Side-blown furnaces—especially oxygen-enriched side-blown furnaces (OSBF)—are widely used in modern lead smelting and battery recycling due to their high efficiency, operational flexibility, and strong adaptability to mixed raw materials. To ensure stable long-term operation, maximize lead recovery, and extend equipment lifespan, proper maintenance practices are essential.

Below is a complete guide to maintaining a side-blown furnace for continuous, long-life performance.

Maintain the Refractory Lining

The refractory lining is the heart of the furnace. Poor lining conditions lead to:

• Heat loss

• Structural deformation

• Unplanned shutdowns

• Potential furnace failure

Maintenance Tips

• Conduct visual inspections every shift

• Measure lining thickness weekly

• Repair localized erosion promptly

• Replace entire lining during scheduled overhauls

Avoid operating the furnace with critically worn refractory materials—this risks catastrophic breakout.

Inspect the Tuyeres (Side-Blown Nozzles)

Tuyeres deliver air or oxygen directly into the molten bath. Their condition directly affects:

• Temperature distribution

• Bath turbulence

• Smelting efficiency

Key Maintenance Procedures

• Check tuyere blockages daily

• Clean slag or accretions around nozzle exits

• Replace nozzles showing signs of erosion

• Monitor tuyere cooling water flow continuously

• Ensure oxygen supply pressure remains stable

Damaged or clogged tuyeres can cause uneven smelting and increase energy consumption.

Maintain the Oxygen and Air Delivery Systems

Since oxygen-enriched smelting relies heavily on accurate oxygen flow:

Checklist

• Inspect pipelines for leaks

• Calibrate flowmeters regularly

• Ensure valves and regulators operate smoothly

• Keep oxygen supply filters clean

• Maintain backup oxygen storage for emergencies

Stable oxygen delivery ensures consistent temperature and proper reaction kinetics.

Monitor Temperature and Bath Conditions

Optimal smelting conditions require:

• Stable molten bath level

• Uniform bath temperature

• Controlled oxidation-reduction environment

Operators Should:

• Check furnace temperature at fixed intervals

• Record fluctuations and identify abnormal patterns

• Adjust fuel and oxygen ratios quickly when needed

• Monitor slag viscosity and color for process clues

Real-time temperature control improves both recovery rate and furnace life.

Manage Slag Formation and Removal

Excess or hardened slag increases:

• Furnace wear

• Fuel consumption

• Smelting time

• Tuyere blockage risk

Best Practices

• Tap slag at recommended levels

• Avoid over-slagging

• Maintain proper flux ratios

• Clean slag channels and tapping holes regularly

Efficient slag management supports smoother furnace operation.

Inspect Cooling Systems

Side-blown furnaces rely on robust cooling systems to protect the refractory and metal shell.

Daily Checks

• Inspect cooling water pressure

• Ensure flowrate is stable

• Check for leaks or corrosion

• Clean heat exchangers periodically

Cooling failures can cause rapid refractory damage.

Maintain Auxiliary Equipment

A furnace operates within a complete system. Maintenance must include:

• Feed systems (conveyors, chargers, feeders)

• Exhaust gas systems (ducts, filters, scrubbers)

• Melting kettles and refining units

• Slag tapping equipment

• Instrumentation and automation controls

Weakness in any auxiliary component can reduce furnace efficiency.

Implement Preventive Maintenance Schedules

Successful smelting plants use structured maintenance programs:

• Daily: tuyere inspection, slag cleaning, oxygen flow check

• Weekly: refractory measurements, pipeline checks

• Monthly: calibration of sensors, burner system inspection

• Annually: full shutdown, lining replacement, safety audit

Preventive maintenance reduces downtime and significantly extends furnace lifespan.

Train Operators Continuously

Experienced operators improve furnace performance more than any piece of hardware.
Training should cover:

• Bath chemistry

• Oxygen control

• Slag formation

• Safety protocols

• Emergency shutdown procedures

Well-trained operators can detect early signs of abnormal behavior and take corrective actions immediately.

Conclusion

Maintaining a side-blown furnace for long-term operation requires:

• Consistent refractory care

• Clean and functional tuyere systems

• Stable oxygen delivery

• Reliable cooling systems

• Proper slag management

• Routine preventive maintenance

• Skilled operators

With disciplined maintenance and monitoring, a side-blown furnace can operate efficiently for years, maintaining high metal recovery rates, low emissions, and stable production.