Designing Furnace Lining/Cooling Systems to Operate with a Competent Freeze Lining

Joubert, Hugo; Dougall, Isobel Mc

doi:10.1007/978-3-030-05861-6_113

Cited by 8 publications

(5 citation statements)

References 12 publications

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“…For the same load case the freeze lining thickness developed on the hot face of the intensive sidewall cooling will reach equilibrium at 60 mm, which is a competent freeze lining thickness. As noted previously, freeze lining thickness is directly proportional to the thermal conductivity of the frozen slag (Joubert and Mc Dougall, 2019). If the thermal conductivity is assumed to increase from 3 W/mK to 5 W/mK considering the operating temperatures (Heimo, 2018), the freeze lining thickness will increase to approximately 101 mm.…”

Section: Calculation Resultsmentioning

confidence: 58%

“…Finally, the thermal conductivity of the frozen slag layer is assumed to be 3 W/mK. The effect of the frozen slag conductivity is limited to determining the slag freeze lining thickness, if formed, and the conductivity has little influence on the sidewall hot face temperature and heat flux (Joubert and Mc Dougall, 2019).…”

Section: Operating Conditions and Slag Propertiesmentioning

confidence: 99%

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Design of sidewall lining/cooling systems for AC or DC ilmenite smelting furnaces

Joubert¹,

Kotzé²

2020

J. S. Afr. Inst. Min. Metall.

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Ilmenite smelting is well established using both direct current and alternating current furnaces. Regardless of the furnace type, the slag produced is aggressive towards the sidewall lining. The formation of a stable slag freeze lining is essential to arrest lining wear and ensure an acceptable furnace campaign life. The sidewall lining can be severely damaged within a short period of time under upset conditions and without a stable freeze lining in place. The sidewall lining/cooling system adjacent to the furnace slag bath must be designed to ensure a stable freeze lining and prevent lining wear under normal as well as upset conditions. In this paper we explore the effectiveness of high-intensity copper coolers compared to the more traditional magnesia working lining combined with an externally cooled furnace shell. An increase in furnace heat losses has been raised as a concern for intensively cooled sidewalls. The estimated furnace heat losses are compared for the different lining/cooling system designs.

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Section: Calculation Resultsmentioning

confidence: 58%

Section: Operating Conditions and Slag Propertiesmentioning

confidence: 99%

Design of sidewall lining/cooling systems for AC or DC ilmenite smelting furnaces

Joubert¹,

Kotzé²

2020

J. S. Afr. Inst. Min. Metall.

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“…The inner lining of the TSL shell is lined with refractory bricks or may be cooled through copper jackets, thus creating a direct freeze-lining of the slag bath, a phenomenon similar to the protective coating formed on the lance surface. The TSL technology employs various lining/cooling arrangements, including pure refractory systems, refractory backed by stave coolers, an interleaved refractory plate cooler lining, and cooled copper hot face designs [31]. Examples of side wall coolers are shown in Figure 13.…”

Section: Refractory Liningmentioning

confidence: 99%

A Review of Top-Submerged Lance (TSL) Processing—Part I: Plant and Reactor Engineering

Kandalam,

Reuter,

Stelter

et al. 2023

Metals

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Part I of this series of papers focuses on plant and reactor engineering aspects of the TSL reactor technology. A general flowsheet is presented, while emphasis is given to the definition of different reactor zones in terms of fluid dynamics and occurring reactions. Then, the technical advantages of TSL processing, such as feed flexibility and high conversion rates (due to induced turbulence), low dust generation, and low fugitive emissions, are explained. In addition, the reactor is analyzed part by part, also taking into account patent literature, focusing on furnace design, settling furnaces for molten phase disengagement, feeding systems regarding input material streams such as concentrates and fuels, vessel cooling arrangements, off-gas system, and aspects associated with the refractory lining. Furthermore, specific focus is given to the centerpiece of the TSL reactor, i.e., the reactor lance. Associated developments have focused on establishing a slag coating to hinder lance wear, i.e., the development of cooling mechanisms (e.g., use of fluid-cooled lance and shroud arrangements), the increment of O2 enrichment within the incoming air stream, and influencing of fluid dynamics (e.g., O2 conversion at the lance tip, bubble formation, and bath splashing). Finally, comprehensive tables concerning process developments and commissioned TSL plants are provided thus concluding Part I of the review.

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“…5 The intention is to establish a steady layer of frozen slag, in order to reduce the heat losses and prevent wear of the side walls. 6 In TSL furnaces, slag also solidifies on the outer surface of the injection lance; here, the slag splashed from the bath freezes, cooled by the inner flowing process gas. This also allows the lifetime of the lance to be extended.…”

Section: Introductionmentioning

confidence: 99%

“…Joubert et al applied finite element analysis to calculate the temperature distributions of copper cooling elements installed in a TSL furnace. 5,6 They compared the use of three different coolants, namely water, mono-ethylene glycol (MEG), and ionic liquid. The numerical results showed that, for both MEG and ionic liquid, the temperatures of the copper element were above the design limit, whereas safer operating conditions were obtained with water.…”

Section: Introductionmentioning

confidence: 99%

CFD Modeling of the Melting Behavior of a Fayalitic Slag

Obiso

Yasuda

Voigt

et al. 2022

JOM

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The melting behavior of a fayalitic slag was investigated with computational fluid dynamics and validated with experimental data. A heating microscope was employed to perform a typical ash melting behavior (AMB) test, in order to gain information about the melting behavior of the slag. The numerical approach is based on using the volume of fluid (VOF) method, in order to track the interface between the slag and the gas phases, and on the enthalpy–porosity model, in order to simulate the slag as a phase change material (PCM). The combined VOF-PCM model was therefore applied to perform a parameter study on the mushy zone constant $$A_{\rm mushy}$$ A mushy , which enters the equations of the enthalpy–porosity sub-model and is an a priori unknown. The goal of the investigation was to determine the correct value for $$A_{\rm mushy}$$ A mushy , by comparing the numerical results to the AMB test.

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Designing Furnace Lining/Cooling Systems to Operate with a Competent Freeze Lining

Cited by 8 publications

References 12 publications

Design of sidewall lining/cooling systems for AC or DC ilmenite smelting furnaces

Design of sidewall lining/cooling systems for AC or DC ilmenite smelting furnaces

A Review of Top-Submerged Lance (TSL) Processing—Part I: Plant and Reactor Engineering

CFD Modeling of the Melting Behavior of a Fayalitic Slag

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