Development of a three-dimensional CFD Model for the Estimation of Accretion Formation in an Industrial-Scale Copper Waste Heat Boiler


Development of a three-dimensional CFD Model for the Estimation of Accretion Formation in an Industrial-Scale Copper Waste Heat Boiler

Schmidt, A.; Montenegro, V.; Reuter, M.; Stelter, M.; Richter, A.

While striving for a circular economy of metals, the Flash Smelting Furnace (FSF) is the most common and “green” aggregate for primary smelting of copper concentrates, because of already today low CO2-emissions compared to other smelting technologies. High dust carry-over often leads to problems with flue dust accretions in its subsequent cooling aggregate, the Waste Heat Boiler (WHB). Removing these accretions causes mechanical stress for the boiler tubes and can lead to extended downtime and maintenance. The WHB has a limited accessibility towards experimental studies because of its harsh process conditions. Hence, Computational Fluid Dynamics (CFD) models appear as convenient option for WHB studies and design, but are not used for the evaluation of flue dust accretions yet. For the inclusion of this feature into a three-dimensional CFD model of the entire WHB, a new sticking function is developed. It is based on the industrial experience that flue dust is only sticky above a certain softening temperature. Since the WHB has a varying dust input due to the flexible operation of the FSF, a parameter study is conducted for standard flue dust, pure copper oxide dust and pure iron oxide dust, finding minor sensitivity towards the flue dust density and no sensitivity towards the dust heat capacity. From these findings, recommendations for the minimization of flue dust accretion formation in the WHB are derived.

Keywords: Copper Production; Flash Smelting Furnace; Waste Heat Boiler; Flue Dust; Accretion Formation; 3D CFD

  • World of Metallurgy - Erzmetall 74(2021)5, 270-276

Permalink: https://www.hzdr.de/publications/Publ-33055
Publ.-Id: 33055