Mathematical modeling of copper infiltration of a refractory floor

摘要

Liquid infiltration between refractory bricks is a common operational problem in copper smelters. Usually, the floor is designed with expansion joints to secure that the bricks are subjected to compressive forces after the first heating cycle. However, following specifications occasionally fail to ensure the desired brick sealing, or furnace cooling for maintenance purposes open the joints. In order to explain the penetration of liquid copper in a refractory lining of a furnace's floor, a mathematical model was developed. The model considers gravity and viscous forces, while surface tension effects are neglected. The equations are integrated exactly in two particular situations. A general solution is also developed via numerical methods. The results give the position of the liquid infiltration front as a function of location and time. No experimental results are presently available. However, examination of refractories after infiltration indicates that the theoretical results are essentially realistic. The results show that refractory floor design deserves thorough consideration in order to bring the lining to work under compression to avoid or minimize liquid infiltration.