This document discusses optimizing the refractory lining design and installation process for anode refining vessels to reduce downtime. It proposes using more corrosion-resistant materials in high-wear areas, installing the lining directly to the shell to improve heat transfer, and using microporous insulation in build-up areas. For installation, it recommends a staging area, personnel access port, and roller line to continuously install brick coursing and cut installation time from 14 to 6 days. Process controls like porous plugs, sacrificial tuyere tubes, and analysis equipment are also proposed to improve performance and reduce downtime. The conclusion states downtime is reduced by zoning high-wear areas, rapid installation techniques, and ability to perform hot repairs

1. OPTIMIZATION OF REFRACTORY LINING DESIGN AND
INSTALLATION PRACTICE TO REDUCE VESSEL DOWNTIME
OF ANODE REFINING VESSELS

2. BLISTER COPPER (>0.6% S) FED TO THE
ANODE REFINING VESSELS DIRECTLY
FROM FLASH/BATH CONVERTING FURNACE
(EST. REFRACTORY LINING LIFE 5-6YRS)
ANODE REFINING VESSEL NOW
A PRIMARY PRODUCTION UNIT
(EST. AVERAGE LINING LIFE
~2 YEARS)

3. THE CONCEPT
• TO DOUBLE THE LIFE OF THE
REFRACTORY LINING OF THE ANODE
VESSEL
(FROM TWO TO FOUR YEARS)
• TO BETTER THAN HALVE THE
INSTALLATION TIME OF THE REFRACTORY
LINING
(FROM 14 to 6 DAYS)

4. OPTIMIZATION OF PERFORMANCE OF
THE REFRACTORY LINING
• UTILIZE CORROSION RESISTANT FUSED
MAGNESIA-CHROME AROUND TUYERES, SLAG LINE,
TAP-OUT SPOUT, SKIMMING AND FEED MOUTH
AND IMPACT AREAS
• INSTALL LINING TO THE SHELL (WITH HIGH
CONDUCTIVITY GRAPHITE PASTE IF NECESSARY) TO
MAXIMIZE HEAT TRANSFER AND LOWER CORROSION RATE
• INSTALL MICROPOROUS INSULATION IN AREAS
WHERE BUILD-UP OCCURS

5. OPTIMIZATION OF INSTALLATION
TIME REQUIREMENTS
• PROVIDE FOR A BRICK STAGING AREA AT ONE
END OF THE VESSEL AND AN ACCESS PORT FOR
PERSONNEL AND A ROLLER LINE TO
SUPPLY BRICK.
• INSTALL BRICK COURSING CONTINUOUSLY
USING A SELF-SUPPORTING METHOD

6. OPTIMIZATION OF PROCESS CONTROL
• USE OF POROUS PLUGS TO IMPROVE HEAT TRANSFER,
ACCELERATE DESULPHURISATION AND REDUCE SLAG
VOLUME.
• INSERT SACRIFICIAL TUYERE TUBE TO REDUCE
CONTACT OF COPPER OXIDE WITH REFRACTORY
ADJACENT TO TUYERE BRICK.
• USE SEMTECH OPC TO ACCURATELY DETERMINE
END POINT OF DESULPHURISATION
AND DEOXIDATION

12. BECANCOUR Production
Facility
ANODE REFINING VESSEL
TUYERE PIPE INSERTION SYSTEM

49. Endwalls 36 hrs Endwalls 36 hrs
Scaffolding 12 hrs
Brick (1/2Half) 48 hrs Brick to T-Plate 36 hrs
Formwork 24 hrs
Brick Top Half (both 120 hrs Brick to Key 36 hrs
Remove Formwork 24 hrs Finishing Key 12 hrs
264 hrs 120 hrs
Traditional
(Formwork/Pogo)
Revised
(T-Plate/Access Door)

50. CONCLUSIONS
•REFRACTORY ANODE VESSEL
INTEGRITY DEPENDS ON
JUDICIOUS ZONING OF THE HIGH
WEAR AREAS
• PRODUCTIVITY CAN BE SEVERELY
HAMPERED IF DOWNTIME IS NOT
STRICTLY LIMITED BY RAPID
INSTALLATION TECHNIQUES AND
THE ABILITY TO PERFORM HOT REPAIRS