Furnace Tapping 2022

No pyrometallurgical smelter can operate without some form of tapping system. It is the one thing all smelters have in common. This collection discusses this meeting point of the science, technology, and skill involved in this process. The tap-hole design process includes a set of design criteria, which need to be revised as the results of laboratory, computational fluid dynamics (CFD), and time-and-motion studies become available. The tap-hole life cycle is considered with designers addressing the requirements for installation and operability as well as for maintenance. Matters such as online monitoring of the tap-hole wear, handling of liquid products, and extraction of fumes are all discussed.  The tap-floor environment requires precision equipment and operating practices. The design and maintenance of the drilling, tapping, and plugging equipment, and materials plays an equally important role in tap-hole life and tap-floor safety, as does protective equipment. Operators want the tap-hole life to be as long as possible since tap-hole failure is often the cause for a reline-a very expensive exercise in an upcycle when the cost of a new lining is small compared to the loss in production. Managing the maintenance and reline schedule is a challenge with lessons often learned the hard way. Even though much has been done to make the tapping process as automatic as possible, tapping of smelters cannot be done without labor. Tap floor operators work in harsh environments where safety is of utmost importance. Selection of suitable personnel and intensive training is required and discussed in this collection.