Abstract
Tapping metal and slag from metallurgical furnaces is a process known for its significant variability and inconsistency. This can create a bottleneck for downstream processes and is also associated with loss of valuable metal product. Being able to optimize the tapping process is of great benefit to furnace economics. In this study the authors apply a mathematical model estimating tapping rates for furnaces tapping metal and slag through a single tap-hole. These estimates are highly dependent on the interior geometry and configuration of the furnace, including the packing of material close to the tap-hole. This packing can easily be disrupted in unpredictable ways by the actions of closing and opening the tap-hole. During a tap, interventions such as injecting clay, drilling, stoking and lancing to control the flow of products through the tap-hole are frequently used, but these can have a somewhat random influence on the tap-rate. Interventions are usually performed subject to the assessment of conditions by human operators and limitations set by plant management. The mathematical model in the present study can predict how these intervention factors affect the consistency of the tapping output and the loss of metal. Results from such predictions will be presented and guidelines on how to improve the operation of the tapping process will be extracted.