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Anode vessel refractory linings

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Refractory Linings of Anode vessels

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Anode vessel refractory linings

  1. 1. OPTIMIZATION OF REFRACTORY LINING DESIGN AND INSTALLATION PRACTICE TO REDUCE VESSEL DOWNTIME OF ANODE REFINING VESSELS
  2. 2. BLISTER COPPER (>0.6% S) FED TO THE ANODE REFINING VESSELS DIRECTLY FROM FLASH/BATH CONVERTING FURNACE (EST. REFRACTORY LINING LIFE 5-6YRS) ANODE REFINING VESSEL NOW A PRIMARY PRODUCTION UNIT (EST. AVERAGE LINING LIFE ~2 YEARS)
  3. 3. THE CONCEPT • TO DOUBLE THE LIFE OF THE REFRACTORY LINING OF THE ANODE VESSEL (FROM TWO TO FOUR YEARS) • TO BETTER THAN HALVE THE INSTALLATION TIME OF THE REFRACTORY LINING (FROM 14 to 6 DAYS)
  4. 4. OPTIMIZATION OF PERFORMANCE OF THE REFRACTORY LINING • UTILIZE CORROSION RESISTANT FUSED MAGNESIA-CHROME AROUND TUYERES, SLAG LINE, TAP-OUT SPOUT, SKIMMING AND FEED MOUTH AND IMPACT AREAS • INSTALL LINING TO THE SHELL (WITH HIGH CONDUCTIVITY GRAPHITE PASTE IF NECESSARY) TO MAXIMIZE HEAT TRANSFER AND LOWER CORROSION RATE • INSTALL MICROPOROUS INSULATION IN AREAS WHERE BUILD-UP OCCURS
  5. 5. OPTIMIZATION OF INSTALLATION TIME REQUIREMENTS • PROVIDE FOR A BRICK STAGING AREA AT ONE END OF THE VESSEL AND AN ACCESS PORT FOR PERSONNEL AND A ROLLER LINE TO SUPPLY BRICK. • INSTALL BRICK COURSING CONTINUOUSLY USING A SELF-SUPPORTING METHOD
  6. 6. OPTIMIZATION OF PROCESS CONTROL • USE OF POROUS PLUGS TO IMPROVE HEAT TRANSFER, ACCELERATE DESULPHURISATION AND REDUCE SLAG VOLUME. • INSERT SACRIFICIAL TUYERE TUBE TO REDUCE CONTACT OF COPPER OXIDE WITH REFRACTORY ADJACENT TO TUYERE BRICK. • USE SEMTECH OPC TO ACCURATELY DETERMINE END POINT OF DESULPHURISATION AND DEOXIDATION
  7. 7. BECANCOUR Production Facility ANODE REFINING VESSEL TUYERE PIPE INSERTION SYSTEM
  8. 8. Endwalls 36 hrs Endwalls 36 hrs Scaffolding 12 hrs Brick (1/2Half) 48 hrs Brick to T-Plate 36 hrs Formwork 24 hrs Brick Top Half (both 120 hrs Brick to Key 36 hrs Remove Formwork 24 hrs Finishing Key 12 hrs 264 hrs 120 hrs Traditional (Formwork/Pogo) Revised (T-Plate/Access Door)
  9. 9. CONCLUSIONS •REFRACTORY ANODE VESSEL INTEGRITY DEPENDS ON JUDICIOUS ZONING OF THE HIGH WEAR AREAS • PRODUCTIVITY CAN BE SEVERELY HAMPERED IF DOWNTIME IS NOT STRICTLY LIMITED BY RAPID INSTALLATION TECHNIQUES AND THE ABILITY TO PERFORM HOT REPAIRS

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