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Numerical study on the effect of torch geometry on the combustion process
inside an Copper melting anode casting furnace
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Ali Afshar *1   , Mohammad Hassan Nobakhti1 |
| 1- Department of Mechanical Engineering, Sciences and Researches Branch, Islamic Azad University, Tehran, Iran |
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Abstract: (31 Views) |
In the present study, a numerical investigation was conducted to examine the effect of burner-head geometry on the combustion flow in the anode furnace of the Sarcheshmeh Copper Complex. The simulations were performed using the finite volume method in ANSYS Fluent with an unstructured three-dimensional mesh. To identify the cause of burner-tip burnout, the k–ε turbulence model was employed to capture the turbulent flow field, while the Eddy Dissipation Concept (EDC) combustion model was used to simulate the combustion process. Burner-tip burnout leads to shutdown of the anode furnace; consequently, upstream units such as the refinery must also cease operation, resulting in complete interruption of copper production. Since experimentally designing a new burner to prevent burnout is time-consuming and economically impractical, the burner-head geometry was modified numerically in this research to achieve optimal performance. The numerical results indicate that the burnout is primarily caused by premature flame formation in the vicinity of the burner head. A comparison of the maximum temperature in this region for the two proposed designs with the current design shows that, in Design 1, the temperature decreases by 31%, while in Design 2, the reduction reaches approximately 47% relative to the existing burner. Moreover, the temperature distribution inside the furnace becomes more uniform in Design 2 compared with both Design 1 and the current configuration, and the maximum flame temperature drops by about 90 K. Based on these results, Design 2 was selected as the final design, and the burner with the modified geometry was manufactured and installed in the plant. Routine performance monitoring confirmed that the burner-tip burnout issue has been completely resolved.
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| Keywords: burner tip burnout, furnace combustion temperature, burner geometry modification |
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Full-Text [PDF 1396 kb]
(18 Downloads)
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Type of Study: Research |
Subject:
Special
Received: 2025/10/1 | Accepted: 2026/01/5 | Published: 2026/03/1
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