电解铝厂制造执行系统软件——SmelterStar

综合自动化技术的应用是提高电解铝企业竞争力的有效手段,当前电解铝厂的过程控制已经基本实现,而制造执行系统的建设则是未来电解铝厂综合自动化发展的必经之路,本文介绍了沈阳铝镁设计研究院有限公司自主研发的具有完全知识产权的电解铝厂制造执行系统软件——SmelterStar。

Pressure leaching technique of smelter dust with high-copper and high-arsenic

The application of pressure leaching technology in the treatment of high-copper and high-arsenic dust was studied.The pressure leaching technique was determined as follows:the liquid to solid ratio(mL/g)of 5:1,the leaching temperature of 453 K,the retention time of 2 h,the initial sulfuric acid concentration of 0.74 mol/L,the oxygen partial pressure of 0.7 MPa,and the agitation speed of 500 r/min.Under these conditions,95%of copper and 99%of zinc and only 6%of iron in the dust were leached,while about 20%of arsenic was also leached.The leaching technique was optimized further to restrain the leaching of arsenic by adding a small quantity of ferrous iron into the leaching system(c(Fe2 +)=0.036 mol/L).Copper and zinc can be effectively separated from arsenic and iron in the leach.The optimal pressure leaching technique of high-copper and high-arsenic smelter dust is proved to be effective.

Behavior, distribution and environmental influence of arsenic in a typical lead smelter

A field study was conducted to determine the behavior and distribution of arsenic during the pyrometallurgy process in a typical SKS(Shuikoushan) lead smelter in Hunan province, China. Environmental influences of arsenic in selected samples were evaluated. Arsenic contents in all input and output samples vary from 0.11% in raw lead to 6.66% in collected dust-2. More arsenic is volatilized in blast furnace and fuming furnace(73.02% of arsenic input) than bottom blowing furnace(10.29% of arsenic input).There are 78.97%, 13.69%, 7.31% of total arsenic distributed in intermediate materials, stockpiled materials and unorganized emissions, respectively. Matte slag-2, collected dust-1 and secondary zinc oxide are hazardous based on the arsenic concentrations of toxicity characteristic leaching procedure. According to risk assessment code(RAC) guideline, arsenic in collected dust-1 poses a very serious risk to the surrounding environment, arsenic in speiss, matte slag-2, water-quenched slag and secondary zinc oxide show low risk, while arsenic in matte slag-1, collected dust-2 and post dust has no risk to the environment.

ANINTELLIGENT DECISION SUPPORTSYSTEM（IDSS） ONTHEPROCESSOFNICKELMATTESMELTER

This paper describes the structure and function of the intelligent decision support system (IDSS) on the process of nickel matte smelter. The knowledge and model base system based on fuzzy-decision rules ale specially suggested. The IDSS possesses the self-learning and adaptive properties, andhas been used for managing and analyzing the production information, optimizing the composition of the charge mixture, and deciding the optimal operational conditions. Electric energy consumption has been reduced remarkably and the yield of nickel has been increased.

Preparation of Granulated Adsorption Material of Water-quenched Slag/rectorite Composite for Removal of Cu(Ⅱ)Ions from Copper Smelter Wastewater

The preparation of granulated adsorption material of water-quenched slag/rectorite composite and the treatment of Cu （ Ⅱ ）-containing copper smelter wastewater with the adsorption material were studied. The experimental results showed that under the conditions with the mass ratio of water-quenched slag to rectorite of 1：1, 10% additive of industrial starch （IS）, and 50% water, and a calcination temperature of 400 ℃, the granulated adsorption material prepared had a density of 1.06 kg/m^3, a porosity of 62.29%, water absorption rate of 58.82%, and compressive strength of 2.22 MPa. The efficiency of wastewater treatment was the best, whereas the rate of spallation loss was low. Under the conditions of natural pH, with the addition of the granulated adsorption material of 0.05 g/mL, a reaction time of 40 minutes, and temperature of 25 ℃, the efficiency of the granulated adsorption material for the removal of Cu （ Ⅱ ） ions from the copper smelter wastewater attained 98.2%, and the quality indexes of the wastewater after treatment conformed with the first level of integrated wastewater discharge standard （GB8978-1996）. The reclamation of the used granulated adsorption material was carried out by de-sorption of the Cu （ Ⅱ） ions from the surface with 1 mol/L sodium chloride solution. The de-sorption rate was 96.4%, and the adsorption material can be reused many times to treat copper smelter wastewater.

Occupational Exposure to Indium of Indium Smelter Workers

Case reports of indium-related lung disease in workers have raised public concern to the human toxicity of indium （In） and its compounds. However, studies evaluating the exposure or health of workers in In smelting plants are rare. Therefore, in this study, we focused on four In smelting plants, with the main objective of characterizing In in smelter plants in China and discussing the potential exposure biomarkers of In exposure.

Flow and Heat Transfer of Basalt Melt in the Feeder of the Smelter Furnace

The flow and heat transfer of the basalt melt in the boundary layer on a flat plate is considered. The conditions of formation of the layer and the intensity of heat transfer are determined. A self-similar analysis using the symmetry method was used. A system of ordinary differential equations in self-similar form is obtained. The fluid flow and heat transfer of molten basalt at a laminar steady-state flow in the feeder furnaces are numerically researched. The term “protective layer” on the interface “basalt melt-lining” is introduced. The dependences for the calculation of dimensionless shear stresses and the Nusselt number on the lining surface are obtained. The conditions of rational organization of the technological process of basalt melt feeding in the furnace feeder are formulated.

Chemical Characterization of Slags from an Old Smelter in Chihuahua, Mexico

Slag is waste from pyrometallurgical processing, usually stored in stacks or warehouses around or near smelters. Slag research has focused on potential environmental problems associated with slag weathering or processing for secondary metal recovery and/or other uses (construction, landscaping, etc.). Located in northern Mexico, the city of Chihuahua has a mining history that dates back to the eighteenth century. A lead smelter located southeast of Chihuahua City;closed in 1997, leaving behind a large pile of slag. In this study, a chemical analysis of smelter slag was carried out. The tailings contain Zn (15 - 35 wt%), Pb (0.5 - 4 wt%), As (0.6 wt%), Sn (888 ppb) and Hg (170 ppb). XRD identified several minerals such as hardystonite (Ca2ZnSi2O7), melanotekite (), kentrolite () and sphalerite (ZnS) in the glass. Major elements are present in phases such as monticellite (CaMgSiO4), kirschsteinite (CaFe2+SiO4), hedenbergite (CaFe2+Si2O6), babingtonite (Fe2Si3O9), magnetite (Fe3O4), and calcite (CaCO3). Whether the goal is reuse, recycling or remediation, research into the properties of slag and its environmental and health impacts (on vulnerable exposed populations) should continue to be relevant.

SURVEY OF SHENYANG SMELTER

The Shenyang Smelter,which is located in Shenyang,the well-known industrialcity of northeastern China,is one of the most important non-ferrous metallurgicalplants in the people’s Republic of China.Shenyang is the capital of Liaoning Provin-ce,where transportation is very convenient by the railway,and it is connected direc-tly with the famous seaports-Dalian and Tianjin.

Water incubation-induced fluctuating release of heavy metals in two smelter-contaminated soils

The soil moisture regime can affect the release of heavy metals in soil. In the previous studies, slightly polluted soils or artificially contaminated soil samples were considered to investigate the effect of soil moisture. We used highly smelter-contaminated and aged soils to study the release of typical heavy metals(Cu, Zn, Cd and Pb) induced by water incubation in batch experiments with characterization via speciation and X-ray diffraction analyses(XRD). The results show that the leachable concentrations of the heavy metals increased slightly in the first 30 days, decreased drastically between 30 and 90 days, and immobilized relatively constant thereafter. The fluctuation was ascribed to the changes of soil Eh and pH, the reductive dissolution of crystalline iron oxides, the formation of new amorphous iron oxides, the absorption of dissolved organic matter and the precipitation of metal sulfide. Speciation analysis indicated that a proportion of the soil heavy metals was transformed from an exchangeable fraction to a less labile fraction after water incubation. And the presence of a lead iron oxide phase and the peak increasing of zinc sulfide were observed via XRD analyses. Finally, water incubation restrained the release of heavy metals after 180 days of incubation, and reduced the leachability of Cu, Zn, Cd and Pb by as much as 1.61%–7.21% for soil A and 0.43%–3.36% for soil B, respectively. The study findings have implications for the formulation of risk control and management strategies for heavy metals in smelter-contaminated soils.

Flowability of various dusts collected from secondary copper smelter off-gas

Stable flow of off-gas dust from dust collector hoppers and storage silos is important for smooth operation. Flow properties of the collected off-gas dust are critical to achieve suitable flow. Various dust samples collected from secondary copper smelter off-gases were studied. The median diameter of the fine-grained dusts varied from 0.8 to 1.4 μm and the flowability ranged from ＂cohesive＂ to ＂very cohesive＂. The flowa- bility of shaft and anode furnace dust improved slightly with increasing consolidation stress and their wall friction angles decreased, which is a typical behavior. In contrast, the flowability of converter dust decreased with increasing consolidation stress and its wall friction angles increased. Pre-shear treatment of converter dust worsened its flowability, increased the wall friction angle, and improved the flowabil- ity with increasing consolidation stress. This is believed to occur because pre-shear treatment fragments small agglomerates in the dust that improve flowability. The presence of such agglomerates was con- firmed by sieving tests. A diagrammatic representation of the flowability showing that the unconfined yield strength is dependent on consolidation stress can be improved by using logarithmically scaled axes.

Zhuzhou Smelter Group Started Its Zinc-based Material Project With 300000-ton Zinc Alloy Product Line

It is reported that Zhuzhou Smelter Group officially launched its zinc-based material project in Nanzhou Industrial Park, Luzhou District, Zhuzhou, Hunan on March, 7. This project includes zinc alloy product line,galvanizing zinc residue treating system and zinc particle and zinc ball manufacturing system.

Enhancing XRF sensor-based sorting of porphyritic copper ore using particle swarm optimization-support vector machine(PSO-SVM)algorithm

X-ray fluorescence(XRF)sensor-based ore sorting enables efficient beneficiation of heterogeneous ores,while intraparticle heterogeneity can cause significant grade detection errors,leading to misclassifications and hindering widespread technology adoption.Accurate classification models are crucial to determine if actual grade exceeds the sorting threshold using localized XRF signals.Previous studies mainly used linear regression(LR)algorithms including simple linear regression(SLR),multivariable linear regression(MLR),and multivariable linear regression with interaction(MLRI)but often fell short attaining satisfactory results.This study employed the particle swarm optimization support vector machine(PSO-SVM)algorithm for sorting porphyritic copper ore pebble.Lab-scale results showed PSO-SVM out-performed LR and raw data(RD)models and the significant interaction effects among input features was observed.Despite poor input data quality,PSO-SVM demonstrated exceptional capabilities.Lab-scale sorting achieved 93.0%accuracy,0.24%grade increase,84.94%recovery rate,57.02%discard rate,and a remarkable 39.62 yuan/t net smelter return(NSR)increase compared to no sorting.These improvements were achieved by the PSO-SVM model with optimized input combinations and highest data quality(T=10,T is XRF testing times).The unsuitability of LR methods for XRF sensor-based sorting of investigated sample is illustrated.Input element selection and mineral association analysis elucidate element importance and influence mechanisms.

中东铝工业的发展简史——世界铝工业百年兴衰史系列(八)

回顾20世纪70年代以来中东铝工业发展历程。中东是世界石油储量的富集地,两次能源危机使这里的石油生产国成为世界最富有的国家之一,有充足的资金发展铝工业。早期只有巴林和阿联酋(迪拜)大力发展铝工业,成果斐然;进入21世纪,卡塔尔、阿曼、沙特先后进军铝工业,各国大力发展非油气产业和调整经济结构,一批具有国际竞争力的新建铝厂拔地而起。中东电解铝厂全部配套自备电厂,用天然气和燃油发电,与下游铝加工合作等,厂区都有预留,扩建空间足。中东各国铝消费量有限,具有典型的出口导向。

典型冶炼厂场地土壤重金属污染特征及生态风险评价

为了掌握冶炼厂场地土壤环境风险水平,为环境风险管理提供技术依据,以典型冶炼厂为研究对象,分别测定了土壤中As、Cu、Ni、Hg、Pb、Cd和Zn等指标浓度,利用反距离权重插值法研究重金属空间分布特征,运用单因子污染指数法、内梅罗综合指数法、地质累积指数法、潜在生态风险指数法和生态风险预警指数法评价了土壤重金属的污染程度和生态风险水平。结果表明:研究区内所有重金属指标浓度均存在超过GB 15618—2018中的风险筛选值的现象,且具有高度变异性。熔炼区、吹炼及贫化区和仓库区土壤重金属污染最严重。Cd、Pb、Hg、Zn、As和Cu指标的Pi和Pn均处于重度污染等级;Cd、Pb、Hg、Zn、As和Cu指标均存在累积风险。研究区内土壤重金属潜在生态风险指数的范围为10322~68663,均处于极强风险等级;生态风险预警指数为409~2467,均处于重警等级。

铅锌冶炼厂周边土壤的重金属污染现状及研究进展

土壤重金属污染是我国土壤污染的一项重要问题,铅锌冶炼厂周边土壤的重金属污染更是难以治理。本文简要说明了我国的铅锌分布情况以及其对环境污染的严重性,阐述了我国铅锌冶炼厂周边土壤重金属污染的来源、特点和危害,分析了我国各地区及国外部分冶炼厂周边土壤的重金属污染现状,整理了我国现阶段对铅锌冶炼厂周边土壤重金属污染治理的措施,以期为今后的重金属污染防治提供一定的参考。

铜冶炼车间回用水分盐中试试验研究

为实现废水的近零排放和资源化处理,采用“生物制剂与双碱法协同脱钙+反渗透装置浓缩+纳滤装置分盐+电渗析装置浓缩+蒸发结晶装置出盐”工艺处理某铜冶炼车间回用水.结果表明,SO_(4)^(2-)截留率>99%,Na_(2)SO_(4)浓水溶解性总固体(TDS)质量浓度达179 g/L,NaCl浓水TDS质量浓度达150 g/L,浓缩液蒸发结晶后得到Na_(2)SO_(4)与NaCl产品盐.Na_(2)SO_(4)达到GB/T 6009-2014《工业无水硫酸钠》二类合格品要求,NaCl满足GB/T 5462-2015《工业盐质量标准》中一级标准.解决了回用水浓水浓度低、Na_(2)SO_(4)产品为杂盐等问题,为有色行业经济高效地处理高含盐废水奠定了工程化基础.

某铅锌冶炼污染场地基于多源信息的重金属稳定化修复及其评价

冶炼污染场地土壤中多重金属复合污染的特征增大了对土壤的修复和最终利用的难度。本研究深入调查了某铅锌冶炼场地土壤重金属污染特征,针对性地制定多种联合稳定化修复方案,采用高精度混合装备添加药剂,实施稳定化修复工程。结果表明,Cd、Pb、Zn和As是场地土壤中最主要的重金属污染物,其中Cd、Pb、As的超标率分别为75.80%、76.43%、88.54%。重金属的分布模式与土壤理化性质、污染物迁移路径、水文地质条件、地层岩性、冶炼工艺、厂区功能布局等密切相关。土壤重金属污染主要来源于冶炼粉尘、废渣和废水排放等冶炼活动。稳定化工程效果显示,在药剂与土壤混匀程度不低于90%时,采用无机混合药剂与TJ400螯合剂的组合方案,对土壤稳定化处理7 d后,土壤中Cd、Pb和As同步稳定化效果最好。本研究结果可对多金属重污染场地土壤的稳定化修复提供实践指导。

电解铝负荷调节能力量化及参与电网协同调度

电解铝负荷具有热惯量特性,可为区域电网提供一定的调节能力。然而,负荷参与调节的前提是电网调度机构能够准确掌握其调节能力,实现负荷调节能力的可观性。从模型-数据双驱动的思路出发,结合电解铝负荷的等效物理模型和电网侧的历史数据构建电解铝负荷的生产-调节模型,从等效物理模型中挖掘负荷的调节能力,从电网侧数据中识别负荷调节能力的关键参数。在评估和量化电解铝负荷的调节能力后,将其纳入到区域电网考虑运行可靠性的协同优化调度模型中。以实际西北电网数据为基础进行测试,结果表明所提方法能够量化电解铝负荷的调节和备用能力,优化电解铝负荷参与电网协同调度。