Natural gas burner for copper smelter converter

Abstract

The aim of this project was to investigate the best scenario for designing and installing a natural gas burner into the Peirce-Smith Converter. Initial data was reviewed on practices of different heating processes used in other converters and related devices. Development of heat balance models evaluated the heat losses during the various heating stages, which was achieved by using a 1D analytical analysis. The pattern of heat flow released inside the furnace for various burner positions was also analysed with the CFD software package Fluent. This information allowed for the optimisation and identification of the most economical and effective position for placement of the new burner. An off the shelf burner was then decided on as it complied with Australian Gas Standard and was capable of handling the three different heating processes used in the running of the converters. Insertion and retraction of the burner system is outlined to achieve minimal downtime between roll outs as well, a maintenance schedule has been addressed in this project as working with combined spaces and explosive fuel can be a very dangerous combination. With the placement of a natural gas burner the new converter furnace combustion system will assist in the improvement of the furnace temperature control, minimise the damage caused to the refractory which will inturn maximise the refractory life, minimise environmental effects and lower fuel expenses saving the company a considerable amount of money.