Polar Division of “Norilsk Nickel” MMC, Norilsk, Russia

L. V. Krupnov, Head of Engineering Department, e-mail: krupnovlv@nk.nornik.ru

A. F. Petrov, Head of the Laboratory of Engineering Maintenance of Industry

“Gipronickel Institute” LLC, Saint Petersburg, Russia

R. V. Starykh, Leading Researcher

Changes in the flash smelting furnace (FSF) charge, as well as some other technological feature typical for FSF operating conditions at “Nadezhda” Metallurgical Plant (NMP) resulted in destabilisation of the furnace' heat and draught-blowing conditions. Scaling formation at the area of the slag settler joining the uptake was the principal manifestation of the above disorders. The formed scaling peculiarity is that it affects not only the slag and the matte baths, but also occupies substantial volume of the gas space, thus hampering furnace gases removal. Causes of scaling formation in NMP' FSF are discussed in the article. Principal changes in the treated feed composition are discussed. Negative effect of technogenic components added to the FSF charge on smelting process parameters is demonstrated. The commonly known mechanisms of build-up formation in pyrometallurgical units are considered. Mechanism of build-up formation in the NMP’ FSF was proposed, based on the published data and results of observation of the NMP’ FSF running performed in the course of its operation, as well as according to the results of study of the charge and smelting products’ samples. During the periods of the feed grade’ deterioration and the overall heating capacity decrease, build-up formation is sharply intensified. Air inflows via the furnace mantle and lining leakages substantially favour build-up formation process. It is stated that identification of the moment of build-up occurrence and intensive growth is hampered since all the available process control parameters are within the acceptable limits. Thus, regular visual inspections of the furnace during shut-downs is the only way of build-up formation and growth. The results produced make it possible to tailor NMP FSF’ operation mode in accordance with the changing composition of the treated feed.

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