铜闪速吹炼过程仿真研究
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摘要
铜闪速熔炼-闪速吹炼技术是美国肯尼柯特公司和芬兰奥托昆普公司合作开发的清洁炼铜工艺(以下简称“双闪”工艺)。1995年,“双闪”工艺在美国Utah冶炼厂正式投入工业生产。生产实践表明,“双闪”工艺与传统的闪速熔炼-PS转炉吹炼工艺相比,具有清洁、高效、投资小、生产费用低等优点。同时国内最近新建的炼铜企业大多选用“双闪”工艺,因此进行闪速吹炼过程仿真研究进行模拟对于研究闪速吹炼工艺有一定的现实意义。
随着科技的发展,计算机仿真技术逐渐引入到冶金工艺过程的模拟,它被认为是研究冶金工艺的第3种手段。冶金研究引入CFD技术,为传统工业试验起到了节约成本,减少试验用时的作用。因此,采用CFD技术进行闪速吹炼过程的研究较好的解决了传统研究无法进行闪速吹炼炉内部区域监测的问题,为闪速吹炼过程的研究提供了一个有效手段,通过CFD技术我们可以研究影响铜闪速吹炼过程的各种限制因素。
本研究是在Fluent中使用UDF函数添加燃烧模型建立闪速吹炼仿真模型,进行了不同颗粒直径,不同工艺风量,不同中央氧量,有无燃烧风等情况的模拟。在上述条件下,本研究通过对闪速吹炼炉各场及颗粒的模拟,给出了颗粒的温度,氧化程度、颗粒运动速度、存活时间和沉淀池分布情况。本研究详细介绍了模拟过程的方式方法,这为闪速吹炼工艺仿真提供了一套较好的解决方案。主要进行的研究内容和研究成果有如下几点:
(1)颗粒行为及颗粒氧化程度研究,在相同工况下进行多种单独颗粒条件的模拟发现,150um颗粒较20um颗粒温度上升慢,氧化程度低,但是150um的颗粒受分布风作用偏移反应塔中心的程度较20um的高。同时研究发现,在没有颗粒破碎和碰撞模拟的情况下大于70um的部分颗粒约有20-30%的Cu_2S仍然未反应。
(2)不同风量对闪速吹炼过程的影响研究。在不同的分布风条件下,反应塔内的高温区域也不相同,分布风量为1059Nm~3/h较风量为765Nm~3/h的高温区域更大,而且中央区域的Cu_2S氧化程度较高。同时通过对1294Nm~3/h与1059Nm~3/h的分布风对比中可以看出,过高的分布风导致颗粒过度偏移反应塔中心,造成中央喷嘴下方O_2浓度过高。颗粒束中心区域Cu_2O生成较多,而颗粒束外侧区域由于氧气不足,导致其氧化不完全。因此在研究的模拟条件下,建议分布风控制在1059Nm~3/h附近。
(3)通过对不同中央氧量的比较发现,中央氧为166Nm~3/h较498Nm~3/h的工况颗粒温度高温区域较小,而且较少的中央氧容易导致颗粒束中心区域更容易存在未反应的Cu_2S。从有无燃烧风模拟的比较发现,在没有燃烧风的工艺条件下,颗粒反应较慢,氧化程度不及有燃烧风的情况。
Copper Flash Smelting - Flash converting technology companies and the United States Kennecott-Outokumpu companies to develop copper technology (hereinafter referred to as "dual flash" process.) In 1995, the "dual flash" process in the United States Utah smelter was put into industrial production. Production practice shows that the "dual flash" flash smelting technology and the traditional converting of converter technology-PS compared with the clean, efficient, small investment, production cost is low. While domestic enterprises are the recent selection of new copper "dual flash" process, so the converting process simulation of flash to simulate the converting process for the study of flash has some practical significance.
With the development of technology, computer simulation technology gradually introduced to the metallurgical process simulation, it is considered to be of metallurgical process means the first 3. Introduction of metallurgy CFD technology has played a test for the traditional industries to save costs and reduce the role of testing time. Therefore, the use of CFD technology to the process of flash converting a better solution to the traditional research can not be flash furnace converting the issue within the regional monitoring, for the converting process of Flash offers an effective means of technology through the CFD We can study the impact of copper flash smelting process of converting the various constraints.
This study is the use of UDF in Fluent combustion modeling flash function to add converting simulation model with different particle diameter, different processes components, different central oxygen, with or without burning air and so the simulation. Under these conditions, the study converting through the flash furnace Ge field and particle simulation, gives the particle temperature, oxidation, particle velocity, the survival time and the distribution of sedimentation tanks. This study details the ways and means of simulation, this converting process simulation for the flash to provide a better solution. Mainly for the research and findings are the following:
(1) particle behavior and the degree of oxidation of particles in the same conditions for a variety of simulated conditions found in separate particles, 150um 20um particles than particles slow rise in temperature, oxidation low, but the particles 150um offset by the distribution of wind over the extent of reaction tower center 20um high. Also found that, in the absence of particle breakage and collision simulation is greater than 70um some cases about 20-30% of the Cu_2S particles remain unreacted.
(2) The amount of wind converting on the flash process of research. The distribution in different wind conditions, the reaction tower is not the same high-temperature region, the distribution air volume 1059Nm~3 / h air volume than 765Nm~3 / h of heat a larger area, and the central region of the Cu_2S higher degree of oxidation. At the same time by 1294Nm~3 / h and 1059Nm~3 / h compared the distribution of the wind can be seen, the distribution of high winds led to over-shift reaction tower center of particles, resulting in high concentrations of O_2 below the central nozzle. Cu_2O particle beam generated more central region, while the particle beam outside the region due to lack of oxygen, resulting in incomplete oxidation. Therefore, under simulated conditions in the study, the proposed distribution of air control in the 1059Nm~3 / h near.
(3) Comparison of different oxygen found in the central, central oxygen as 166Nm~3 / h over 498Nm~3 / h the temperature of the hot zone conditions smaller particles, and less prone to the central oxygen particle beam central region there are not more likely to respond the Cu_2S. Whether the combustion air from the comparison between the simulation, the wind in the absence of combustion conditions, the particles slow reaction, oxidation is less than a burning wind of the situation.
随着科技的发展,计算机仿真技术逐渐引入到冶金工艺过程的模拟,它被认为是研究冶金工艺的第3种手段。冶金研究引入CFD技术,为传统工业试验起到了节约成本,减少试验用时的作用。因此,采用CFD技术进行闪速吹炼过程的研究较好的解决了传统研究无法进行闪速吹炼炉内部区域监测的问题,为闪速吹炼过程的研究提供了一个有效手段,通过CFD技术我们可以研究影响铜闪速吹炼过程的各种限制因素。
本研究是在Fluent中使用UDF函数添加燃烧模型建立闪速吹炼仿真模型,进行了不同颗粒直径,不同工艺风量,不同中央氧量,有无燃烧风等情况的模拟。在上述条件下,本研究通过对闪速吹炼炉各场及颗粒的模拟,给出了颗粒的温度,氧化程度、颗粒运动速度、存活时间和沉淀池分布情况。本研究详细介绍了模拟过程的方式方法,这为闪速吹炼工艺仿真提供了一套较好的解决方案。主要进行的研究内容和研究成果有如下几点:
(1)颗粒行为及颗粒氧化程度研究,在相同工况下进行多种单独颗粒条件的模拟发现,150um颗粒较20um颗粒温度上升慢,氧化程度低,但是150um的颗粒受分布风作用偏移反应塔中心的程度较20um的高。同时研究发现,在没有颗粒破碎和碰撞模拟的情况下大于70um的部分颗粒约有20-30%的Cu_2S仍然未反应。
(2)不同风量对闪速吹炼过程的影响研究。在不同的分布风条件下,反应塔内的高温区域也不相同,分布风量为1059Nm~3/h较风量为765Nm~3/h的高温区域更大,而且中央区域的Cu_2S氧化程度较高。同时通过对1294Nm~3/h与1059Nm~3/h的分布风对比中可以看出,过高的分布风导致颗粒过度偏移反应塔中心,造成中央喷嘴下方O_2浓度过高。颗粒束中心区域Cu_2O生成较多,而颗粒束外侧区域由于氧气不足,导致其氧化不完全。因此在研究的模拟条件下,建议分布风控制在1059Nm~3/h附近。
(3)通过对不同中央氧量的比较发现,中央氧为166Nm~3/h较498Nm~3/h的工况颗粒温度高温区域较小,而且较少的中央氧容易导致颗粒束中心区域更容易存在未反应的Cu_2S。从有无燃烧风模拟的比较发现,在没有燃烧风的工艺条件下,颗粒反应较慢,氧化程度不及有燃烧风的情况。
Copper Flash Smelting - Flash converting technology companies and the United States Kennecott-Outokumpu companies to develop copper technology (hereinafter referred to as "dual flash" process.) In 1995, the "dual flash" process in the United States Utah smelter was put into industrial production. Production practice shows that the "dual flash" flash smelting technology and the traditional converting of converter technology-PS compared with the clean, efficient, small investment, production cost is low. While domestic enterprises are the recent selection of new copper "dual flash" process, so the converting process simulation of flash to simulate the converting process for the study of flash has some practical significance.
With the development of technology, computer simulation technology gradually introduced to the metallurgical process simulation, it is considered to be of metallurgical process means the first 3. Introduction of metallurgy CFD technology has played a test for the traditional industries to save costs and reduce the role of testing time. Therefore, the use of CFD technology to the process of flash converting a better solution to the traditional research can not be flash furnace converting the issue within the regional monitoring, for the converting process of Flash offers an effective means of technology through the CFD We can study the impact of copper flash smelting process of converting the various constraints.
This study is the use of UDF in Fluent combustion modeling flash function to add converting simulation model with different particle diameter, different processes components, different central oxygen, with or without burning air and so the simulation. Under these conditions, the study converting through the flash furnace Ge field and particle simulation, gives the particle temperature, oxidation, particle velocity, the survival time and the distribution of sedimentation tanks. This study details the ways and means of simulation, this converting process simulation for the flash to provide a better solution. Mainly for the research and findings are the following:
(1) particle behavior and the degree of oxidation of particles in the same conditions for a variety of simulated conditions found in separate particles, 150um 20um particles than particles slow rise in temperature, oxidation low, but the particles 150um offset by the distribution of wind over the extent of reaction tower center 20um high. Also found that, in the absence of particle breakage and collision simulation is greater than 70um some cases about 20-30% of the Cu_2S particles remain unreacted.
(2) The amount of wind converting on the flash process of research. The distribution in different wind conditions, the reaction tower is not the same high-temperature region, the distribution air volume 1059Nm~3 / h air volume than 765Nm~3 / h of heat a larger area, and the central region of the Cu_2S higher degree of oxidation. At the same time by 1294Nm~3 / h and 1059Nm~3 / h compared the distribution of the wind can be seen, the distribution of high winds led to over-shift reaction tower center of particles, resulting in high concentrations of O_2 below the central nozzle. Cu_2O particle beam generated more central region, while the particle beam outside the region due to lack of oxygen, resulting in incomplete oxidation. Therefore, under simulated conditions in the study, the proposed distribution of air control in the 1059Nm~3 / h near.
(3) Comparison of different oxygen found in the central, central oxygen as 166Nm~3 / h over 498Nm~3 / h the temperature of the hot zone conditions smaller particles, and less prone to the central oxygen particle beam central region there are not more likely to respond the Cu_2S. Whether the combustion air from the comparison between the simulation, the wind in the absence of combustion conditions, the particles slow reaction, oxidation is less than a burning wind of the situation.
引文
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