Peirce Smith Converter Hood Design Analysis Using Computational Fluid Dynamics Modeling

The efficient capture of process off-gas in primary copper smelting operations presents significant engineering challenges, particularly in Peirce-Smith converter systems where high-temperature, high-volume gas flows must be effectively managed. Inadequate hood design can result in fugitive emissions, compromised workplace air quality, and reduced overall smelter efficiency. Gas Cleaning Technologies, in collaboration with Cominco Research, conducted a comprehensive computational fluid dynamics (CFD) analysis to address these critical design challenges and establish optimum parameters for converter hood performance.

This technical study employed advanced CFD modeling techniques to simulate and analyze complex off-gas flow patterns within Peirce-Smith converter hood systems. The modeling approach enabled detailed visualization of gas velocity profiles, temperature distributions, and turbulent flow characteristics under various operating conditions. By systematically evaluating different hood geometries and configuration parameters, the analysis identified key design factors that influence capture efficiency and minimize escape of process gases to the surrounding work environment.

The CFD analysis yielded quantifiable design recommendations for optimizing hood geometry, positioning, and dimensional specifications tailored to specific converter operations. These findings provide metallurgical facilities with engineering data to improve existing hood systems or design new installations with enhanced capture performance. The computational modeling approach demonstrated in this publication offers a cost-effective alternative to physical prototyping, enabling design optimization prior to capital expenditure on equipment fabrication and installation.

For copper smelting operations seeking to improve environmental compliance, reduce fugitive emissions, and enhance workplace conditions, this publication demonstrates Gas Cleaning Technologies' application of advanced engineering tools to solve practical industrial challenges. The methodologies and design principles established through this CFD analysis are applicable to a wide range of pyrometallurgical processes requiring effective off-gas capture and management systems.