CFD Analysis of a Flash Converting Furnace

This chapter provides a detailed analysis of the flash converting furnace (FCF) process, focusing on the typical FCF smelting process, industrial benchmarking, and advanced CFD modelling techniques. The analysis begins with an overview of the typical FCF smelting process, including the granulation, drying, and grinding of matte, and the critical role of the matte burner in achieving optimal combustion efficiency. The chapter then delves into industrial benchmarking, comparing the specific smelting intensity (SSI) and specific reaction energy (SRE) of the typical FCF with other flash furnaces. The CFD analysis section outlines the development and features of a custom-built CFD model, including the use of the Reynolds Averaged Navier Stokes (RANS) equations and the Shear Stress Transport (SST) turbulence model. The results of the CFD analysis are presented, highlighting the velocity streamlines, particle trajectories, temperature distribution, and SO2 liberation rate within the FCF. The chapter concludes with a summary of the findings and the potential applications of CFD analysis in improving FCF operations. Additionally, the chapter discusses Hatch's innovative technologies, such as Waffle cooling elements and concentrate burner technology, which are crucial for improving furnace stability and operational efficiency. This chapter offers a comprehensive overview of the FCF process, providing valuable insights into the optimization and improvement of FCF operations.