铜闪速炉系统数值熔炼模型及反应塔炉膛内形在线仿真监测研究
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摘要
铜闪速熔炼是一个多操作变量、多过程耦合的复杂熔炼过程。在投入工业应用半个多世纪以来，闪速熔炼工艺以其巨大的技术优势和良好的经济效益获得了世界火法炼铜行业的亲睐，特别是“四高”作业制度的实现，更是开创了铜工业高技术熔炼的新时代。熔炼强度的不断增加，熔炼指标的不断提高，都给闪速炉生产系统提出了更高的要求。因此，以进一步强化生产和节能降耗为目标，以“数学模拟—全息仿真—整体优化”为技术路线，开展铜闪速炉熔炼过程的合理强化与反应塔炉衬保护的计算机仿真研究就显得日趋重要。
为了适应生产强化的要求，更好的协调系统配置，科学地挖掘闪速炉生产潜力，本文通过对闪速炉熔炼过程及系统设备的详细研究，以闪速熔炼过程物料衡算和热量衡算的数学模型为基础，综合熔炼系统四环节六大因素，开发了闪速炉生产系统数值熔炼仿真模型，并针对贵溪冶炼厂闪速炉系统进行了仿真强化试验，论证了其扩产改建的可能，同时提出了铜锍品位、富氧浓度、闪速炉渣成分以及精矿含铜品位等生产参数的合理选择方案。
熔炼过程的强化不仅对系统设备要求更高，而且使得炉衬的工作环境更为恶劣，损毁加快。通过对闪速炉反应塔炉衬蚀损机理的研究，作者发现，在反应塔壁面挂渣良好的保护作用下，反应过程中高温熔锍、熔渣以及腐蚀性气体的侵蚀是造成塔壁耐火砖衬损毁的主要原因，而采取有效措施，降低反应塔壁面炉衬的工作温度在合理的范围之内，将有助于塔壁的保护，延长炉体寿命。
在铜闪速炉反应塔炉膛内形数值仿真研究中，作者建立了闪速炉反应塔炉衬热场的数值解析模型；给出了反应塔炉膛内形的定义并进行了物理界定，分析了闪速炉反应塔内壁挂渣层厚度及移动边界的形成与变化机理，提出并定义了反应塔壁面挂渣的“过冷态”与“过热态”的概念；详细研究并提出了实现闪速炉反应塔炉膛内形仿真研究的物理模型以及数学求解方法，开发了反应塔炉膛内形在线监测系统，并分别在贵溪冶炼厂与金隆铜业有限责任公司两座闪速炉系统上投入使用，实现了闪速熔炼过程中对反应塔塔壁状况的实时仿真监测与预警分析，为现场调整操作参数，控制塔壁温度，加强炉体保护提供了可靠依据。
本文还对闪速炉反应塔壁面结构进行了数值仿真与优化研究。通过建立局部塔壁的三维传热数值解析模型，作者提出了，提高塔壁耐火材料的热导率，降低壁面温度，适当减少砖衬厚度，以进一步延长炉体使用寿命的结构优化方案。
The copper flash smelting process is a complicated process coupled with multi-operational variables and reactions. For more than fifty years being applied in industry, the flash smelting technology has attracted great attentions of copper-smelting professionals worldwide with its technical advantages and better economic benefits, and further opened a new era of higher technological level in copper industry since the working regime of 'Four Highs' has been put in practice. Along with enhanced smelting intensity and smelting norms, higher demands are set on the productive system of flash smelting furnace (FSF). Hence it seems to be more important to follow the technical sequence of'mathematical modeling-hologram simulation-comprehensive optimization' and to carry out computational simulation and optimization researches on rational enhancement of the copper-smelting process and protection of the FSF furnace's linings, aiming to further intensify smelting processes and reduce energy consumptions.
In order to meet the demands for enhanced production, to coordinate better systematic arrangement and to scientifically tap the latent power of system production, in this paper, based on detailed study of the smelting processes, equipments and models for balance computation of material and heat in flash smelting process, a mathematical model for simulation and optimizations of flash smelting system has been developed by considering four links and six factors in the system. Moreover, simulative enhancement experiments for Guixi Smelter's FSF have been carried out, possibilities for the system to be enlarged and re-built been expounded, and optical parameters such as matte grade, oxygen-enriched smelting, slag compositions and copper concentrate been proposed.
Intensified smelting process not only sets higher demands on the system equipments but also makes the work environment of furnace linings even worse and more prone to be damaged. Based on the study of erosion mechanism of linings in a reaction shaft of FSF, the author found that, under the cover of frozen slag, the refractory bricks of shaft were mainly damaged at high temperature by the erosion of smelted matte, slag and erosive gas. So, if effective measures are to be adopted to control the linings' surface temperature within a reasonable range, the inner walls of the shaft will be protected better and the furnace life will be prolonged longer.
In numerical simulation of the frozen profile of reaction shaft in a copper flash smelting furnace, the author established a numerical model for the temperature field of shaft's linings. Giving the shaft's frozen profile definition and physical boundaries and analyzing the forming process and variation mechanism of wall slag and moving boundaries in reaction shaft, the author proposed and defined the conception of 'over-cooled state' and 'over-heated state', studied in detail the physical model and its mathematical solution during the research of the frozen profile of reaction shaft, and developed an on-line monitoring system for the frozen profile of shaft's inner surface. The system
2002
later has been applied in two flash furnaces located in Guixi Smelter and Jinlong Copper Company, Ltd respectively. Since provided with real time simulative monitoring and warning analysis of wall situations of the reaction shaft in a smelting process, technicians then are greatly helped in better adjusting operation parameters in-site, controlling the wall temperature and protecting the furnace.
Finally in this paper, the author carried out both the numerical simulation and optimization researches on wall structures of reaction shaft in Guixi's flash furnace. By establishing a three-dimensional analytical model for heat transfers in local wall of the shaft, the author proposed optimized structures of reaction shaft, such as improving the heat conductivity of the wall refractory, decreasing the wall temperature and reducing the thickness of bricks, to help the furnace to work better and longer.
为了适应生产强化的要求，更好的协调系统配置，科学地挖掘闪速炉生产潜力，本文通过对闪速炉熔炼过程及系统设备的详细研究，以闪速熔炼过程物料衡算和热量衡算的数学模型为基础，综合熔炼系统四环节六大因素，开发了闪速炉生产系统数值熔炼仿真模型，并针对贵溪冶炼厂闪速炉系统进行了仿真强化试验，论证了其扩产改建的可能，同时提出了铜锍品位、富氧浓度、闪速炉渣成分以及精矿含铜品位等生产参数的合理选择方案。
熔炼过程的强化不仅对系统设备要求更高，而且使得炉衬的工作环境更为恶劣，损毁加快。通过对闪速炉反应塔炉衬蚀损机理的研究，作者发现，在反应塔壁面挂渣良好的保护作用下，反应过程中高温熔锍、熔渣以及腐蚀性气体的侵蚀是造成塔壁耐火砖衬损毁的主要原因，而采取有效措施，降低反应塔壁面炉衬的工作温度在合理的范围之内，将有助于塔壁的保护，延长炉体寿命。
在铜闪速炉反应塔炉膛内形数值仿真研究中，作者建立了闪速炉反应塔炉衬热场的数值解析模型；给出了反应塔炉膛内形的定义并进行了物理界定，分析了闪速炉反应塔内壁挂渣层厚度及移动边界的形成与变化机理，提出并定义了反应塔壁面挂渣的“过冷态”与“过热态”的概念；详细研究并提出了实现闪速炉反应塔炉膛内形仿真研究的物理模型以及数学求解方法，开发了反应塔炉膛内形在线监测系统，并分别在贵溪冶炼厂与金隆铜业有限责任公司两座闪速炉系统上投入使用，实现了闪速熔炼过程中对反应塔塔壁状况的实时仿真监测与预警分析，为现场调整操作参数，控制塔壁温度，加强炉体保护提供了可靠依据。
本文还对闪速炉反应塔壁面结构进行了数值仿真与优化研究。通过建立局部塔壁的三维传热数值解析模型，作者提出了，提高塔壁耐火材料的热导率，降低壁面温度，适当减少砖衬厚度，以进一步延长炉体使用寿命的结构优化方案。
The copper flash smelting process is a complicated process coupled with multi-operational variables and reactions. For more than fifty years being applied in industry, the flash smelting technology has attracted great attentions of copper-smelting professionals worldwide with its technical advantages and better economic benefits, and further opened a new era of higher technological level in copper industry since the working regime of 'Four Highs' has been put in practice. Along with enhanced smelting intensity and smelting norms, higher demands are set on the productive system of flash smelting furnace (FSF). Hence it seems to be more important to follow the technical sequence of'mathematical modeling-hologram simulation-comprehensive optimization' and to carry out computational simulation and optimization researches on rational enhancement of the copper-smelting process and protection of the FSF furnace's linings, aiming to further intensify smelting processes and reduce energy consumptions.
In order to meet the demands for enhanced production, to coordinate better systematic arrangement and to scientifically tap the latent power of system production, in this paper, based on detailed study of the smelting processes, equipments and models for balance computation of material and heat in flash smelting process, a mathematical model for simulation and optimizations of flash smelting system has been developed by considering four links and six factors in the system. Moreover, simulative enhancement experiments for Guixi Smelter's FSF have been carried out, possibilities for the system to be enlarged and re-built been expounded, and optical parameters such as matte grade, oxygen-enriched smelting, slag compositions and copper concentrate been proposed.
Intensified smelting process not only sets higher demands on the system equipments but also makes the work environment of furnace linings even worse and more prone to be damaged. Based on the study of erosion mechanism of linings in a reaction shaft of FSF, the author found that, under the cover of frozen slag, the refractory bricks of shaft were mainly damaged at high temperature by the erosion of smelted matte, slag and erosive gas. So, if effective measures are to be adopted to control the linings' surface temperature within a reasonable range, the inner walls of the shaft will be protected better and the furnace life will be prolonged longer.
In numerical simulation of the frozen profile of reaction shaft in a copper flash smelting furnace, the author established a numerical model for the temperature field of shaft's linings. Giving the shaft's frozen profile definition and physical boundaries and analyzing the forming process and variation mechanism of wall slag and moving boundaries in reaction shaft, the author proposed and defined the conception of 'over-cooled state' and 'over-heated state', studied in detail the physical model and its mathematical solution during the research of the frozen profile of reaction shaft, and developed an on-line monitoring system for the frozen profile of shaft's inner surface. The system
2002
later has been applied in two flash furnaces located in Guixi Smelter and Jinlong Copper Company, Ltd respectively. Since provided with real time simulative monitoring and warning analysis of wall situations of the reaction shaft in a smelting process, technicians then are greatly helped in better adjusting operation parameters in-site, controlling the wall temperature and protecting the furnace.
Finally in this paper, the author carried out both the numerical simulation and optimization researches on wall structures of reaction shaft in Guixi's flash furnace. By establishing a three-dimensional analytical model for heat transfers in local wall of the shaft, the author proposed optimized structures of reaction shaft, such as improving the heat conductivity of the wall refractory, decreasing the wall temperature and reducing the thickness of bricks, to help the furnace to work better and longer.
引文
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