The variation characteristics of bubble morphology and the thermal-physical properties of bubble boundary in the top-blown smelting furnace were explored by means of the computational fluid dynamics method.The essenti...The variation characteristics of bubble morphology and the thermal-physical properties of bubble boundary in the top-blown smelting furnace were explored by means of the computational fluid dynamics method.The essential aspects of the fluid phase(e.g.,splashing volume,dead zone of copper slag,and gas penetration depth)were explored together with the effect of sinusoidal pulsating gas intake on the momentum-transfer performance between phases.The results illustrated that two relatively larger vortices and two smaller vortices appear in the bubble waist and below the lance,respectively.The expansion of larger ones as well as the shrinking of smaller ones combine to cause the contraction of the bubble waist.Compared to the results of the case with a fixed gas injection velocity(V_(g)=58 m/s),the splashing volume and dead zone volume of the slag under the V_(g)=58+10sin(2πt)condition are reduced by 24.9%and 23.5%,respectively,where t represents the instant time.Gas penetration depth and slag motion velocity of the latter are 1.03 and 1.31 times high-er than those of the former,respectively.展开更多
Mathematical model for mass transfer of chemical reactions on the surface of the smelting bath pit in oxygen top blown smelting furnace was put forward. Additionally, one of two mathematical models for mass transfer o...Mathematical model for mass transfer of chemical reactions on the surface of the smelting bath pit in oxygen top blown smelting furnace was put forward. Additionally, one of two mathematical models for mass transfer of chemical reactions forming copper matte in smelting bath and the other for parameters of smelting process were developed. The verification tests were simultaneously carried out in a pilot scale furnace and the experimental results show that these mathematical models are convincing. Thus, these numerical models are reliable to simulate pyritic smelting process for copper nickel mineral in oxygen top blown furnace.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 numerical simulation analysis for reactions of chalcopyrite and pyriteparticles coupled with momentum, heat and mass transfer between the particle and gas in a flashsmelting furnace is presented. In the simulation, ...A numerical simulation analysis for reactions of chalcopyrite and pyriteparticles coupled with momentum, heat and mass transfer between the particle and gas in a flashsmelting furnace is presented. In the simulation, the equations governing the gas flow are solvednumerically by Eular method. The particle phase is introduced into the gas flow by theparti-cle-source-in-cell technique (PSIC). Predictions including the fluid flow field, temperaturefield, concentration field of gas phase and the tracks of particles have been obtained by thenumerical simulation. The visualized results show that the reaction of sulfide particles is almostcompleted in the upper zone of the shaft within 1.5 m far from the central jet distributor (CJD)type concentrate burner. The simulation results are in good agreement with data obtained from aseries of experiments and tests in the plant and the error is less than 2%.展开更多
A monitoring method that has been designed for the first time for blast furnace wall with copper staves manufactured in China was introduced. Combining the method of ＂inverse problem＂ and the concept ＂non-inverse p...A monitoring method that has been designed for the first time for blast furnace wall with copper staves manufactured in China was introduced. Combining the method of ＂inverse problem＂ and the concept ＂non-inverse problem＂, the monitoring program for blast furnace wall with copper staves has been realized, which can be used to calculate online the accretion thickness and temperature of hot surface of copper staves after obtaining the values of thermocouples of copper staves. The accretion state obtained in the actual investigation has proved that the result of the program is correct. The monitoring program shows that the accretion would easily fluctuate when the accretion layer is extremely thick or thin, thereby the stable and smooth operation of the blast furnace is hindered. By maintaining appropriate accretion thickness, both long campaigns and high productivity of the blast furnace can be achieved; furthermore, it can also optimize the operation of blast furnace and maximize its production. Approximately 30--50 mm in thickness of accretion layer is maintained on the wall of Shougang blast furnace 2, which can meet the requirement for obtaining both long campaign and high productivity.展开更多
The quantificational and normative design is the precondition of improving the design of copper staves for blast furnaces. Based on a 3-dimensional temperature field calculation model, from the view point of heat tran...The quantificational and normative design is the precondition of improving the design of copper staves for blast furnaces. Based on a 3-dimensional temperature field calculation model, from the view point of heat transfer and long campaigns note with the core of forming accretion, the forming-accretion-ability （FAA） and the rib hot surface maximum temperature difference （ATmax） as quantificational indexes to direct and evaluate the design of copper staves for blast furnaces were presented. The application of the two indexes in design essentially embodies the new long campaigns in the stage of design. With the application of the two indexes, good results can be obtained. Firstly, it was suggested that the rib height of a copper stave can be reduced to 15 mm, which is a new method and theory for the reduction of copper staves. Secondly, the influence of insert on FAA and ATmax, is decided by the volume of insert. According to this, the principle of design for the hot surface geometry of copper staves was put forward that the ratio of the rib hot surface to the copper stave hot surface （abbreviated as the ratio of rib to stave） must be maintained in the range of 45% to 55%; for the present copper stave with a 35-40 mm thick rib, the ratio of rib to stave in the range of 50% to 55% can optimize the design of copper staves; for the copper stave with a smaller rib thickness, for example 15 ram, the ratio of rib to stave in the range of 45% to 50% can optimize the design of copper staves. It can be summarized that the thicker the rib thickness, the larger is the ratio of rib to stave. 2008 University of Science and Technology Beijing. All rights reserved.展开更多
Fluid flow, heat transfer and combustion in Jinlong CJD concentrate burnerflash smelting furnace have been investigated by numerical modeling and flow visualization. Themodeling is based on the Eulerian approach for t...Fluid flow, heat transfer and combustion in Jinlong CJD concentrate burnerflash smelting furnace have been investigated by numerical modeling and flow visualization. Themodeling is based on the Eulerian approach for the gas flow equations and the Lagrangian approachfor the particles. Interaction between the gas phase and particle phase, such as frictional forces,heat and mass transfer, are included by the addition of sources and sinks. The modeling resultsincluding the fluid flow field, temperature field, concentration field of gas phase and thetrajectories of particles have been obtained. The predicted results are in good agreement with thedata obtained from a series of experiments and tests in the Jinlong Copper Smelter and thetemperature error is less than 20 K.展开更多
The software that simulates the flow, temperature, concentration and the heat generation field in the Outkumpu flash smelting furnace, was developed by a numerical method of the particle-gas flow together with some ch...The software that simulates the flow, temperature, concentration and the heat generation field in the Outkumpu flash smelting furnace, was developed by a numerical method of the particle-gas flow together with some chemical reaction models. Many typical operating conditions were chosen for simulation in order to obtain the effect of the distribution air, process air, central oxygen and the oil-burner position etc. The concepts about optimum operation, 3C(concentration of high temperature, high oxygen and laden concentrate particles), are concluded from these simulated results, which have been checked primarily by operational experiments.展开更多
A mathematical model has been presented to study the combustion of a single copper concentrate particle with high moisture content. By using the presented model, the effect of particle moisture content on particle tem...A mathematical model has been presented to study the combustion of a single copper concentrate particle with high moisture content. By using the presented model, the effect of particle moisture content on particle temperature, sulfur oxidation, and combustion heat generation has been evaluated. The mineralogical composition of the commonly used concentrate at Khatoonabad flash smelting furnace has been used in this study. It was found that the particle moisture content is removed in the sub-second time range and thus the moisture has marginal impact on the variation of particle temperature and on the reaction rate when the gas temperature is assumed to be constant in the reaction shaft. When a concentrate with high moisture content is charged, the particle size enlargement due to the agglomeration of concentrate particles causes an abrupt fall in the particle reaction rate.展开更多
A mathematical model of multistage and multiphase reactions in flash smelting furnace, which based on the description of chemical reactions and reaction rate, is presented. In this model, main components of copper con...A mathematical model of multistage and multiphase reactions in flash smelting furnace, which based on the description of chemical reactions and reaction rate, is presented. In this model, main components of copper concentrate are represented as FeS 2 and CuFeS based on experiment, intermediate products are assumed to be S 2 and FeS, and the final products are assumed as FeS, FeO, SO 2, Cu 2S, FeO and FeO(SiO 2) 2. The model incorporates the transport of momentum, heat and mass, reaction kinetics between gas and particles, and reactions between gas and gas. The k-ε model is used to describe gas phase turbulence. The model uses the Eulerian approach for the gas flow equations and the Lagrangian approach for the particles. The coupling of gas and particle equations is performed through the particle source in cell(PSIC) method. Comparison between the model predictions and the plant measurements shows that the model has high reliability and accuracy.展开更多
An experiment of a new type full size copper stave for a real blast furnacewas carried out in a special-designed experimental system. The 3-D temperature distribution insidethe stave including isotherm was obtained ba...An experiment of a new type full size copper stave for a real blast furnacewas carried out in a special-designed experimental system. The 3-D temperature distribution insidethe stave including isotherm was obtained based on the experiment data. And the effects of thetemperature of cooling water and the velocity of the water as well as the temperature of the furnaceon the 3-D temperature distribution were obtained. The experimental and calculation results showthat the highest temperature of the hot surface is lower than 90 deg C which is very good for thesolidified slag formation on the hot surface and protecting the stave.展开更多
Copper staves have been equipped on nearly all of BF （blast furnaces） with volume over than 1000 m3 in China since their introduction from abroad about more than 10 years ago. Because of short application and lack o...Copper staves have been equipped on nearly all of BF （blast furnaces） with volume over than 1000 m3 in China since their introduction from abroad about more than 10 years ago. Because of short application and lack of experience, phenomena of thickened or naked of copper stave happen occasionally which influence production severely. So it is important to study the model of forming-accretion on BF copper stave and realize real-time monitoring of forming-accretion on different copper staves. Therefore, mathematic model of calculating accretion thickness by heat flow of BF is proposed, and the calculated results indicate that accretion thickness could be kept at a reasonable range of around 50 mm by controlling heat flux around 22.0 kW/mz. The monitoring program based on the model was applied to a certain BF in China successfully, and it is found that slip of BF near the inner wall is one of most important reasons that cause fluctuation of accretion thickness. During the period of scheduled maintenance of the certain BF, the thickness of accretion measured through the static pressure holes is in good accordance with the value calculated by the monitoring program, so the results calculated by the monitoring program can be used to guide industrial production展开更多
基金the Applied Basic Research Project of Yunnan Province,China(No.202301 AT070411).
文摘The variation characteristics of bubble morphology and the thermal-physical properties of bubble boundary in the top-blown smelting furnace were explored by means of the computational fluid dynamics method.The essential aspects of the fluid phase(e.g.,splashing volume,dead zone of copper slag,and gas penetration depth)were explored together with the effect of sinusoidal pulsating gas intake on the momentum-transfer performance between phases.The results illustrated that two relatively larger vortices and two smaller vortices appear in the bubble waist and below the lance,respectively.The expansion of larger ones as well as the shrinking of smaller ones combine to cause the contraction of the bubble waist.Compared to the results of the case with a fixed gas injection velocity(V_(g)=58 m/s),the splashing volume and dead zone volume of the slag under the V_(g)=58+10sin(2πt)condition are reduced by 24.9%and 23.5%,respectively,where t represents the instant time.Gas penetration depth and slag motion velocity of the latter are 1.03 and 1.31 times high-er than those of the former,respectively.
文摘Mathematical model for mass transfer of chemical reactions on the surface of the smelting bath pit in oxygen top blown smelting furnace was put forward. Additionally, one of two mathematical models for mass transfer of chemical reactions forming copper matte in smelting bath and the other for parameters of smelting process were developed. The verification tests were simultaneously carried out in a pilot scale furnace and the experimental results show that these mathematical models are convincing. Thus, these numerical models are reliable to simulate pyritic smelting process for copper nickel mineral in oxygen top blown furnace.
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.
文摘A numerical simulation analysis for reactions of chalcopyrite and pyriteparticles coupled with momentum, heat and mass transfer between the particle and gas in a flashsmelting furnace is presented. In the simulation, the equations governing the gas flow are solvednumerically by Eular method. The particle phase is introduced into the gas flow by theparti-cle-source-in-cell technique (PSIC). Predictions including the fluid flow field, temperaturefield, concentration field of gas phase and the tracks of particles have been obtained by thenumerical simulation. The visualized results show that the reaction of sulfide particles is almostcompleted in the upper zone of the shaft within 1.5 m far from the central jet distributor (CJD)type concentrate burner. The simulation results are in good agreement with data obtained from aseries of experiments and tests in the plant and the error is less than 2%.
基金Item Sponsored by National Natural Science Foundation of China(60472095)
文摘A monitoring method that has been designed for the first time for blast furnace wall with copper staves manufactured in China was introduced. Combining the method of ＂inverse problem＂ and the concept ＂non-inverse problem＂, the monitoring program for blast furnace wall with copper staves has been realized, which can be used to calculate online the accretion thickness and temperature of hot surface of copper staves after obtaining the values of thermocouples of copper staves. The accretion state obtained in the actual investigation has proved that the result of the program is correct. The monitoring program shows that the accretion would easily fluctuate when the accretion layer is extremely thick or thin, thereby the stable and smooth operation of the blast furnace is hindered. By maintaining appropriate accretion thickness, both long campaigns and high productivity of the blast furnace can be achieved; furthermore, it can also optimize the operation of blast furnace and maximize its production. Approximately 30--50 mm in thickness of accretion layer is maintained on the wall of Shougang blast furnace 2, which can meet the requirement for obtaining both long campaign and high productivity.
基金the National Natural Science Foundation of China(No.60672145).
文摘The quantificational and normative design is the precondition of improving the design of copper staves for blast furnaces. Based on a 3-dimensional temperature field calculation model, from the view point of heat transfer and long campaigns note with the core of forming accretion, the forming-accretion-ability （FAA） and the rib hot surface maximum temperature difference （ATmax） as quantificational indexes to direct and evaluate the design of copper staves for blast furnaces were presented. The application of the two indexes in design essentially embodies the new long campaigns in the stage of design. With the application of the two indexes, good results can be obtained. Firstly, it was suggested that the rib height of a copper stave can be reduced to 15 mm, which is a new method and theory for the reduction of copper staves. Secondly, the influence of insert on FAA and ATmax, is decided by the volume of insert. According to this, the principle of design for the hot surface geometry of copper staves was put forward that the ratio of the rib hot surface to the copper stave hot surface （abbreviated as the ratio of rib to stave） must be maintained in the range of 45% to 55%; for the present copper stave with a 35-40 mm thick rib, the ratio of rib to stave in the range of 50% to 55% can optimize the design of copper staves; for the copper stave with a smaller rib thickness, for example 15 ram, the ratio of rib to stave in the range of 45% to 50% can optimize the design of copper staves. It can be summarized that the thicker the rib thickness, the larger is the ratio of rib to stave. 2008 University of Science and Technology Beijing. All rights reserved.
文摘Fluid flow, heat transfer and combustion in Jinlong CJD concentrate burnerflash smelting furnace have been investigated by numerical modeling and flow visualization. Themodeling is based on the Eulerian approach for the gas flow equations and the Lagrangian approachfor the particles. Interaction between the gas phase and particle phase, such as frictional forces,heat and mass transfer, are included by the addition of sources and sinks. The modeling resultsincluding the fluid flow field, temperature field, concentration field of gas phase and thetrajectories of particles have been obtained. The predicted results are in good agreement with thedata obtained from a series of experiments and tests in the Jinlong Copper Smelter and thetemperature error is less than 20 K.
文摘The software that simulates the flow, temperature, concentration and the heat generation field in the Outkumpu flash smelting furnace, was developed by a numerical method of the particle-gas flow together with some chemical reaction models. Many typical operating conditions were chosen for simulation in order to obtain the effect of the distribution air, process air, central oxygen and the oil-burner position etc. The concepts about optimum operation, 3C(concentration of high temperature, high oxygen and laden concentrate particles), are concluded from these simulated results, which have been checked primarily by operational experiments.
文摘A mathematical model has been presented to study the combustion of a single copper concentrate particle with high moisture content. By using the presented model, the effect of particle moisture content on particle temperature, sulfur oxidation, and combustion heat generation has been evaluated. The mineralogical composition of the commonly used concentrate at Khatoonabad flash smelting furnace has been used in this study. It was found that the particle moisture content is removed in the sub-second time range and thus the moisture has marginal impact on the variation of particle temperature and on the reaction rate when the gas temperature is assumed to be constant in the reaction shaft. When a concentrate with high moisture content is charged, the particle size enlargement due to the agglomeration of concentrate particles causes an abrupt fall in the particle reaction rate.
文摘A mathematical model of multistage and multiphase reactions in flash smelting furnace, which based on the description of chemical reactions and reaction rate, is presented. In this model, main components of copper concentrate are represented as FeS 2 and CuFeS based on experiment, intermediate products are assumed to be S 2 and FeS, and the final products are assumed as FeS, FeO, SO 2, Cu 2S, FeO and FeO(SiO 2) 2. The model incorporates the transport of momentum, heat and mass, reaction kinetics between gas and particles, and reactions between gas and gas. The k-ε model is used to describe gas phase turbulence. The model uses the Eulerian approach for the gas flow equations and the Lagrangian approach for the particles. The coupling of gas and particle equations is performed through the particle source in cell(PSIC) method. Comparison between the model predictions and the plant measurements shows that the model has high reliability and accuracy.
文摘An experiment of a new type full size copper stave for a real blast furnacewas carried out in a special-designed experimental system. The 3-D temperature distribution insidethe stave including isotherm was obtained based on the experiment data. And the effects of thetemperature of cooling water and the velocity of the water as well as the temperature of the furnaceon the 3-D temperature distribution were obtained. The experimental and calculation results showthat the highest temperature of the hot surface is lower than 90 deg C which is very good for thesolidified slag formation on the hot surface and protecting the stave.
文摘Copper staves have been equipped on nearly all of BF （blast furnaces） with volume over than 1000 m3 in China since their introduction from abroad about more than 10 years ago. Because of short application and lack of experience, phenomena of thickened or naked of copper stave happen occasionally which influence production severely. So it is important to study the model of forming-accretion on BF copper stave and realize real-time monitoring of forming-accretion on different copper staves. Therefore, mathematic model of calculating accretion thickness by heat flow of BF is proposed, and the calculated results indicate that accretion thickness could be kept at a reasonable range of around 50 mm by controlling heat flux around 22.0 kW/mz. The monitoring program based on the model was applied to a certain BF in China successfully, and it is found that slip of BF near the inner wall is one of most important reasons that cause fluctuation of accretion thickness. During the period of scheduled maintenance of the certain BF, the thickness of accretion measured through the static pressure holes is in good accordance with the value calculated by the monitoring program, so the results calculated by the monitoring program can be used to guide industrial production
