Numerical Simulation and “Post-mortem” Studies: The Holistic Approach for Optimized Lining Concepts in the Copper Smelting Furnaces

The refractories are indispensable products in every high temperature process, such as in steel, glass, cement and non-ferrous industries, e.g. copper, nickel and lead furnaces. Copper smelting furnaces are typically lined with magnesia-chromite refractories. The installed refractory lining is exposed to several stresses, rather complex in their interaction. Therefore, a detailed investigation and understanding of wear mechanisms through “post-mortem studies” is an important prerequisite for the refractory producer. This study evaluates the common refractory wear mechanisms as observed in the copper anode furnace. All these wear parameters lead to severe degeneration of the brick microstructure and to a decreased lining life. The infiltration results in significant changes in the material properties; the influence of these changes on the lining was investigated with numerical thermo-mechanical finite element simulations considering a virgin lining, an infiltrated one and a worn one. Based on such research results, combined with specific process knowledge, RHI Magnesita can recommend appropriate brick lining solutions for metallurgical copper smelting furnaces.