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This paper summarizes an analytical approach to designDesign blisterBlister and moltenMolten anodeAnode copperCopper laundersLaunders for a copperCopper refiningRefining furnaceFurnace. BlisterBlister laundersLaunders are designed to feed the fire-refiningRefining furnaceFurnace with blisterBlister from an upstream converting furnaceFurnace. MoltenMolten copperCopper laundersLaunders are designed to feed the downstream anodeAnode casting wheels from the refiningRefining furnaceFurnace. Due to geometrical limitations at the plant, there were designDesign challenges associated with both blisterBlister and moltenMolten copperCopper laundersLaunders. The laundersLaunders are relatively long (each ~100 ft in length) and relatively shallow (~3° slope angle). Long and shallow laundersLaunders tend to cause slower flow velocity, leading to excessive heat loss. The excessive heat loss negatively impacts downstream processes, including blisterBlister refiningRefining at the furnaceFurnace and anodesAnode casting quality at the casting wheel. A benchmarking study with similar smeltersSmelter is conducted to compare designDesign parameters. Furthermore, computational Fluid Dynamics (CFDComputational Fluid Dynamics (CFD)) simulations were carried out to determine flow trajectories for several designDesign cases. The comparison of CFDComputational Fluid Dynamics (CFD) results for different designDesign cases were utilized to optimizeOptimize the designDesign against low-velocity regions and metalMetal splashing risks. The currentCurrent paper aims to showcase the efficacy of analytical methods in overcoming designDesign challenges in copperCopper launder systemsLaunder system.

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Design Optimization of Blister and Casting Launders: A Flow Analysis Approach

  • 会议论文

  • 发表日期：

    2025年

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  • Rafael Berti,
  • Helio Villanueva,
  • Dave Jakelski,
  • Reza Farshidi,
  • Sina Mostaghel

摘要

This paper summarizes an analytical approach to designDesign blisterBlister and moltenMolten anodeAnode copperCopper laundersLaunders for a copperCopper refiningRefining furnaceFurnace. BlisterBlister laundersLaunders are designed to feed the fire-refiningRefining furnaceFurnace with blisterBlister from an upstream converting furnaceFurnace. MoltenMolten copperCopper laundersLaunders are designed to feed the downstream anodeAnode casting wheels from the refiningRefining furnaceFurnace. Due to geometrical limitations at the plant, there were designDesign challenges associated with both blisterBlister and moltenMolten copperCopper laundersLaunders. The laundersLaunders are relatively long (each ~100 ft in length) and relatively shallow (~3° slope angle). Long and shallow laundersLaunders tend to cause slower flow velocity, leading to excessive heat loss. The excessive heat loss negatively impacts downstream processes, including blisterBlister refiningRefining at the furnaceFurnace and anodesAnode casting quality at the casting wheel. A benchmarking study with similar smeltersSmelter is conducted to compare designDesign parameters. Furthermore, computational Fluid Dynamics (CFDComputational Fluid Dynamics (CFD)) simulations were carried out to determine flow trajectories for several designDesign cases. The comparison of CFDComputational Fluid Dynamics (CFD) results for different designDesign cases were utilized to optimizeOptimize the designDesign against low-velocity regions and metalMetal splashing risks. The currentCurrent paper aims to showcase the efficacy of analytical methods in overcoming designDesign challenges in copperCopper launder systemsLaunder system.