Peirce Smith Converter Hood Improvements at BHP Copper

High-intensity copper converting operations generate extreme thermal loads and aggressive off-gas conditions that challenge conventional hood designs and materials. BHP Copper faced significant operational challenges with their existing Peirce-Smith converter hood system, including thermal degradation, inadequate cooling, and compromised structural integrity under sustained high-temperature exposure. Gas Cleaning Technologies was engaged to develop an engineered solution that would withstand the demanding conditions of modern, intensified converter operations while maintaining effective gas capture performance.

The GCT project approach incorporated comprehensive thermal analysis to characterize heat flux patterns, surface temperatures, and thermal stress distribution throughout the hood structure during various phases of converter operation. This detailed thermal modeling informed the development of a new hood design incorporating enhanced cooling systems, optimized material selection, and structural reinforcements targeted to areas experiencing the highest thermal loading. The design solution balanced the competing requirements of thermal protection, structural durability, and operational accessibility for maintenance and blowing operations.

The implemented hood improvements delivered measurable benefits in terms of extended equipment service life, reduced maintenance frequency, and improved reliability of the gas capture system. By addressing thermal management through engineering analysis rather than reactive maintenance, the project established a sustainable basis for supporting BHP Copper's high-intensity converting operations. The thermal analysis methodologies and design principles developed through this project have broader applicability to other pyrometallurgical facilities operating under similarly demanding conditions.

This publication demonstrates Gas Cleaning Technologies' capability to provide customized engineering solutions for complex metallurgical equipment challenges. Organizations facing hood performance limitations, thermal damage issues, or seeking to support operational intensification can benefit from GCT's integrated approach combining thermal modeling, mechanical design, and practical implementation experience in demanding industrial environments.