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High-temperature process off-gases from sulfide smelting operations require careful thermal management before entering downstream gas cleaning and acid production systems. Inadequate or improperly designed cooling systems can result in SO3 formation, refractory damage, equipment fouling, and compromised performance of subsequent gas treatment stages. The selection and design of gas cooling systems must address multiple competing requirements including heat recovery efficiency, capital cost, maintenance considerations, and process chemistry constraints specific to non-ferrous metallurgical applications.
This technical review, authored by Paykan Safe of Goodfellow/Gas Cleaning Technologies in collaboration with BHP Copper, systematically examines gas cooling options applicable to sulfide smelting processes. The analysis evaluates alternative cooling approaches including radiation coolers, convective heat exchangers, evaporative cooling systems, and direct water injection, characterizing the technical features, operational characteristics, and application suitability of each technology. Particular attention is devoted to the critical issue of SO3 formation, which occurs when gas temperatures, residence times, and catalytic conditions combine to convert SO2 to SO3, creating downstream handling problems and acid plant operational challenges.
The publication establishes engineering criteria for cooling system selection tailored to specific process requirements, gas flow characteristics, temperature reduction objectives, and site-specific constraints. Decision factors include available plot space, cooling water availability, heat recovery value, maintenance access requirements, and integration with overall smelter energy balance. The systematic selection methodology enables engineers to identify the most appropriate cooling technology for their specific application rather than defaulting to conventional solutions.
Non-ferrous smelter operators planning new installations, evaluating cooling system upgrades, or addressing operational problems related to gas cooling will find this publication provides essential engineering guidance. Gas Cleaning Technologies' experience in designing and troubleshooting gas cooling systems across diverse metallurgical applications brings practical insight to the selection and design process, supporting solutions that deliver reliable long-term performance.
