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

This paper summarizes an analytical approach to design blister and molten anode copper launders for a copper refining furnace. Blister launders are designed to feed the fire-refining furnace with blister from an upstream converting furnace. Molten copper launders are designed to feed the downstream anode casting wheels from the refining furnace. Due to geometrical limitations at the plant, there were design challenges associated with both blister and molten copper launders. The launders are relatively long (each ~100 ft in length) and relatively shallow (~3° slope angle). Long and shallow launders tend to cause slower flow velocity, leading to excessive heat loss. The excessive heat loss negatively impacts downstream processes, including blister refining at the furnace and anodes casting quality at the casting wheel. A benchmarking study with similar smelters is conducted to compare design parameters. Furthermore, computational Fluid Dynamics (CFD) simulations were carried out to determine flow trajectories for several design cases. The comparison of CFD results for different design cases were utilized to optimize the design against low-velocity regions and metal splashing risks. The current paper aims to showcase the efficacy of analytical methods in overcoming design challenges in copper launder systems.