Study the effect of different operation parameters on the reaction shaft performance of a copper flash smelting furnace: Mass and energy balance analysis

Mass and energy balance analysis is one of the classical methods of modeling applied in the flash furnace smelting process. This method is an efficient method for degrading the theoretical parameters of silica flux and air required for oxidation processes. In this study, the reaction shaft of the Sarcheshmeh flash smelting furnace has been modeled using the mass and energy balance method. A modeling code has been developed to calculate the oxygen content required for oxidation processes and the silica flux for slagging. Different parameters are effective in the working conditions of the flash smelting furnace. In this research, the effect of concentrate mineralogical analysis, oxygen enrichment, flue dust share, and the amount of natural gas was investigated. The modeling results show that by increasing chalcocite in the feed mixture, the average temperature in the reaction shaft will decrease. Increasing the oxygen enrichment increases the temperature and reduces the amount of off-gases that leave the furnace. The calculation can be repeated via modeling from different modes until improved furnace conditions are achieved and smelting operation is controlled.