The copper smelting reverberatory furnace is a core piece of equipment in copper production. The furnace area has expanded from the original 180㎡ to 271㎡, with a daily capacity of approximately 1,000 tons of concentrate and 400 tons of blister copper. The original system included two cyclone separators, exhaust fans, a spray cooling system in the brick flue, and two 30㎡ rod-type electrostatic precipitators (ESPs). The existing system utilizes two ESPs in cross-flow parallel configuration and three exhaust fans in parallel operation. However, as production capacity has increased, several issues with the existing system have surfaced, necessitating a comprehensive upgrade.
•Problems in the Dust Collection System
1.Uneven Gas Flow Distribution
The dust collection system suffers from uneven airflow distribution. Cross-flow operation exacerbates non-uniform gas distribution in the electric field, significantly reducing the efficiency of mechanical and electrostatic dust collection. Consequently, some untreated flue gases are discharged directly through the stack, leading to low dust collection efficiency.
2.Inconsistent Fan Specifications in Parallel Configuration
The three exhaust fans in parallel operation have inconsistent specifications, causing dust accumulation at the inlet butterfly valves. This buildup negatively impacts the suction capacity and overall system efficiency.
3.Insufficient Cooling of Flue Gas
The spray cooling system in the flue is insufficient, resulting in flue gas temperatures exceeding 300℃, which damages the fans and ESPs. When furnace material collapses or coal feed overruns, sudden temperature surges deform the ESP steel structures, cause cracking in the casing, and result in fractures in the supporting concrete beams.
4.Air Leakage and Dust Removal Challenges
Numerous points of air leakage and dust discharge in the system lead to severe dust escape issues, complicating the process of dust conveyance.
5.Aging Electrostatic Precipitator Equipment
The aging rod-type ESP frequently encounters issues such as wire breakage, insufficient rapping strength, electrode wire agglomeration, and blocked distribution plates. Annual quartz tube consumption reaches approximately 100 units. Frequent component replacement and cleaning significantly increase maintenance costs, and dispersed operation further complicates maintenance, making it difficult to sustain stable production.
Technical Upgrades
1.Optimization of the Process Flow
The collection hopper, cyclone separators, and spray cooling equipment in the original system were removed to simplify the two-stage process of the waste heat boiler and ESPs, reducing system complexity.
2.Sliding Valve Design
Sliding valves were installed to horizontally cut off airflow while preserving the old exhaust fan chamber as a structural support for flue pipes.
3.Disc Valve Design
Disc valves were employed to vertically cut off airflow, shortening the length of the ESPs. The layout of the main duct and diffuser at the ESP inlet was optimized, and protective measures were added to underground drainage pipes.
4.Optimized Duct Layout
Exhaust ducts were arranged in a cross-over configuration to make full use of the old exhaust fan chamber, rectifier room, and the roof of the new rectifier room as support structures. Cooling air devices were installed in the lower sections of the ducts, such as in the rectifier room, centralized control room, and exhaust fan station, to address high operating temperatures during summer.
5.Automatic Flue Gas Flow Regulation
An automatic flue gas flow regulation system was implemented to coordinate the operation of the new and old dust collection systems, improving operational flexibility and efficiency.
6.Centralized Control Room Setup
A centralized control room was established between the new and old systems, integrating control hubs, technical parameter displays, and remote operations. This allowed for centralized monitoring and management, significantly enhancing operational efficiency.
7.Improved Working Environment
Workshop offices and duty rooms were set up near the operation areas, providing a better working environment for staff.
8.Overtemperature Protection and Commissioning of New Equipment
The new ESP is designed to operate at temperatures below 350℃ and was commissioned simultaneously with the new waste heat boiler.
Overtemperature alarms and temporary overtemperature suction cooling devices were added to prevent system damage from furnace material collapses or coal feed overruns.
This technical upgrade targeted the key issues in the dust collection system of the copper smelting reverberatory furnace, focusing on optimizing processes, enhancing equipment reliability, and improving environmental compliance. As a result, significant improvements were achieved in gas flow distribution, dust collection efficiency, equipment stability, and operational reliability. The upgraded system fully meets the expanded production requirements and stringent environmental dust control standards. This project not only resolved long-standing operational challenges but also laid a solid foundation for the sustainable and efficient operation of the copper smelting plant in the future.
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