The underlying message is clear. Our programs, and in many cases, key courses to Share? technologically based society cannot be have disappeared from the curriculum. There has been a marked decline in student JOM: The sustained without the continued supply of metals from both primary and secondary enrollments in metallurgical process Magazine is sources. Metallurgical engineers are engineering programs in industrialized seeking case needed to provide innovative solutions countries. to the emerging and complex challenges In addition, those countries whose studies, member faced by the industry. economies rely on primary metal perspectives, production in general, do not have Status of Metallurgical WKH¿QDQFLDOUHVRXUFHVRUHGXFDWLRQ and non- Education Programs strong enough to establish technical project Over the past 100 years, the principal and sustain strong processing overviews with pathways that have been developed for and metallurgical process engineering the education of our young engineers programs. strong industrial have been through tertiary institutions, Across the globe, the strong support applications. To our colleges and . In general, previously given by industry for mining the standards of training of professional and metallurgical education has faded. suggest an article engineers have never been higher. Schools of Mines, once the source of idea, contact All recognized engineering programs skilled workforces for primary production, have been closed. The numbers of Kaitlin Calva, are subject to rigorous scrutiny by accreditation panels representing academic positions at universities JOM Magazine the various engineering . supported by industry have declined. The Managing Editor, $FFUHGLWHGOHDUQLQJSURJUDPVPXVWIXO¿OO result is that, internationally, with the few minimum standards of learning outcomes exceptions of countries having centrally at [email protected]. covering fundamental and specialist controlled economies, there has been a knowledge, graduate attributes and GHFOLQHLQ¿QDQFLDOUHVRXUFHVGLUHFWHG professional engineering skills.2–4 Major towards providing opportunities for future efforts are being made across all tertiary metallurgical engineering professionals. institutions to improve teaching and In short, the quality and sustainability of learning practice, to enhance the quality of metallurgical in deep learning and provide the foundations most regions of the world are under threat for lifelong learning. at the very time that innovation and the However, if we examine the structure ability to meet major technical challenges and content of metallurgical engineering are becoming the central tenants to the SURJUDPVZH¿QGSDUWLFXODUO\LQWKH future of the industry. Industry will be the and Europe, that the majority ¿UVWWRORVHLIWKHDYDLODELOLW\RIZHOO have morphed over time into materials trained metallurgical engineers continues and engineering (MSE) programs to decline. Those companies and countries —a matrix of disciplines that are related that invest in their workforce are the through the common elements of structure/ ones most likely to survive the emerging composition; properties; performance, challenges and to take advantage of the and product synthesis.5 This change has opportunities ahead. been driven by major investments into A concerted effort is needed by industry, the of new professional societies, and academia materials, and their application to new to promote and sustain the education manufacturing technologies. While the DQGUHVHDUFKFDSDFLWLHVLQWKH¿HOGRI expansion and growth of metallurgical metallurgical process engineering at our education into these new areas is welcome, tertiary institutions. close examination reveals a marked The World Needs Metallurgical Process Engineers 465

Metallurgists of the Future If the need for continued metallurgical education is accepted, it is timely to ask some important questions. What knowledge, skills, and attributes do we need from our future metallurgical engineering workforce to prepare them for the challenges that lie ahead? How are we to ensure that we provide appropriate learning and career pathways for future professional metallurgical engineers? We need metallurgical engineers who can understand and provide innovative solutions to complex problems, and who can adapt to the rapid changes in technologies. All metallurgical engineers need , and synthesis. Figure 1. Common core a background and understanding of knowledge and skills that The common features that could be can be used to define , the basic , materials, XVHGWRGH¿QHWKHPHWDOOXUJLFDOSURFHVV and develop metallurgical and other engineering sciences in order to engineering (MPE) programs for the future, process engineering be able to communicate and effectively and the core knowledge and skills needed, (MPE) programs. work with other professionals in the can be summarized by four interrelated industry. Some would argue that a general areas: specialist metallurgical process HQJLQHHULQJHGXFDWLRQLVVXI¿FLHQW knowledge and skills; process control/ However, the metallurgical industry also reaction engineering; process modeling needs engineers with specialist knowledge and optimization; and process and and advanced skills in mineral (physical) synthesis (see Figure 1). processing, hydro/electro-metallurgy, It is not by chance that many of these and pyrometallurgy. In order to truly areas of knowledge and core skills are understand metallurgical processes and common to graduates. have an appreciation of the potential for That discipline has been successful in process improvement, a graduate transforming itself from its origins in should have an understanding of the whole applied to encompassing a wide value chain. range of process industries that include The metallurgist of the future will petroleum, oil and gas, , inorganic spend more time utilizing the powerful chemicals, , environmental computer tools that have become available engineering, and new materials. It is time through the digital revolution rather to combine the strengths of process and WKDQSDWUROOLQJWKHVKRSÀRRUFRQWUROOLQJ systems thinking, which are at the heart individual unit operations. Using these of modern chemical engineering, with sophisticated computer-based tools to specialist metallurgy knowledge and skills, analyze complex data sets and predict to reinvigorate the metallurgical process process outcomes, metallurgical engineers engineering discipline. In this way, we can can play a key role in increasing the create educational structures that embrace productivities of integrated operations the needs of the current and the future DQGRURSWLPL]LQJWKHRYHUDOO¿QDQFLDO metallurgical industry. 7 returns of these operations. The ability  $ÀH[LEOH\HWVRXQGDQGUREXVWVWUXFWXUH to apply these principles to different can be built by utilizing the strengths of physical and chemical systems can be process engineering in the early years of the provided by integrating this specialist programs. Basic and engineering sciences metallurgical knowledge with core in year one and process engineering process engineering knowledge and skills and modeling fundamentals in year two in chemical , mass and with contextual learning of metallurgical energy , reaction kinetics, process applications. In years three and four, control, , the study would include specialist 466 Hayes

Figure 2. A proposed metallurgical courses and courses from In practice, the details of programs program structure for related disciplines as appropriate for local offered at different institutions will vary bachelor’s of engineering metallurgical process industry requirements. The proposed depending on local and regional industry engineering programs structure of such a program, one that needs. In some countries, the focus will be based on a strong incorporates the features of a core of on mineral processing and the preparation process engineering process engineering and broadening of mineral concentrates; in others, the core with flexibility to through links to different branches and emphasis will be on the development cover the many branches and specializations that VSHFLDOLVW¿HOGVRIPHWDOOXUJ\LVLOOXVWUDWHG of metal recovery and recycling or new embody the discipline. schematically in Figure 2. In this way, a process routes for the production of strong and sound metallurgical process advanced materials. The point is that engineering program can be constructed a common set of core knowledge and using, and on, the existing skills is required to be able to tackle these teaching and learning resources within problems as a professional metallurgical our engineering faculties. The model engineer. SURYLGHVÀH[LELOLW\WKDWHQDEOHVLQGLYLGXDO institutions to offer or develop programs Essential Elements for the WKDWUHÀHFWVWUHQJWKVLQSDUWLFXODUEUDQFKHV Sustainability of MPE of metallurgical engineering. Continuing the analogy of the tree This framework could be used to (see Figure 3 on the following page), develop four-RU¿YH-year bachelor’s the healthy growth of plants requires or B.E./M.E. programs in metallurgical the provision of the atmosphere (sun,

process engineering. The structure is not water, CO2) and a fertile environment intended to be prescriptive and may not (essential elements, organic matter, be suitable or appropriate for all tertiary nutrients, microbiological activity). We institutions. It is, however, the basis for the can draw some useful analogies between B.E. dual major program in chemical and this example and the requirements for metallurgical engineering that has been sustaining metallurgical education. running successfully since 2006 at The University of Queensland. The World Needs Metallurgical Process Engineers 467

In the metallurgical context, the atmosphere that is essential for the growth and sustainability of metallurgical engineering as a discipline is one that includes: • Acknowledgement at senior leadership FKLHIH[HFXWLYHRI¿FHU OHYHOV and proactive industry support for metallurgical engineering education • Creating attractive, challenging, and visible career paths • Promoting a positive and exciting vision of the ways in which professional metallurgical engineers can contribute to the future sustainability of our society

The fertile environment necessarily includes: • Ensuring that recognized tertiary institutions have appropriate numbers of academic staff and learning facilities to be able to provide specialist metallurgy learning at undergraduate and postgraduate levels • Active engagement between university/ industry to identify the challenges faced by the minerals, primary and recycled metals, and advanced materials industries • Providing supportive learning environments and collaborations between complimentary academic disciplines, e.g., MSE programs and Most university programs are active in Figure 3. The essential conditions for the healthy chemical engineering departments recruiting students whenever and wherever they can, since their funding is principally growth of plants, which provides a useful analogy • Providing appropriate funding models to based on enrolment numbers. Potential sustain undergraduate and postgraduate for the requirements for actions by universities to re-establish the sustaining metallurgical process metallurgy programs SUR¿OHRIPHWDOOXUJLFDOSURFHVVHQJLQHHULQJ education. include: Strategies to Develop Our • Re-establishing attractive undergraduate Future Workforce majors in MPE programs with a focus  $PDMRULVVXHLVDWWUDFWLQJVXI¿FLHQW on core metallurgical and process young would-be engineers into engineering skills metallurgical engineering programs. For • 'HYHORSLQJÀH[LEOHHQWU\DQGSDWKZD\V WKLVWRRFFXUWKHUHKDVWREHDVLJQL¿FDQW into MPE programs change in perceptions on their part. The industry needs to embrace a new vision • Articulating clear, exciting career and demonstrate that the focus is just not pathways and opportunities for graduates about making money—young people want • Promoting and marketing a positive view to feel that they are genuinely playing of the future of the metallurgical industry a part in shaping the future. We need to excite their interest; to show them how they can utilize their skills in creating a sustainable society and a healthier environment. 468 Hayes

The numbers of students expected in In this article, I have put forward these MPE programs are small relative some thoughts about the knowledge, to other engineering disciplines, which skills, and attributes needed in our future makes them hard to justify to university metallurgical engineering workforce and . For this reason alone, the SURSRVHGDÀH[LEOHHGXFDWLRQDOVWUXFWXUH establishment of MPE programs needs based on process metallurgy, that could DGGLWLRQDOPRUDODQG¿QDQFLDOVXSSRUW be used to deliver the next generation from the minerals and metallurgical of engineers. I look forward to hearing industries. other ideas on how we can meet these goals, actions, and initiatives that can be Potential actions by industry include: taken so that we can address the rapid • Actively supporting and engaging with changes faced by the modern metallurgical academic and research staff through industry, and move closer to the economic, funding industry focused research technical, and social sustainability of our • Providing industry-funded academic society. SRVLWLRQVLQVSHFLDOLVW¿HOGVRI metallurgical engineering End Notes • Developing long-term partnerships in 1. EIT, European Institute of Innovation and support of research and development Technology, https://eit.europa.eu/eit-community strengths in fundamental research in /eit-raw-materials. VHOHFWHGFRUH¿HOGVRIH[SHUWLVH 2. ABET, Accreditation Board for Engineering • Attracting prospective students into and Technology, Engineering Accreditation the industry through providing and Commission, www..org/. supporting quality industrial work 3. EA, Engineers , experiences and internships for early www.engineersaustralia.org.au/. year (1, 2, 3) undergraduate students 4. Institution of Chemical Engineers (IChem E), • Providing mentoring, technical www.icheme.org/. development, engineering skills and 5. M.C. Flemings, “What Next for Departments career guidance to early career graduate of and Engineering?”, Annu. engineers Rev. Mater. Sci. 1999, vol. 29, pp.1–23. 6. P.C. Hayes, "The Changing World of • Establishing continuing professional Metallurgical Education," Extraction 2018, development programs within 2018, pp. 57 –67. companies that support deep learning of 7. E. Jak, "The Role of Research in advanced skills Pyrometallurgy Technology Development from • Establishing good relationships and Fundamentals to Process Improvements— ongoing dialogue between senior Future Opportunities,” Extraction 2018, 2018, management in companies and pp.19–37. universities, to provide a mechanism of explaining industry needs and Peter Hayes is professor of metallurgical opportunities for collaborations engineering within the School of Chemical Engineering at The University Summary of Queensland, Brisbane, Australia. He is The world needs metallurgical process currently the Metallurgical Engineering engineers to ensure continued metal Program leader and is senior researcher resource supply and sustainability of our in the Pyrometallurgy Innovation Centre (PYROSEARCH) at the university. He has technologically based society. been an active TMS member since 1986. This will require concerted efforts by industry, professional societies, and academia across the globe to promote and sustain the education and research FDSDFLWLHVLQWKH¿HOGRIPHWDOOXUJLFDO process engineering at our tertiary institutions. JO themagazine