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.