Because of the tremendous cost of pilot-plant-scale metal industrial trials, previous attempts to develop new metallurgical processes have generally relied on scaling up small bench-scale experiments. Because of the lack of true understanding of the rate constants, mixing phenomena, and geometric effects that control the success of the real process, many previous pilot-plant operations have been unsuccessful. Water modeling and mathematical modeling instead have become the main approaches to optimize the metallurgical reactors. To achieve success, the model must accurately predict the phenomena of true interest, including the following:
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