CA1233986A - Modified metallurgical converters and method of repairing same - Google Patents

Modified metallurgical converters and method of repairing same

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Publication number
CA1233986A
CA1233986A CA000465600A CA465600A CA1233986A CA 1233986 A CA1233986 A CA 1233986A CA 000465600 A CA000465600 A CA 000465600A CA 465600 A CA465600 A CA 465600A CA 1233986 A CA1233986 A CA 1233986A
Authority
CA
Canada
Prior art keywords
converter
shell
portions
metallurgical
refractory lining
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000465600A
Other languages
French (fr)
Inventor
Luis Torres Jorquera
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Corporacion Nacional del Cobre de Chile CODELCO
Original Assignee
Corporacion Nacional del Cobre de Chile CODELCO
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Corporacion Nacional del Cobre de Chile CODELCO filed Critical Corporacion Nacional del Cobre de Chile CODELCO
Application granted granted Critical
Publication of CA1233986A publication Critical patent/CA1233986A/en
Expired legal-status Critical Current

Links

Abstract

MODIFIED METALLURGICAL CONVERTERS
AND METHOD OF REPAIRING SAME
ABSTRACT
A modified metallurgical converter wherein removable segments or portions are provided in the anticipated areas of highest wear of its refractory lining, and methods for repairing same. Also, a method for improving the service and operational life of such metallurgical converters.

Description

MODIFIED METALLURGICAL CONVERTERS
AND METHOD OF REPAIRING SAME

Technical Field:
The present invention relates to metallurgical converters and more specifically, to modified metallurgical converters which provide easy access for the repair of its internal refractory lining.
Background Art:

A number of metallurgical converters for copper, nickel, lead or other nonferrous ores or the like, are well known in the mining art. These converters generally include those known as Peirce-Smith, Teniente, Noranda, or other similar types.

The converters which are most commonly used are basically characterized as having a cylindrical horizontal shell which can be of variable dimensions depending upon the specific production requirements. The material of construction for the shell is generally carbon steel lined with a refractory material in order to allow the converter to operate properly in contact with liquid metallic elements at temperatures of approximately 1200~C and above The converter is used to oxidize various components of the ores. For example, in the conversion of copper mattes, air is introduced through molten copper matte to oxidize any metal sulfides which are present. This oxidation is accomplished by injecting an oxidizing agent, most commonly air, into the molten ore bath in the converter through ..

~2~

tuyeres which extend through the shell and refractory lining.
These tuyeres are located in a predetermined arrangement usually in the bottom or lower portion of the converter shell.

During the course of operation of the converter over an extended time period, the refractory lining begins to wear or deteriorate. Usually, the refractory areas adjacent to and around the tuyeres experience the greatest wear because of the turbulence from the introduction of the air and the locali%ed heating caused by the reaction of the air with the ore components. Also, the refractory lining can spall, crack or flake if subjected to extreme temperature fluctuations.
Therefore, it becomes necessary to shut down the equipment and repair or replace the damaged refractory lining.

Previously, the usual method of repair would be to stop the operation of the convertor, allow it to cool to ambient temperatures, remove the heads to facilitate entry into the shell, and replace the damaged or deteriorated portions oE
the refractory lining. The repair or replacement of the refractory lining is difficult and time consuming since maintenance personnel would have to work within the converter shell itself. In addition, the reliability of a reEractory lining is suspect in the areas where the new or replacement lining must be joined or bonded to the remaining portions of the original lining. For this reason, it is Gften preferably to replace the entire refractory lining of the vessel in order to achieve longer service lives and more reliable operation when the converter is put back on stream.

~3~

Furthermore, the loss of production due to the removal of the converter from service for a considerable length of time and the repair cost (i.e. materials and labor) for installing the replacement refractory lining are relatively high. Therefore, the mining industry has long been searching for an alternative method of reliably repairing or maintaining these converters to avoid such long down time periods and high repair costsO

Brief Description of the Invention The applicant has discovered that modifying the steel shell of the converter by installing easily removable shell portions or segments in the areas which are expected to receive the most severe service, such as the tuyere zones, allows the refractory lining in this zone to be easily replaced or repaired without having to replace the entire refractory lining of the converter or first cool the unit to room temperature The modified converter of the invention and the method for its repair represent numerous advantages due to the shorter repair time involved, which in turn means greater operating availability and greater associated productivity; conservation of repair material and labor costs; more convenient working conditions for maintenance personnel; an more reliable operation of the converter when it is returned to service.

Summary of the Invention The present invention relates to an improved metallurgical converter having a cylindrical shell which is lined with a refractory material wherein the shell of the converter is modified by providing a plurality of removable segments or portions in the areas where the greatest degree of lining deterioration is anticipated. Each segment is connected to the remainder of the shell by a flange and bolt assembly to Eacilitate its removal and replacement.
Furthermore the removal of each segment can preferably be effected from the outside of the converter Another aspect of this modified metallurgical converter relates to the modification of the shell to provide a plurality of removable segmented portions around the tuyere area. Again, each segment is connected to the remainder of the shell by a flange and bolt assembly to facilitate their removal and replacement, and each segment can preferably be removed or replaced from the outside of the converter.
Another aspect of the invention relates to the improvement of the shell of a metallurgical converter wherein a plurality of segmented portions are provided in the zones of most frequent repair. These segmented portions have connection means to facilitate easy attachment to and removal from the remaining portion of the converter shell.
Preferably, the connection means comprises a flange along the longitudinal edges of the segmented portions and a corresponding mating flange on the longitudinal edges of the remaining portion of the shell. Also, the flanges of the segmented and remaining portions are advantageously joined by bolting means.
Another embodiment of the invention relates to a method for repairing deteriorated refractory portions oE a modified metallurgical converter as described hereinabove which comprises stopping the operation of the converter; removing the segmented portions containing the damaged refractory lining without cooling the converter from its operating temperatures; and reattaching the segments having a replaced or repaired refractory lining to the converter shell.
Another method of the invention relates to the repair of damaged or deteriorated areas of the refractory lining of a metallurgical converter wherein the portions or segments of the converter shell which are anticipated to experience the greatest wear are configured, dimensioned, and positioned to acilitate easy removal and replacement. These portions or segments can be removed and replaced without the necessity of cooling the converter to ambient temperatures, and preferably can be removed and replaced from the outside of the converter.
lso disclosed herein is a specific method for repairing the deteriorated refractory lining around the tuyeres of a metallurgical converter wherein portions or segments of the shell encompassing the tuyeres and adjacent areas where wear of the refractory lining is anticipated, are configured, dimensioned and positioned to facilitate easy removal and replacement from the outside of the converter without having to cool the converter to ambient temperatures.
A further embodiment OL the invention relates to a method for extending the service life of a metallurgical converter which comprises modifying the converter by installing easily removable portions or segments in the shell in the areas which are expected to experience the highest wear or use during operation.

Further benefits and advantages of the invention will become apparent from a consideration of the following description given with reference to the accompanying drawing figures which specify and show preferred embodiments of the present invention.

-6- ~33~8~

srief Description of the Drawings Fig. 1 is a front view of a prior art converter unit;
Fig. 2 is a side view of the converter of Fig. l;
Fig. 3 is a front view of a converter unit according to the present invention;
Fig. 4. is a detail of a removable section of the shell of the converter of Fig. 3; and Fig. 5 is a side view of the removable shell section of Fig. 4.

Detailed Description of the Preferred Embodiments The pyrometallurgical processes used for the production of copper from copper sulfide concentrates comprise the stages of smelting followed by converting. The first stage is ordinarily carried out in a static furnace, the most common of which is a reverberatory furnace, such as an Outokumpu or INCO flash furnace. The conversion process is usually carried out in Peirce-Smith horizontal converters Other modern processes, such as those used by Noranda and El Teniente, use converters that completely or at least partially combine these two stages.

A common characteristic of the above-mentioned processes is the use of the horizontal Peirce-Smith converter furnace as the main equipment item for producing blister copper. A
typical prior art converter is shown in Figs. 1 and 2. This converter 7 consists of a metal cylinder 1 having means for rotary motion 2. The cylinder or shell 1 is lined with a refractory material (not shown) and has an outlet 3 for the discharge of gases.

7 39~i The oxidizing gas, which is used to promote reactions in the converter, is injected through tuyeres 4, which are tubular openings of approximately 2 inches in diameter, made horizontally or at a slight angle along at least part and preferably the entire length of the shell at a given location. These tuyere openings are usually located under the central shalt of the converter when the latter i5 in its operating position. This arrangement is illustrated in Fig.
1. The tuyeres introduce the oxidizing gas from a gas distributing system to the molten metal bath in the shell.
In the conversion of copper matte, the bath contains copper sulfide and molten copper. Thus, special steel tubes of approximately 2 inches winner diameter), suitably connected to an air distributing system 5, are inserted inko openings made through the refractory metal lining.

The refractory lining is selected based on the particular requirements of the type of operation carried out in the converter. Over time, this lining undergoes gradual deterioration which is reflected in wear of the refractory lining. Over the course of its service life, the thickness of the lining is reduced to a limit that impairs the strength of the shell and the operating efficiency of the converter.
At that time, the equipment has to be shut down in order to undergo an overhaul, which primarily includes replacement of the worn portions of the refractory lining which might jeopardize the continuous operation of the unit when returned to service. The time normally employed in carrying out this overhaul, calculated from the time when the equipment stops operating until it is returned to service, is 12 to 20 hours, depending on the type of converter. This period includes the time necessary to cool the unit to ambient temperatures as ~3~

well as to reheat the unit to working temperatures. This downtime represents a significant loss of production capacity.

The present mode of operation of these converters causes the greatest wear of the refractory lining in the areas surrounding the tuyeres and the zones adjacent thereto. TAe wear in these areas determines when the converter must be removed from operation for repair of the refractory lining.
Since the repair of the refractory lining necessitates cooling ox the converter to ambient temperatures. This, in turn, detrimentally afEects the useEul life of the unworn portions of the refractory lining, which requires more frequent future repairs. Thus, the reliability of the convertor is reduced and maintenance costs are increased.

In order to increase the availability and reliability of this equipment, the applicant has discovered a way to modify the shell of the converter which then makes it possible to completely replace the worn portions of the refractory lining from the outside of the converter without having to cool the unit to room temperature. Usually, the portions of the refractory lining which experience the greatest wear occurs around the tuyeres.
A preferred embodiment of the present invention consists of a metallurgical converter as shown in Figs. 3-5. This modification is based on the provision oE a segmented converter shell in the tuyere zone 10. By making each seyment 11 easily removable, it becomes possible -to expeditiously replace the refractory material of this zone of the converter _.

~;~33~6 g Each segment section of the shell includes a given number of tuyeres and in turn defines a number of courses of a refractory or brick over and under the tuyere zone. The amount of brick or refractory reinforcement in this area depends on the anticipated type and degree of wear in that zone. The length of the segments depends on the length of the equipment, the number of tuyeres required by the converter, and the facilities available at the plant for removing these segments. These segments consist of equal portions of rectangular shapes which follow the curvature of the she]l. The remaining portion of the shell and the segments have, on their longitudinal edges, flanges 12 projecting toward the outside of the converter, which facilitate the joining of the segments to the shell by bolts without the converter losing any mechanical strength compared to an integral (i.e., non-segmented) converter unit.

The principal operations carried out in the preferred repair of the refractory material of the tuyere zone in the modified converters of the present invention is as follows:

a) stop operation of the converter, without cooling the unit from its working temperature;
b) disconnect the tubes of the air distributing system;
c) loosen the bolts which connect the flanges oE
the segments and shell;
d) remove the segments from the outside;
e) replace the refractory lining of etch segment;
f) replace the metal segments into the shells; and g) reconnect the air distributing system to the tuyeres.

-10~ 339~

This modification in design and simple procedure for repair of the metallurgical converters of the present invention, is applicable to many typ0s of converters in the metals industry, preferably for the conversion of nonferrous metals such as copper, nickel, lead and the like. This simple system presents significant advantages over the traditional repair procedures for this equipment, including:

1) increasing the availability of the converter by appreciably reducing the repair time, which allows greater productivity of the equipment;
2) reducing the cost of future repairs and increasing the reliability and useful life by of the undeteriorated portions of the refractory lining of the converter by avoiding the detrimental effect caused by cooling to ambient temperatures;
3) improving and simplifying the working conditions for repair and maintenance personnel;
4) applying this procedure to any portion of the shell that may require more frequent repair of the refractory lining.
While it is apparent that the invention herein disclosed .is well calculated to fulfill the desired results, it will be appreciated that numerous modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims cover all such modiEications and embodiments as fall wi-thin the true spirit and scope of the present invention.

Claims (7)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-
1. In a metallurgical converter for non-ferrous ore having a cylindrical shell which is lined with a refractory material which is capable of pro-viding protection for the shell from the effects of molten ore and a plurality of tuyeres for introduction of an oxidizing agent, the improvement which comprises a portion of said shell being formed by a plurality of removable segmented portions each consisting essentially of a generally arcuate reinforcing plate containing a plurality of tuyeres surrounded by a re-fractory lining on the side of the segment which extends into the converter.
2. The metallurgical converter according to claim 1 wherein each segmented portion is connected to the remainder of the shell by a flange and bolt assembly to facilitate the removal and replacement of said segments.
3. The metallurgical converter according to claim 2 wherein the removal of each segment can be effected from the outside of the converter.
4. In a metallurgical converter for non-ferrous ore having a cylindrical shell which is lined with a refractory material which is capable of providing protection for the shell from the effects of molten ore and a plurality of tuyeres for introduction of an oxidizing agent, the improvement which comprises a portion of said shell being formed by a plurality of segmented portions, said segmented portions consisting essentially of a generally arcuate rein-forcing plate containing a plurality of tuyeres surrounded by a refractory lining on the side of the segment which ex-tends into the converter and having connection means to faci-litate easy attachment to and removal from the remaining part of the shell.
5. The metallurgical converter of claim 4 wherein the connection means comprises a flange along the longitudinal edges of the segmented portions and a corresponding mating flange on the longitudinal edges of the remaining part of the shell.
6. The metallurgical converter of claim 5 wherein the flanges of the segmented portions and remaining portions are joined by bolting means.
7. A method for repairing portions of deteriorated refractory lining in a metallurgical converter which comprises stopping the operation of the converter; removing segmented portions containing the damaged refractory lining, without substantially cooling the converter from its operating temp-eratures; replacing or repairing the damaged refractory lining of each segmented portion; and reattaching the segments having a replaced or repaired refractory lining to the converter shell.
CA000465600A 1983-10-18 1984-10-17 Modified metallurgical converters and method of repairing same Expired CA1233986A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CL34027 1983-10-18
CL3402783 1983-10-18

Publications (1)

Publication Number Publication Date
CA1233986A true CA1233986A (en) 1988-03-15

Family

ID=4574594

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000465600A Expired CA1233986A (en) 1983-10-18 1984-10-17 Modified metallurgical converters and method of repairing same

Country Status (1)

Country Link
CA (1) CA1233986A (en)

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Effective date: 20050315