通过数值仿真的方法,分析闪速熔炼反应塔内Fe3O4含量的分布与变化规律,提出降低渣含铜的途径和措施。计算表明,精矿喷嘴操作参数的优化匹配,可以减少反应塔底部Fe3O4的生成量。氧浓或氧量分布为调控的主要参数;工艺风氧浓高,工艺风速低,有利于减少Fe3O4生成量;增加SiO2含量,颗粒中的Fe3O4含量明显降低,但需综合考虑此因素对渣含铜的影响。调整反应塔精矿喷嘴的工艺风氧量和氧浓,使反应塔内的氧势呈合理的梯度分布,将有助于渣含铜的降低。

Flash smelting is a major process for copper pyrometallurgy,most of its reactions are completed in the reaction shaft.To study the flash smelting mechanism,is mainly focused on the suspensions smelting reaction process in the shaft.This article describes in details the experiment of sampling the high temperature reaction particles with the quick cooling method,particles are examined and analyzed allsidedly for the purpose of analyzing the suspensions smelting reaction process mechanism.Conclusions are made as follows:(1) To study the reaction process in the shaft,the quick cooling sampling method is feasible.(2) The particle distribution in the reaction shaft is uneven and the particles are relatively concentrated at the center of the shaft.(3) Oxidation of particles are quite uneven.(4) A great deal of free quartz flux are not consumed in the slagging reaction.(5) Strawberry or honeycomb-shaped particles,particles with holes and some laminar oxidation particles found under reflected light microscope,which are the potent evidences of the existence of the particle splitting.At the same time,the average diameter of the particles in the shaft is 7 times as that of the concentrate particles,which proves the existence of the particle collision and gathering.

在总结前人闪速熔炼反应模型——粒子分裂模型和两粒子碰撞模型的基础上，根据对金隆闪速炉反应塔工艺物料颗粒高温急冷试样的分析结果，通过从微粒运动学、两相流体力学以及统计分析和归纳等方面的论证，提出了闪速熔炼过程反应模型——粒子脉动碰撞模型（简称PPC Model），认为：在闪速炉反应塔不同高度上，精矿粒子的分裂和颗粒群内粒子脉动碰撞过程同时存在；精矿粒子脉动是粒子碰撞聚合主要原因；随着氧化反应的进行，在颗粒中心形成熔融硫化物和SO2气泡，颗粒外表面是多孔的氧化铁壳；熔融核中气相的生成促使粒子分裂和脉动，当地氧气浓度和温度越高，这一过程越强烈；反应塔中由于粒子的大小、粒子的成分、粒子的周围的氧气浓度和粒子温度的不同，导致各粒子之间的氧化程度差别极大；过氧化粒子在反应塔中下降时，它们彼此之间、或者与反应慢的欠氧化粒子相碰撞，聚合长大，同时过氧化颗粒被欠氧化粒子还原。

小波分析是一种新的信号处理技术，具有良好的时频局部化特征。为了克服BP网络自身算法的缺陷，得到更高的学习精度和更快的收敛速度，使用小波包分析的特征提取及神经网络的非线性映射特性，构造了小波神经网络，以此为基础开发出的软件系统具有使用的特征量少，建造预报系统较为简单等优点。将之应用于炼铜转炉炉渣重量及成分预报，该模型完全能够较准确地预报出渣量和成分。其平均拟合误差为1.5％，平均预报误差为3.1％。

Based on the principal of heat transfer, a mathematical model of the wall of reaction shaft in a flash smelting furnace was developed, and the simulation results of the distribution of temperature field and the slag thickness of the wall in the shaft were obtained. It is the first time to realize the on line display of the freeze profile of reaction shaft. Compared with the practical data, the computational results are satisfactory. The error of the hearth temperature is less than 40?℃, and the average error of the slag thickness is less than 3%. The software provides not only a way to monitor the reaction shaft in practice, but also a theoretical base for optimization of flash smelting furnace. At the same time, great influences of the cooling jackets on the temperature of the hearth are also found. It is concluded that a strengthened cooling system will effectively prolong the life of the refractory.

Based on the material balance and heat balance，300 groups of historical data about copper converters are simulated dynamically on the computer and main element composition of a melt and the temperature in the molten bath are calculated every other one minute in the period of air refining.Then，they are fitted with quartic curve and the coefficients gotten by fitting are regarded as outputs of neural network.Partial initial data and the optimized operation parameters are considered as inputs of the neural network.Through training，the neural network can simulate the change of the furnace condition during air refining.It is able to self-study by increasing the number of new samples.It is applied to monitor the furnace condition of copper converter and constitute a real-time forecast system of furnace condition in copper converter.The system has been successfully used in operation of copper converter in a smelter.Production quota is obviously improved after running-in for four months.Copper production and the weight of cold input are increased respectively by 6.0％ and by 8.0％.Average converter life-span is improved from 213 to 235 times.A new idea has been provided for realization of in-line real-time control of copper converter.

To control the smelting temperature of the copper converter((1 250±10) ℃ in slag-making period, (1 180±10) ℃ in copper-making) and improve the life-cycle of the converter, the smelting process of cold materials is simplified in this paper and the dynamic models of smelting rate and smelting time are established. The parameters of the models are determined. The models are used in the Intellectual Decision Support System of the Operation- Optimization of copper converter. The software system automatically tells operators the maximum feeding of each cold material according to the current left heat and the melt temperature showed in the monitor interface of furnace conditions. Thus, the melt temperature can be controlled within a feasible limits. The practice shows that the application of the models makes the average life-cycle of the converter lining be improved from 213 furnace-times to 235 furnace-times and make the cold materials feeding improved by 8 percent under the condition that not enough cold materials are provided.

Based on the computational model developed by the authors, the computer simulation on the rational enhancement of flash smelting system is carried out Some important factors affecting the limit productivity such as the matte grade, the oxygen concentration, the ratio of Fe/SiO 2 in the slag, and the copper grade of concentrate are also discussed

本文通过理论计算,建立了铜锍吹炼造铜期出炉烟气温度的数学模型,提出一种对造铜期终点进行预报的简便新方法,并将之应用到工业生产上,烟气温度信号预报值与生产经验相比,偏差约为2～3分钟,显然要比经验法更科学,而且具有成本低、操作简单的优点,值得其它有条件的铜冶炼厂推广应用.

An investigation of the use of a three-phase fluidized bed reactor for arsenic dissolution from antimony refining slag was made. The flow characteristics of the slag pulp and factors affecting leaching were examined. Experimental results showed that for a liquid/solids weight ratio of 2.0 and at ambient temperature, an extraction of arsenic of 97% can be reached in 30 min.