Brazilian Ferronickel Smelter Improves Slag Granulation Operation Using Copper Water-Cooled Launders

This chapter explores the transformation of the slag granulation process at the Anglo American Barro Alto ferronickel plant in Brazil. It delves into the challenges faced with traditional steel launders and the innovative solution of implementing copper water-cooled launders. The text discusses the design considerations, thermal simulations, and operational results that justified the switch. It highlights the significant improvements in productivity, safety, and maintenance efficiency achieved through this modification. The study also covers the optimization of slag flow and granulation control, as well as the reduction of splashes and spills. The conclusion underscores the advantages of copper launders, including reduced launder temperature, improved slag flow, extended lifespan, easier maintenance, and enhanced safety. This chapter provides a comprehensive overview of the benefits and practical implications of adopting copper water-cooled launders in ferronickel smelting processes.