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| Efficient heat exchange and dust recovery mechanisms for copper smelting waste heat boiler |
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Received:May 13, 2025
Revised:June 09, 2025
Accepted:June 24, 2025
Published Online:April 30, 2026
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| DOI：10.3969/j.issn.1005-7854.2026.02.016 |
| KeyWord:waste heat boiler;gas-solid flow;flue gas heat exchange;particle deposition;numerical simulation |
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| 1.China 15th Metallurgical Construction Group Co. Ltd., Wuhan 430075, China;2.School of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, China |
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| Abstract: |
| Waste heat boiler (WHB) is the core equipment for recovering waste heat from high-temperature flue gas in the copper pyrometallurgical process. However, the strongly coupled high-temperature environment and complex gas-solid two-phase flow within WHB significantly increase the difficulty of elucidating the coupled mechanisms governing the gas-dust system. In this study, the Multiphase Particle-in-Cell (MP-PIC) method was employed to numerically simulate the gas-solid flow and heat transfer behavior within an industrial WHB. After verifying the reliability of the model, the structure of the slag-screen tube banks was optimized to improve heat exchange efficiency and dust recovery rates. The results indicate that vortex flow in the radiation section and a pronounced gas bypassing phenomenon in the hopper area are the primary factors weakening gas-solid heat transfer performance, resulting in a boiler exhaust temperature as high as 636 K. Furthermore, the low probability of effective collision between particles and heat exchange tubes limits gas-solid separation efficiency, with an initial particle sedimentation rate of only 41.07%. By increasing the number of slag-screen tube banks to three, the flow field distribution was significantly improved. This optimization led to a temperature reduction of 70 K at the inlet of the heat exchange section and 30 K at the boiler outlet, while the particle sedimentation rate increased by 6.98%. Further investigation revealed that expanding the tube pitch to 400 mm promotes sufficient contact between the flue gas and the tube bundles, which is more conducive to enhancing heat transfer. The findings of this study provide theoretical support and engineering references for the structural optimization and operational control of waste heat boilers in copper smelting. |
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