氧化铝沉降槽赤泥分离过程的仿真与实验研究及参数优化
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摘要
赤泥沉降分离是氧化铝生产工艺中十分关键的工序之一,对氧化铝产品的质量和产量有着重要影响。近年来铝土矿品位的不断降低,导致氧化铝生产中沉降分离工序问题频发,沉降槽的产能及其运行稳定性已经成为制约氧化铝生产的瓶颈之一。因此,全面深入地研究沉降槽及赤泥沉降分离过程,对目前沉降槽产能提升和沉降槽的优化设计具有重要指导意义。
本文以实际生产中的高效深锥沉降槽为研究对象,从提升絮凝反应效率的角度出发,采用数值计算、实验研究和理论分析的研究方法,对沉降槽内固液两相流动、混合及分离过程进行了深入研究。本研究的主要工作与相关结论如下：
(1)针对沉降槽赤泥分离过程在国内鲜有研究以及国外研究多属于保密性技术成果这一现状,本文建立了较为完善的可用于研究沉降槽内赤泥分离过程的三维稳态数值模型。利用所建立的数值模型对沉降分离过程进行较系统的模拟计算,通过与测试值的对比验证了计算模型的可靠性与正确性。
(2)以改善中心桶内赤泥浓度场从而提升絮凝反应效率为出发点,提出了最优固含体积分数的评价指标以及沉降槽进料方式的改造和优化方案。利用本研究所建立的数值模型对优化方案进行数值模拟,并在此基础上对某氧化铝厂沉降槽进行工业改造,获得了理想的经济效益。数值计算结果表明：中心桶内的平均固含由改造前的71.8g·1-1降低到56.8g·1-1,最优絮凝固含的体积分数从改造前的7%提高到了24.3%,能极大促进桶内絮凝反应效率的提升。工业应用结果表明：在进料固含提升10g·1-1的前提下,改造后沉降槽的底流固含较改造前提高了2.4%,溢流浮游物降低了2%,絮凝剂消耗量降低了8.1%,一条生产线每年为生产企业节约成本163.5万元。
(3)设计并搭建了沉降槽水模型实验平台,提出了有限个颗粒脉冲示踪法,并利用停留时间分布的理论实现了对中心桶内流体流动分布规律的定性和定量研究。实验结果表明：中心桶内同时存在混合流动、不参与主体流动的“死区”和流体“短路”现象,环形挡流板可以有效地减小“短路”现象的发生；中心桶尺寸对中心桶内流体的分布规律有着重要影响。流体的无因次平均停留时间随着中心桶高径比的增大而增加。
(4)利用非理想流动模型及停留时间数字特征,提出了评价中心桶内物料流动规律的分析方法。以隔室模型为依据,提出了有效流动区域体积分数这一评价指标以评估中心桶内流场分布对絮凝剂与赤泥混合程度的影响。在稳态数值模型的基础上建立了沉降槽中心桶内矿浆混合过程的瞬态数值模型。利用本研究所提出的数值模型、评价方法以及评价指标对不同结构、工艺参数下中心桶内矿浆的流动分布进行计算并对结果进行深入的讨论和分析。仿真结果表明：中心桶内的矿浆流动属于大混合程度的流动,ADM模型参数Pe数介于0.21至3.21之间,TISM模型表明中心桶可近似为1.19至3.44个串联的全混流动釜；结构、工艺参数对中心桶内矿浆流动分布规律有着重要影响,当结构、工艺参数变化时,中心桶内的流动区域之间存在相互转化的关系。
(5)利用正交试验理论,以有效流动区域体积分数为优化指标,采用数值模拟的方法对影响中心桶内矿浆流动分布规律的5个因素进行了优化研究,得到如下结论：中心桶高度(D)和进料流量(A)对评价指标有着高度显著影响,进料管位置(C)对评价指标有着显著影响,中心桶直径(B)有较为显著的影响,而挡流板位置(E)无显著影响：工艺参数最佳组合为A5B1C5D1E1，对其进行数值模拟的结果表明,中心桶内有效流动区域的体积分数ζeff达到90%,较基准工况提高23%,能明显改善中心桶内的流场环境,促进絮凝反应效率的提升
(6)建立了沉降槽内赤泥颗粒压缩沉积过程的一维稳态快速预测数学模型。利用Matlab编程实现了稳态下沉降槽内赤泥通量预测的数值计算,并结合测试数据验证了数学模型的可靠性和正确性。利用这一预测模型并结合传统的矿浆物性参数的测定方法,可以快速地对沉降槽的生产性能进行预测计算,从而为沉降槽的设计、控制及沉降过程的数字化提供了技术依据。
Red mud separation is one of the most important procedures in Alumina refinery industry, and it has significant impact on the quality and the yield of alumina products.Problems were frequently occurred in the solid-liquid separation process due to the degradation of the bauxite's grade in recent years, which make thickeners'capacity and stability becoming the bottleneck in alumina refinery industry. Therefore,a comprehensive study of the thickener and red mud separation process will provide great benefit for improving capacity, optimization as well as predictive design of the thickener.
For the purposes of promoting the flocculation reaction rate, a high rate converging base thickener on an industry scale was chosen as the research object, and the solid-liquid separation process inside the thickener was investigated through numerical calculation, experimental study as well as theoretical analysis techniques respectively. The main detailed work and findings of this research were expatiated hereunder:(1)The domestic researches of separation thickener and red mud separation process was rare and relevant publications was lack of details due to confidential issue.Therefore a three-dimensional numerical model was established which can be applied to investigate the red mud separation process of the thickener.The model was validated through the on-site data.
(2) For the purpose of improving the red mud concentration distribution and the flocculation reaction rate, the best volume fraction of solid concentration was proposed as the evaluation indicator and a novel self-dilute inlet pipe was also created and optimized based on the self-defined evaluation factor using the numerical simulation technique. The optimized self-dilute inlet pipe was introduced to a alumina refinery enterprise.The numerical simulation results indicated that the feedwell's average solid concentration was decreased from71.8g·1to56.8g·1, and the best flocculation volume fraction was increased from7%to21% after introducing the self-dilute inlet pipe.The self-dilute inlet pipe can dramatically improve the flocculation reaction rate in the feedwell.The on-site modification result reported that the solid concentration of the underflow was increased by2.4%while the amount of overflow's float and the flocculants dose was decreased by2%and8.1%respectively1.635million Yuan can be saved from the capital cost of the enterprise annually.
(3) An experimental thickener model was established. Tracer-Respond as well as Finite Granules Trace Method was proposed and used to investigate the flow patterns of the feedwell qualitatively and quantitatively. The swirling flow, dead zones and "short circuit" were detected during the experiment, and the buff ring can minimize the "short circuit"'s occurrence dramatically. The feedwell's aspect ratio have significant effect on its flow patterns.The dimensionless mean residence time was increased along with the feedwell's aspect ratio increase.
(4) A transient numerical model was established which can be used to investigate the mixing process of bauxite slurry. The effective flow regime volume fraction ζeff was introduced as the evaluation criteria, non-ideal flow models,non-linear regression and residence time distribution's moments were combined as the analysis method to investigate the flow distribution of the feedwell under different structural and process parameters.The simulation results indicated that the feed flows inside the feedwell belong to highly dispersed flow scheme.Under such condition, the AMD model parameter Pe is between0.21to3.21, and the feed flow inside the feedwell can be depicted as1.19—3.44mixing tanks connected in series.The structural and process parameters have dominate influence on feed flow's distribution of the feedwell. The dead zone and plug flow will convert into each other when altering the feedwell's diameter and the buff ring's position; Feedwell's height and the feed inlet rate can lead a conversion between the dead zone and the mixing flow of the feedwell;Inlet pipe's position can also lead a conversion between the dead zone,plug flow and mixing flow in the feedwell.
(5)According to the orthogonal experimental design and the evaluation criteria ζeff, five factors which influence the feed flow's distribution of the feedwell were simulated and optimized. Among which, the feedwell height (D) and the inlet feed rate(A) are most significant factor, while the inlet pipe's position(C) is significant and the feedwell's diameter(B) is less significant, the buff ring's position gives no significant impact. The optimum factor scheme is A5B1C5D1E1, and the simulation results show that the ζeff can be increased up to90%compared that of the base case's67%.The optimum scheme can provide a better flow environment and promote the flocculation reaction rate.
(6)Based on the red mud's settling and thickening mechanism, a one-dimensional mathematical model was established to depict the red mud's thickening-compression process.The calculation of predictive solid flux of the thickener was realized by Matlab programming, and the model was validated through on-site data. Combined with traditional feed material properties characterization techniques,thickener's capacity can be predicted rapidly, which will benefit the control, design and the digitization for the thickening process of the thickener.
本文以实际生产中的高效深锥沉降槽为研究对象,从提升絮凝反应效率的角度出发,采用数值计算、实验研究和理论分析的研究方法,对沉降槽内固液两相流动、混合及分离过程进行了深入研究。本研究的主要工作与相关结论如下：
(1)针对沉降槽赤泥分离过程在国内鲜有研究以及国外研究多属于保密性技术成果这一现状,本文建立了较为完善的可用于研究沉降槽内赤泥分离过程的三维稳态数值模型。利用所建立的数值模型对沉降分离过程进行较系统的模拟计算,通过与测试值的对比验证了计算模型的可靠性与正确性。
(2)以改善中心桶内赤泥浓度场从而提升絮凝反应效率为出发点,提出了最优固含体积分数的评价指标以及沉降槽进料方式的改造和优化方案。利用本研究所建立的数值模型对优化方案进行数值模拟,并在此基础上对某氧化铝厂沉降槽进行工业改造,获得了理想的经济效益。数值计算结果表明：中心桶内的平均固含由改造前的71.8g·1-1降低到56.8g·1-1,最优絮凝固含的体积分数从改造前的7%提高到了24.3%,能极大促进桶内絮凝反应效率的提升。工业应用结果表明：在进料固含提升10g·1-1的前提下,改造后沉降槽的底流固含较改造前提高了2.4%,溢流浮游物降低了2%,絮凝剂消耗量降低了8.1%,一条生产线每年为生产企业节约成本163.5万元。
(3)设计并搭建了沉降槽水模型实验平台,提出了有限个颗粒脉冲示踪法,并利用停留时间分布的理论实现了对中心桶内流体流动分布规律的定性和定量研究。实验结果表明：中心桶内同时存在混合流动、不参与主体流动的“死区”和流体“短路”现象,环形挡流板可以有效地减小“短路”现象的发生；中心桶尺寸对中心桶内流体的分布规律有着重要影响。流体的无因次平均停留时间随着中心桶高径比的增大而增加。
(4)利用非理想流动模型及停留时间数字特征,提出了评价中心桶内物料流动规律的分析方法。以隔室模型为依据,提出了有效流动区域体积分数这一评价指标以评估中心桶内流场分布对絮凝剂与赤泥混合程度的影响。在稳态数值模型的基础上建立了沉降槽中心桶内矿浆混合过程的瞬态数值模型。利用本研究所提出的数值模型、评价方法以及评价指标对不同结构、工艺参数下中心桶内矿浆的流动分布进行计算并对结果进行深入的讨论和分析。仿真结果表明：中心桶内的矿浆流动属于大混合程度的流动,ADM模型参数Pe数介于0.21至3.21之间,TISM模型表明中心桶可近似为1.19至3.44个串联的全混流动釜；结构、工艺参数对中心桶内矿浆流动分布规律有着重要影响,当结构、工艺参数变化时,中心桶内的流动区域之间存在相互转化的关系。
(5)利用正交试验理论,以有效流动区域体积分数为优化指标,采用数值模拟的方法对影响中心桶内矿浆流动分布规律的5个因素进行了优化研究,得到如下结论：中心桶高度(D)和进料流量(A)对评价指标有着高度显著影响,进料管位置(C)对评价指标有着显著影响,中心桶直径(B)有较为显著的影响,而挡流板位置(E)无显著影响：工艺参数最佳组合为A5B1C5D1E1，对其进行数值模拟的结果表明,中心桶内有效流动区域的体积分数ζeff达到90%,较基准工况提高23%,能明显改善中心桶内的流场环境,促进絮凝反应效率的提升
(6)建立了沉降槽内赤泥颗粒压缩沉积过程的一维稳态快速预测数学模型。利用Matlab编程实现了稳态下沉降槽内赤泥通量预测的数值计算,并结合测试数据验证了数学模型的可靠性和正确性。利用这一预测模型并结合传统的矿浆物性参数的测定方法,可以快速地对沉降槽的生产性能进行预测计算,从而为沉降槽的设计、控制及沉降过程的数字化提供了技术依据。
Red mud separation is one of the most important procedures in Alumina refinery industry, and it has significant impact on the quality and the yield of alumina products.Problems were frequently occurred in the solid-liquid separation process due to the degradation of the bauxite's grade in recent years, which make thickeners'capacity and stability becoming the bottleneck in alumina refinery industry. Therefore,a comprehensive study of the thickener and red mud separation process will provide great benefit for improving capacity, optimization as well as predictive design of the thickener.
For the purposes of promoting the flocculation reaction rate, a high rate converging base thickener on an industry scale was chosen as the research object, and the solid-liquid separation process inside the thickener was investigated through numerical calculation, experimental study as well as theoretical analysis techniques respectively. The main detailed work and findings of this research were expatiated hereunder:(1)The domestic researches of separation thickener and red mud separation process was rare and relevant publications was lack of details due to confidential issue.Therefore a three-dimensional numerical model was established which can be applied to investigate the red mud separation process of the thickener.The model was validated through the on-site data.
(2) For the purpose of improving the red mud concentration distribution and the flocculation reaction rate, the best volume fraction of solid concentration was proposed as the evaluation indicator and a novel self-dilute inlet pipe was also created and optimized based on the self-defined evaluation factor using the numerical simulation technique. The optimized self-dilute inlet pipe was introduced to a alumina refinery enterprise.The numerical simulation results indicated that the feedwell's average solid concentration was decreased from71.8g·1to56.8g·1, and the best flocculation volume fraction was increased from7%to21% after introducing the self-dilute inlet pipe.The self-dilute inlet pipe can dramatically improve the flocculation reaction rate in the feedwell.The on-site modification result reported that the solid concentration of the underflow was increased by2.4%while the amount of overflow's float and the flocculants dose was decreased by2%and8.1%respectively1.635million Yuan can be saved from the capital cost of the enterprise annually.
(3) An experimental thickener model was established. Tracer-Respond as well as Finite Granules Trace Method was proposed and used to investigate the flow patterns of the feedwell qualitatively and quantitatively. The swirling flow, dead zones and "short circuit" were detected during the experiment, and the buff ring can minimize the "short circuit"'s occurrence dramatically. The feedwell's aspect ratio have significant effect on its flow patterns.The dimensionless mean residence time was increased along with the feedwell's aspect ratio increase.
(4) A transient numerical model was established which can be used to investigate the mixing process of bauxite slurry. The effective flow regime volume fraction ζeff was introduced as the evaluation criteria, non-ideal flow models,non-linear regression and residence time distribution's moments were combined as the analysis method to investigate the flow distribution of the feedwell under different structural and process parameters.The simulation results indicated that the feed flows inside the feedwell belong to highly dispersed flow scheme.Under such condition, the AMD model parameter Pe is between0.21to3.21, and the feed flow inside the feedwell can be depicted as1.19—3.44mixing tanks connected in series.The structural and process parameters have dominate influence on feed flow's distribution of the feedwell. The dead zone and plug flow will convert into each other when altering the feedwell's diameter and the buff ring's position; Feedwell's height and the feed inlet rate can lead a conversion between the dead zone and the mixing flow of the feedwell;Inlet pipe's position can also lead a conversion between the dead zone,plug flow and mixing flow in the feedwell.
(5)According to the orthogonal experimental design and the evaluation criteria ζeff, five factors which influence the feed flow's distribution of the feedwell were simulated and optimized. Among which, the feedwell height (D) and the inlet feed rate(A) are most significant factor, while the inlet pipe's position(C) is significant and the feedwell's diameter(B) is less significant, the buff ring's position gives no significant impact. The optimum factor scheme is A5B1C5D1E1, and the simulation results show that the ζeff can be increased up to90%compared that of the base case's67%.The optimum scheme can provide a better flow environment and promote the flocculation reaction rate.
(6)Based on the red mud's settling and thickening mechanism, a one-dimensional mathematical model was established to depict the red mud's thickening-compression process.The calculation of predictive solid flux of the thickener was realized by Matlab programming, and the model was validated through on-site data. Combined with traditional feed material properties characterization techniques,thickener's capacity can be predicted rapidly, which will benefit the control, design and the digitization for the thickening process of the thickener.
引文
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