**Abstract**
This paper presents the practical implementation of replacing the graphite flow tank with a copper water-jacketed tank, based on an analysis of the causes behind the wear and failure of the slag flow tank in the flash furnace. The study highlights the challenges faced by Guixi Smelter as production capacity expanded, leading to increased slag discharge and tank damage. To address these issues, a temperature control system was introduced, along with automatic control of key equipment, significantly improving operational efficiency and reducing maintenance costs.
**Introduction**
In recent years, Guixi Smelter has focused on technological advancement to enhance its production capacity, upgrading from 93,000 to 200,000 tons annually. However, this expansion revealed weak points in the production process, particularly in the flash furnace's slag discharge system. The increasing slag volume and elevated temperatures led to frequent failures in the graphite flow tanks, directly affecting furnace performance. In response, the smelter implemented a real-time monitoring and control system, integrating microcomputer technology for improved stability and safety.
The system utilizes standard current or pulse signals from various sensors, which are isolated and converted into voltage signals for processing by a single-chip microcomputer. These signals are used to control solenoid valves and motors, ensuring precise regulation of the slag flow and maintaining optimal operating conditions. This approach not only enhances control but also improves system reliability and reduces downtime.
**Loss Cause Analysis**
The primary cause of the flow tank loss is the high temperature of the slag. As production increases, so does the amount of slag, placing greater stress on the existing graphite tanks. The introduction of high-temperature, high-volume smelting techniques further accelerated the degradation of the tanks, leading to frequent replacements and production interruptions.
To address this, a transformation project was initiated. The goal was to design a more durable and efficient slag flow tank that could withstand higher temperatures and reduce maintenance needs. The new design incorporated copper water-jacketed tanks, which offer superior thermal conductivity and corrosion resistance compared to traditional materials.
**Design and Implementation**
The new copper water-jacketed flow tanks were designed with enhanced heat dissipation capabilities. They feature a thick inner wall to protect the cooling copper tubes, ensuring long-term durability and safe operation. The cooling medium chosen was water due to its excellent heat transfer properties, despite the need for careful monitoring to prevent potential safety risks.
The transformation significantly improved the service life of the flow tanks. Before the upgrade, the graphite tanks lasted only a few weeks, while the copper tanks can now operate for months without failure. This change reduced both material and labor costs, contributing to overall cost savings and improved production efficiency.
**Results and Benefits**
After implementing the copper water-jacketed flow tanks, the smelter observed substantial improvements in production continuity and safety. The frequency of tank failures decreased, allowing for uninterrupted operations. Additionally, the system’s ease of maintenance and low failure rate made it a cost-effective solution for the plant.
The economic benefits were also significant. Annual cost savings reached approximately 160,000 yuan, primarily due to reduced material consumption and lower labor requirements. The transformation not only addressed the immediate issue of tank wear but also aligned with the long-term goals of the smelter, supporting sustainable and efficient production.
**Conclusion**
The replacement of graphite flow tanks with copper water-jacketed tanks proved to be a successful and necessary step in modernizing the flash furnace’s slag handling system. It effectively solved the problem of tank failure caused by rising slag temperatures and volumes, ensuring stable and continuous production. The project demonstrated the importance of adapting to changing production demands through innovative engineering solutions, ultimately enhancing the efficiency and profitability of the smelting process.
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