Using computational fluid dynamics to modify a waste-heat boiler design

This article describes the use of a general purpose computational-fluid-dyn amics code for improving and optimizing waste-heat boilers in the Outokumpu flash smelting process. The codes offer opportunities to study the transpo rt phenomena for fluid and particulate flow and heat and mass transfer. The simulation includes gas- and dust-flow behaviors and gas cooling by convec tion and radiation. The results were used in the boiler modification for in creased capacity and higher cooling efficiency. The modified boiler, with i ts unique design, has been in use at Outokumpu's Harjavalta copper smelter since June 1995 with excellent performance.