Thermal modeling of air gaps on the cooling capacity of finger coolers in an electric smelting furnace

AbstractWhile water cooling systems are used to freeze a slag layer on the refractory sidewall to prevent refractory erosion by the molten slag, it should not remove excessive thermal energy from the electric smelting furnace. One and three-dimensional thermal mathematical models are used to examine conditions where a solid slag layer will form on the refractory. The effect and sensitivity of an air gap between the copper cooling finger and the refractory is examined from the slag solidification perspective. Will a protective slag solidify on the refractory? Other issues examined include copper finger tip temperature, number of fingers per unit transverse area versus larger fingers, location of finger tip into the furnace wall and from the slag interface (depth of penetration) and maximum operating sidewall heat flux q max where no protective slag layer is formed. These are important factors that affect cooling finger placement in the electric smelting furnace. A 1 mm air gap can potentially decrease the ...