Characteristics and Impact of Fouling from Copper Production on the Operation of a Waste Heat Recovery Boiler

The paper focuses on the characteristics of fouling from copper production on the tube surface in a waste heat recovery boiler during the transfer of heat from the flash furnace process gas. The likely mechanism of deposit formation on the tubes is described, and the morphology and chemical composition of the bound deposit taken from the radiation zone of the waste heat recovery boiler are reviewed. In addition, the impact of the presence of bound and loose deposits on the tube’s surface on the increase in the deposit surface temperature and the decrease in the heat transferred at the inner side of the tube is evaluated. Changes in the chemical, mineralogical, and phase constitutions along the thickness of the build-up were established on the basis of XRF, SEM, and XRD quantitative analyses. The heat exchanger tube temperature distribution was computed with the finite element method using an axi-symmetrical solution of the heat conductivity equation. Computing was carried out for a clean tube surface as well as for a case with loose and bound deposits present on the surface, with thicknesses of 0.5 cm, 1 cm, and 2 cm. The boundary conditions at the deposit side varied. For loose deposits with a thickness of 0.5 cm, the decline in the heat transferred was similar to the values obtained for a bound deposit with a thickness of 2 cm. It was established that, for a deposit with a thickness of 20 mm, there was an approximately 80% decline in the energy transferred by the walls compared to the clean tube surface. This study represents a novel approach by integrating mineralogical and phase analyses with finite element modelling to comprehensively assess the impact of both bound and loose deposits on heat transfer efficiency in waste heat recovery boilers from copper production.