CFD Analysis of a Flash Converting Furnace

Abstract

Assessment of concentrate smelting within the reaction shaft of a Flash Converting Furnace (FCF) was performed using Computational Fluid Dynamics (CFD). Hatch has previously published content relating to CFD techniques for assessments to evaluate Flash Smelting Furnaces (FSFs) and Direct to Blister Furnaces (DBFs). This paper extends previous assessments to evaluate a ‘typical FCF’ from a gas and particle flow perspective using a
custom built CFD model.

The CFD model was compiled in ANSYS CFX 2024 utilising custom multi-phase (solid/gas) combustion reactions for copper matte particles. The CFD approach provides valuable input into; gas flow dynamics, combustion particle behaviour, particle residence times, plume shaping, concentrate burner design, location and extent of furnace wall cooling, and furnace geometry (including shaft and freeboard volumes).

The analysis summary of a ‘typical FCF’ is presented within this paper and the analysis tools used can be applied by Hatch to any operating FCF to assess current/future process conditions and upgrades.