A computational fluid dynamics （CFD） simulation was carried out with CFX4,3 to investigate the melt flow and temperature distributions in the settler of a flash furnace. Sixteen cases of one slag tap hole adopted wi...A computational fluid dynamics （CFD） simulation was carried out with CFX4,3 to investigate the melt flow and temperature distributions in the settler of a flash furnace. Sixteen cases of one slag tap hole adopted with one matte tap hole （1-to-l） and one slag tap hole adopted with two matte tap holes （1-to-2） operation modes were modelled. The simulation results show that the melt flows are similar in both two operation modes, but evident circulations can be found in the case of the 1-to-2 operation mode. The combination modes of the slag and matte tap holes are found to have a significant effect on the temperature distributions of the melt. The melt temperature is more uniform in the case of the 1-to-2 mode. Selection of a matte tap hole farther away from the inlet is more conducive to achieve a uniform distribution of the melt temperature in the settler in nractical tannine oneration展开更多
According to the innate characteristic of four types of furnace, the copper flash continuous smelting （CFCS） furnace can be considered a synthetic reactor of two relatively independent processes： flash matte smelti...According to the innate characteristic of four types of furnace, the copper flash continuous smelting （CFCS） furnace can be considered a synthetic reactor of two relatively independent processes： flash matte smelting process （FMSP） and copper continuous converting process （CCCP）. Then, the CFCS thermodynamic model was proposed by establishing the multi-phase equilibrium model of FMSP and the local-equilibrium model of CCCP, respectively, and by combining them through the smelting intermediates. Subsequently, the influences of the furnace structures were investigated using the model on the formation of blister copper, the Fe3O4 behavior, the copper loss in slag and the copper recovery rate. The results show that the type D furnace, with double flues and a slag partition wall, is an ideal CFCS reactor compared with the other three types furnaces. For CFCS, it is effective to design a partition wall in the furnace to make FMSP and CCCP perform in two relatively independent zones, respectively, and to make smelting gas and converting gas discharge from respective flues.展开更多
A mathematical model of the particle heating process in the reaction shaft of flash smelting furnace was established and the calculation was performed.The results indicate that radiation plays a significant role in th...A mathematical model of the particle heating process in the reaction shaft of flash smelting furnace was established and the calculation was performed.The results indicate that radiation plays a significant role in the heat transfer process within the first 0.6 m in the upper part of the reaction shaft,whilst the convection is dominant in the area below 0.6 m for the particle heating.In order to accelerate the particle ignition,it is necessary to enhance the convection,thus to speed up the particle heating.A high-speed preheated oxygen jet technology was then suggested to replace the nature gas combustion in the flash furnace,aiming to create a lateral disturbance in the gaseous phase around the particles,so as to achieve a slip velocity between the two phases and a high convective heat transfer coefficient.Numerical simulation was carried out for the cases with the high-speed oxygen jet and the normal nature gas burners.The results show that with the high-speed jet technology,particles are heated up more rapidly and ignited much earlier,especially within the area of the radial range of R=0.3−0.6 m.As a result,a more efficient smelting process can be achieved under the same operational condition.展开更多
The copper flash smelting process is characterized by its involvement of wide energy sources and high energy consumption, so the energy conservation is usually a highly concerned topic for the flash smelting enterpris...The copper flash smelting process is characterized by its involvement of wide energy sources and high energy consumption, so the energy conservation is usually a highly concerned topic for the flash smelting enterprises. However, due to the complexity of the system, it is quite difficult to perform a timely comprehensive analysis of the energy consumption of the whole production system. Aiming to realize an online assessment of the energy consumption of the system, great effort was first made in Jinguan Copper, Tongling Nonferrous Metals Group Co. Ltd. Methods were proposed to solve technical difficulties such as the acquisition and processing of data with different sampling frequencies, the online evaluation of the electricity consumption, and timely evaluation of product output in the periodic process. As a result, a software system was developed to make the online analysis of the energy consumption and efficiency from the three levels ranging from the system to the equipment. The analytical results at the system level was introduce. It’s found that electricity is the most consumed energy in the system, accounting for 77.3% of the total energy consumption. The smelting unit has the highest energy consumption, accounting for 52.8% of the total energy consumed in the whole enterprise.展开更多
An experimental model of maldistribution was established and grey correlation analysis method was employed to describe quantitatively the maldistribution phenomenon in the feeding device of copper flash smelting.Parti...An experimental model of maldistribution was established and grey correlation analysis method was employed to describe quantitatively the maldistribution phenomenon in the feeding device of copper flash smelting.Particle motion in the feeding device was separated into uniform flow in chute and restricted slanting parabolic motion in distributor channel.Factors affecting particle velocity at the chute outlet and particle moving distance in the distributor channel,which also cause the maldistribution,were analyzed based on the assumption of pseudo fluid.Experiments were conducted to study the maldistribution using river sand.The results indicate obvious mass maldistribution and an even higher degree with the increase of feeding mass rate;meanwhile,size maldistribution is negligible.Also,feeding intensity has a larger impact on circumferential maldistribution than on radial maldistribution.Based on the experimental results of the eight factors impacting the maldistribution,grey relation of each factor was calculated using grey correlation analysis.The importances of these factors were sequenced.The results show that a proper adjustment of the structure will ameliorate the maldistribution phenomenon in the feeding device of copper flash smelting.展开更多
基金Project (2002AA00104) supported by the National High-tech Research and Development Program of China
文摘A computational fluid dynamics （CFD） simulation was carried out with CFX4,3 to investigate the melt flow and temperature distributions in the settler of a flash furnace. Sixteen cases of one slag tap hole adopted with one matte tap hole （1-to-l） and one slag tap hole adopted with two matte tap holes （1-to-2） operation modes were modelled. The simulation results show that the melt flows are similar in both two operation modes, but evident circulations can be found in the case of the 1-to-2 operation mode. The combination modes of the slag and matte tap holes are found to have a significant effect on the temperature distributions of the melt. The melt temperature is more uniform in the case of the 1-to-2 mode. Selection of a matte tap hole farther away from the inlet is more conducive to achieve a uniform distribution of the melt temperature in the settler in nractical tannine oneration
基金Project (50904027) supported by the National Natural Science Foundation of ChinaProject (2013BAB03B05) supported by the National Key Technology R&D Program of China+1 种基金Project (20133BCB23018) supported by the Foundation for Young Scientist(Jinggang Star)of Jiangxi Province,ChinaProject (2012ZBAB206002) supported by the Natural Science Foundation of Jiangxi Province,China
文摘According to the innate characteristic of four types of furnace, the copper flash continuous smelting （CFCS） furnace can be considered a synthetic reactor of two relatively independent processes： flash matte smelting process （FMSP） and copper continuous converting process （CCCP）. Then, the CFCS thermodynamic model was proposed by establishing the multi-phase equilibrium model of FMSP and the local-equilibrium model of CCCP, respectively, and by combining them through the smelting intermediates. Subsequently, the influences of the furnace structures were investigated using the model on the formation of blister copper, the Fe3O4 behavior, the copper loss in slag and the copper recovery rate. The results show that the type D furnace, with double flues and a slag partition wall, is an ideal CFCS reactor compared with the other three types furnaces. For CFCS, it is effective to design a partition wall in the furnace to make FMSP and CCCP perform in two relatively independent zones, respectively, and to make smelting gas and converting gas discharge from respective flues.
基金funded by Jinguan Copper of Tongling Non-ferrous Metals Group Co., Ltd.
文摘A mathematical model of the particle heating process in the reaction shaft of flash smelting furnace was established and the calculation was performed.The results indicate that radiation plays a significant role in the heat transfer process within the first 0.6 m in the upper part of the reaction shaft,whilst the convection is dominant in the area below 0.6 m for the particle heating.In order to accelerate the particle ignition,it is necessary to enhance the convection,thus to speed up the particle heating.A high-speed preheated oxygen jet technology was then suggested to replace the nature gas combustion in the flash furnace,aiming to create a lateral disturbance in the gaseous phase around the particles,so as to achieve a slip velocity between the two phases and a high convective heat transfer coefficient.Numerical simulation was carried out for the cases with the high-speed oxygen jet and the normal nature gas burners.The results show that with the high-speed jet technology,particles are heated up more rapidly and ignited much earlier,especially within the area of the radial range of R=0.3−0.6 m.As a result,a more efficient smelting process can be achieved under the same operational condition.
基金Project(1301021018) supported by Science and Technology Research Project of Anhui Province,China
文摘The copper flash smelting process is characterized by its involvement of wide energy sources and high energy consumption, so the energy conservation is usually a highly concerned topic for the flash smelting enterprises. However, due to the complexity of the system, it is quite difficult to perform a timely comprehensive analysis of the energy consumption of the whole production system. Aiming to realize an online assessment of the energy consumption of the system, great effort was first made in Jinguan Copper, Tongling Nonferrous Metals Group Co. Ltd. Methods were proposed to solve technical difficulties such as the acquisition and processing of data with different sampling frequencies, the online evaluation of the electricity consumption, and timely evaluation of product output in the periodic process. As a result, a software system was developed to make the online analysis of the energy consumption and efficiency from the three levels ranging from the system to the equipment. The analytical results at the system level was introduce. It’s found that electricity is the most consumed energy in the system, accounting for 77.3% of the total energy consumption. The smelting unit has the highest energy consumption, accounting for 52.8% of the total energy consumed in the whole enterprise.
基金Project(2010AA065201) supported by the National High Technology Research and Development Program of China
文摘An experimental model of maldistribution was established and grey correlation analysis method was employed to describe quantitatively the maldistribution phenomenon in the feeding device of copper flash smelting.Particle motion in the feeding device was separated into uniform flow in chute and restricted slanting parabolic motion in distributor channel.Factors affecting particle velocity at the chute outlet and particle moving distance in the distributor channel,which also cause the maldistribution,were analyzed based on the assumption of pseudo fluid.Experiments were conducted to study the maldistribution using river sand.The results indicate obvious mass maldistribution and an even higher degree with the increase of feeding mass rate;meanwhile,size maldistribution is negligible.Also,feeding intensity has a larger impact on circumferential maldistribution than on radial maldistribution.Based on the experimental results of the eight factors impacting the maldistribution,grey relation of each factor was calculated using grey correlation analysis.The importances of these factors were sequenced.The results show that a proper adjustment of the structure will ameliorate the maldistribution phenomenon in the feeding device of copper flash smelting.
