| Abstract Scope |
Freeport-McMoRan Inc. (FCX) operates a top-submerged lance (TSL) furnace for copper concentratesmelting at the Miami smelter. To mitigate accelerated refractory wear caused by the turbulent TSLenvironment, the furnace was retrofitted with a jacket and plate cooling system that is segmentedmechanically into three sections to minimize the influence of vertical growth and permit local repairs.Due to heat load intensity, the furnace was divided thermally into four sections: Bath Blocks,Freeboard, Upper Freeboard, and Kettle. Heat-loss data from these sections is integrated intocontrol room operation process control enabling precise furnace temperature control and predictivemodels for campaign life. This design has improved furnace reliability, enabled targeted refractoryreplacement of high wear areas, and optimized reline forecasting. A notable outcome has been industry-leading lance performance, attributed to refined temperature control and monitoring. Further improvements to fully integrated process control are ongoing by utilizing heat flux for controlling natural gas flows while accounting for the dynamics of the furnace through the campaign. This paper will present the cooling system layout, data utilization methods, and the resulting gains in operational efficiency and furnace longevity. |