Operational and economic imperatives in the metallurgical industry have led to numerous advancements in furnace design. Modern furnaces provide high production rates, high percentage online time, long campaign life between rebuilds and safe operating conditions._x000D_
Current trends for maximising plant efficiency include increasing the throughput of existing process vessels (often by a factor of two or more) and the use of newer, highly intense processes. In both instances, the process intensity results in the generation of higher heat fluxes to the crucible walls._x000D_
High-intensity furnace operation with the objectives mentioned above has become possible with the following furnace design features: Strong sidewall cooling systems, using copper coolers, to accommodate the high heat fluxes encountered while protecting the crucible refractories; Robust, spring-loaded furnace horizontal and vertical binding systems which maintain tight brick joints through-out all stages of operation; and Well-designed, intensely cooled tapholes for metal, matte and slag._x000D_
The integration of these features along with properly selected refractories, appropriate instrumentation systems and efficient water-cooling systems is also highly critical._x000D_
These design features have been successfully implemented in electric smelting furnaces, flash smelting and converting furnaces (Outokumpu and INCO types) and lance injection furnaces (Mitsubishi, Ausmelt and Isasmelt types). This paper will discuss design aspects and operating results for several installations.