Smelting with oxygen bottom blowing is one of the main methods used in the frame of copper pyrometallurgy.With this approach,feed materials and oxygen-enriched air are introduced in reversed order to enhance multiphas...Smelting with oxygen bottom blowing is one of the main methods used in the frame of copper pyrometallurgy.With this approach,feed materials and oxygen-enriched air are introduced in reversed order to enhance multiphaseflow within the furnace.Understanding the flow structure and temperature distribution in this setup is crucial foroptimizing production.In this study,gas-liquid interactions,and temperature profiles under varying air-injectionconditions are examined by means of numerical simulation for a 3.2 m×20 m furnace.The results indicate that thehigh-velocity regions are essentially distributed near the lance within the reaction region and the flue gas outlet,while low-velocity regions are located close to the furnace walls on both side of the reaction region.Dead regionsappear in the sedimentation region,with gas velocities surpassing those of the molten phase.As the injection rateincreases from 0.50 to 0.80 Nm3/s,the stabilization time of the average liquid surface velocity decreases from 2.6 sto 1.9 s,exhibiting a similar trend to the gas holdup.During stabilization,the average liquid surface velocity risesfrom 0.505 to 0.702 m/s.The average turbulent kinetic energy(TKE)of the fluid in the molten bath increases from0.095 to 0.162 m^(2)/s^(2).The proportion of the area distribution with TKE greater than 0.10 m^(2)/s^(2) and the gas holdupat steady state both rise with an increase in the injection quantity.The maximum splashing height of the melt growsfrom approximately 0.756 to 1.154 m,with the affected area expanding from 14.239 to 20.498 m^(2).Under differentworking conditions with varying injection quantities,the average temperature changes in melt zone and flue gaszone of the furnace are small.The temperature in the melt and in the flue-gas zone spans the interval 1200℃–1257℃,and 1073℃–1121℃,respectively.The temperature distribution of the melt and flue gas reveals a patterncharacterized by elevated temperatures in the reaction zone,gradually transitioning to lower temperatures in thesedimentation region.展开更多
The melt stirring in a large copper smelting oxygen bottom-blown furnace is caused by the large amount of gas movement blown in by two rows of oxygen lances.At present,the two rows of oxygen lances provide oxygen of e...The melt stirring in a large copper smelting oxygen bottom-blown furnace is caused by the large amount of gas movement blown in by two rows of oxygen lances.At present,the two rows of oxygen lances provide oxygen of equal strength,and the stirring in the central area of the melt is insufficient,which restricts the efficient progress of the smelting reaction.This study proposes a strong-weak coupling oxygen supply method and establishes an equivalent model based on a large bottom-blown furnace(LBBF)of an enterprise to simulate the bubble characteristics and flow characteristics of the molten pool.The results show that adjusting the flow ratio between the two rows of oxygen lances can create a“strong”and a“weak”coexisting source of disturbance in an LBBF.It is worth noting that when the flow rate ratio of the two rows of oxygen lances is 1.6,the peak velocity generated by the“strong”distur bance source in the molten pool increases by 18.92%,and the disturbance range increases.This method effectively strengthens the stirring in the central area of the molten pool,improves smelting efficiency,and does not produce harmful melt splashes.It provides important guidance for optimizing production practice.展开更多
The SKS furnace is a horizontal cylindrical reactor similar to a Noranda furnace,however,the oxygen enriched air isblown into the furnace from the bottom.Mechanism model of the SKS process was developed by analyzing t...The SKS furnace is a horizontal cylindrical reactor similar to a Noranda furnace,however,the oxygen enriched air isblown into the furnace from the bottom.Mechanism model of the SKS process was developed by analyzing the smeltingcharacteristics deeply.In our model,the furnace section from top to bottom is divided into seven functional layers,i.e.,gas layer,mineral decomposition transitioning layer,slag layer,slag formation transitioning layer,matte formation transitioning layer,weakoxidizing layer and strong oxidizing layer.The furnace along the length direction is divided into three functional regions,that is,reaction region,separation transitioning region and liquid phase separation and settling region.These layers or regions play differentroles in the model in describing the mechanism of the smelting process.The SKS smelting is at a multiphase non-steady equilibriumstate,and the oxygen and sulfur potentials change gradually in the length and cross directions.The smelting capacity of the SKSprocess could be raised through reasonably controlling the potential values in different layers and regions.展开更多
A computational thermodynamics model for the oxygen bottom-blown copper smelting process(Shuikoushan,SKS process)was established,based on the SKS smelting characteristics and theory of Gibbs free energy minimization.T...A computational thermodynamics model for the oxygen bottom-blown copper smelting process(Shuikoushan,SKS process)was established,based on the SKS smelting characteristics and theory of Gibbs free energy minimization.The calculated results of the model show that,under the given stable production condition,the contents of Cu,Fe and S in matte are71.08%,7.15%and17.51%,and the contents of Fe,SiO2and Cu in slag are42.17%,25.05%and3.16%.The calculated fractional distributions of minor elements among gas,slag and matte phases are As82.69%,11.22%,6.09%,Sb16.57%,70.63%,12.80%,Bi68.93%,11.30%,19.77%,Pb19.70%,24.75%,55.55%and Zn17.94%,64.28%,17.79%,respectively.The calculated results of the multiphase equilibrium model agree well with the actual industrial production data,indicating that the credibility of the model is validated.Therefore,the model could be used to monitor and optimize the industrial operations of SKS process.展开更多
There are many bottom-blown smelting furnaces in metallurgical industry. When oxygen or air sprays from the jet nozzle into the bottom of the furnace, the melting phase will be frozen and a hemispherical porous zone w...There are many bottom-blown smelting furnaces in metallurgical industry. When oxygen or air sprays from the jet nozzle into the bottom of the furnace, the melting phase will be frozen and a hemispherical porous zone with a mushroom head shape will be formed around the nozzle. The mushroom head can pro- tect the jet nozzle and mitigate the liquid spray on the surface of melt. In order to analyze the formation process of a mushroom head in the bottom-blown smelting furnaces, a hydraulic experiment system was designed and the formation of the mushroom head was investigated by hydraulic experiment. The hydrau- lic experiment results show that the formation process is mainly divided into generating crushing genera- ting process and stable mushroom head generation process. The formation of stable mushroom head re- quires certain thermodynamic condition and water splash is more intense without a mushroom head than with a mushroom head. The size, porosity and diameter of the mushroom head are affected by the flow rate, temperature and heat capacity of the bottom-blowing gas and the temperature of the superheat and the physical parameters of the melt.展开更多
基金Supported by Yunnan Fundamental Research Projects(Nos.202301AT070469,202301AT070275)Supported by Yunnan Major Scientific and Technological Projects(No.202202AG050002).
文摘Smelting with oxygen bottom blowing is one of the main methods used in the frame of copper pyrometallurgy.With this approach,feed materials and oxygen-enriched air are introduced in reversed order to enhance multiphaseflow within the furnace.Understanding the flow structure and temperature distribution in this setup is crucial foroptimizing production.In this study,gas-liquid interactions,and temperature profiles under varying air-injectionconditions are examined by means of numerical simulation for a 3.2 m×20 m furnace.The results indicate that thehigh-velocity regions are essentially distributed near the lance within the reaction region and the flue gas outlet,while low-velocity regions are located close to the furnace walls on both side of the reaction region.Dead regionsappear in the sedimentation region,with gas velocities surpassing those of the molten phase.As the injection rateincreases from 0.50 to 0.80 Nm3/s,the stabilization time of the average liquid surface velocity decreases from 2.6 sto 1.9 s,exhibiting a similar trend to the gas holdup.During stabilization,the average liquid surface velocity risesfrom 0.505 to 0.702 m/s.The average turbulent kinetic energy(TKE)of the fluid in the molten bath increases from0.095 to 0.162 m^(2)/s^(2).The proportion of the area distribution with TKE greater than 0.10 m^(2)/s^(2) and the gas holdupat steady state both rise with an increase in the injection quantity.The maximum splashing height of the melt growsfrom approximately 0.756 to 1.154 m,with the affected area expanding from 14.239 to 20.498 m^(2).Under differentworking conditions with varying injection quantities,the average temperature changes in melt zone and flue gaszone of the furnace are small.The temperature in the melt and in the flue-gas zone spans the interval 1200℃–1257℃,and 1073℃–1121℃,respectively.The temperature distribution of the melt and flue gas reveals a patterncharacterized by elevated temperatures in the reaction zone,gradually transitioning to lower temperatures in thesedimentation region.
基金Project(2022YFC3901501)supported by the National Key R&D Program of ChinaProject(U20A20273)supported by the National Natural Science Foundation of China+1 种基金Project(2022JJ10078)supported by the Natural Science Foundation for Distinguished Young Scholars of Hunan Province,ChinaProject(2021RC3005)supported by the Science and Technology Innovation Program of Hunan Province,China。
文摘The melt stirring in a large copper smelting oxygen bottom-blown furnace is caused by the large amount of gas movement blown in by two rows of oxygen lances.At present,the two rows of oxygen lances provide oxygen of equal strength,and the stirring in the central area of the melt is insufficient,which restricts the efficient progress of the smelting reaction.This study proposes a strong-weak coupling oxygen supply method and establishes an equivalent model based on a large bottom-blown furnace(LBBF)of an enterprise to simulate the bubble characteristics and flow characteristics of the molten pool.The results show that adjusting the flow ratio between the two rows of oxygen lances can create a“strong”and a“weak”coexisting source of disturbance in an LBBF.It is worth noting that when the flow rate ratio of the two rows of oxygen lances is 1.6,the peak velocity generated by the“strong”distur bance source in the molten pool increases by 18.92%,and the disturbance range increases.This method effectively strengthens the stirring in the central area of the molten pool,improves smelting efficiency,and does not produce harmful melt splashes.It provides important guidance for optimizing production practice.
基金Project(51620105013)supported by the National Natural Science Foundation of China
文摘The SKS furnace is a horizontal cylindrical reactor similar to a Noranda furnace,however,the oxygen enriched air isblown into the furnace from the bottom.Mechanism model of the SKS process was developed by analyzing the smeltingcharacteristics deeply.In our model,the furnace section from top to bottom is divided into seven functional layers,i.e.,gas layer,mineral decomposition transitioning layer,slag layer,slag formation transitioning layer,matte formation transitioning layer,weakoxidizing layer and strong oxidizing layer.The furnace along the length direction is divided into three functional regions,that is,reaction region,separation transitioning region and liquid phase separation and settling region.These layers or regions play differentroles in the model in describing the mechanism of the smelting process.The SKS smelting is at a multiphase non-steady equilibriumstate,and the oxygen and sulfur potentials change gradually in the length and cross directions.The smelting capacity of the SKSprocess could be raised through reasonably controlling the potential values in different layers and regions.
基金Project(51620105013)supported by the National Natural Science Foundation of China
文摘A computational thermodynamics model for the oxygen bottom-blown copper smelting process(Shuikoushan,SKS process)was established,based on the SKS smelting characteristics and theory of Gibbs free energy minimization.The calculated results of the model show that,under the given stable production condition,the contents of Cu,Fe and S in matte are71.08%,7.15%and17.51%,and the contents of Fe,SiO2and Cu in slag are42.17%,25.05%and3.16%.The calculated fractional distributions of minor elements among gas,slag and matte phases are As82.69%,11.22%,6.09%,Sb16.57%,70.63%,12.80%,Bi68.93%,11.30%,19.77%,Pb19.70%,24.75%,55.55%and Zn17.94%,64.28%,17.79%,respectively.The calculated results of the multiphase equilibrium model agree well with the actual industrial production data,indicating that the credibility of the model is validated.Therefore,the model could be used to monitor and optimize the industrial operations of SKS process.
基金supported by the Fundamental Research Funds for the Central Universities(No.FRF-TP-15-022A3)
文摘There are many bottom-blown smelting furnaces in metallurgical industry. When oxygen or air sprays from the jet nozzle into the bottom of the furnace, the melting phase will be frozen and a hemispherical porous zone with a mushroom head shape will be formed around the nozzle. The mushroom head can pro- tect the jet nozzle and mitigate the liquid spray on the surface of melt. In order to analyze the formation process of a mushroom head in the bottom-blown smelting furnaces, a hydraulic experiment system was designed and the formation of the mushroom head was investigated by hydraulic experiment. The hydrau- lic experiment results show that the formation process is mainly divided into generating crushing genera- ting process and stable mushroom head generation process. The formation of stable mushroom head re- quires certain thermodynamic condition and water splash is more intense without a mushroom head than with a mushroom head. The size, porosity and diameter of the mushroom head are affected by the flow rate, temperature and heat capacity of the bottom-blowing gas and the temperature of the superheat and the physical parameters of the melt.
