Analyzing Furnace-Lining Integrity Using Nodal Wear Modeling

The study presents the Nodal Wear Model, developed to analyze corrosion phenomena on refractory and ceramic materials in contact with corrosive fluids within furnace linings. The primary objective is to optimize pyrometallurgical processes for metal production by ensuring high-quality and sustainable operations. A finite-element method grid is utilized to determine the thermal field in the furnace lining, alongside a modified geometry to account for wear-corrosion phenomena influenced by thermal activation. The model requires recalculating modifications to accurately represent the surface interactions with molten phases. The results highlight the economic implications of material quality in furnace linings, emphasizing that while costs may not drive overall process costs, the lining's quality significantly affects operational longevity. Furthermore, the research discusses the necessity of recycling lining materials, maintaining their safety, and ensuring environmental stability upon disposal. The evaluation method incorporates lifecycle assessment metrics to understand energy intensity concerning the refractory materials utilized. This comprehensive approach is vital in achieving sustainability goals while enhancing metal production efficiency in ferrous and nonferrous industries.