Copper smelting mechanism in oxygen bottom-blown furnace

The SKS furnace is a horizontal cylindrical reactor similar to a Noranda furnace, however, the oxygen enriched air is blown into the furnace from the bottom. Mechanism model of the SKS process was developed by analyzing the smelting characteristics 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, weak oxidizing 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 different roles in the model in describing the mechanism of the smelting process. The SKS smelting is at a multiphase non-steady equilibrium state, and the oxygen and sulfur potentials change gradually in the length and cross directions. The smelting capacity of the SKS process could be raised through reasonably controlling the potential values in different layers and regions.     

Mathematical model of multistage and multiphase chemical reactions in flash furnace

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回火热处理炉的数学模型

根据传热学原理建立了钢板温度预测数学模型。研究了炉内物料跟踪及目标温度,介绍了钢板在炉时间及辊道速度的计算;进行了650℃回火钢板温度均匀性测试。结果显示,在650℃进行热处理时,钢板温差在±3℃以内。     

矿热炉与AOD炉双联法冶炼不锈钢的设计

根据国内外冶炼不锈钢工艺的发展趋势和不锈钢厂与镍铁合金厂的生产工艺特点,以及徐州金象冶金有限公司的实际条件,确定了一套节约能耗、减少成本的生产工艺:立窑烧结—25 000 kVA的矿热炉—酸性炉衬AOD炉—碱性炉衬AOD炉—浇铸或连铸进行不锈钢生产,经分析表明,此工艺具诸多优点,对镍铁行业的发展提供重要参考。     

氧气底吹铜熔池熔炼过程的机理及产物的微观分析

对氧气底吹熔炼过程气体喷吹行为、造锍熔炼化学反应机理及熔炼炉内热工作状态进行理论分析及水模型实验和取样分析验证。结果表明,氧气底吹气流能使熔体形成均匀的扩散区,实现熔体的搅拌,在气体连续相区和液体连续相区,气液、液液之间的相互作用强烈,为炉内化学反应及传热传质提供了良好的动力学条件;氧气底吹熔炼过程在零配煤的情况下能达到自热熔炼,在节能减排方面,该工艺具有很强的优势;获得了铜渣、冰铜和蘑菇头中各组分的形貌,确定了铜渣、冰铜和蘑菇头的物相组成,渣样主要由冰铜相、磁铁矿相、铁橄榄石相和玻璃体相组成,熔炼内的氧势和硫势分布有利于反应的进行,能有效抑制Fe3O4的形成以及降低渣含铜。     

铜闪速炉内颗粒受热过程的数学建模与数值优化

为了研究闪速炉冶炼颗粒着火延迟问题,建立反应塔内颗粒受热过程的数学模型,并进行计算.结果表明,在塔高0.6 m范围内,辐射换热对于颗粒的加热过程影响较大,而在反应塔0.6 m以下区域,对流换热占主导作用.鉴于强化对流换热过程对提高颗粒加热速度进而提高着火高度更有效,因此,建议采用高速热氧射流技术代替闪速炉内的天然气,使...     

Operation optimization of concentrate burner in copper flash smelting furnace

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 op-eration, 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.     

Intelligent prediction model of matte grade in copper flash smelting process

Due to the importance of detecting the matte grade in the copper flash smelting process, the mechanism model was established according to the multi-phase and multi-component mathematic model. Meanwhile this procedure was a complicated production process with characteristics of large time delay, nonlinearity and so on. A fuzzy neural network model was set up through a great deal of production data. Besides a novel constrained gradient descent algorithm used to update the parameters was put forward to improve the parameters learning efficiency. Ultimately the self-adaptive combination technology was adopted to paralleled integrate two models in order to obtain the prediction model of the matte grade. Industrial data validation shows that the intelligently integrated model is more precise than a single model. It can not only predict the matte grade exactly but also provide optimal control of the copper flash smelting process with potent guidance.     

钢板卷制过程的数学模型

针对大型卷板机数控自动化的工程需求,根据板材的力学性能及卷制流程中的几何参数,研究并建立了适用于大型板材卷制工艺要求的一般数学模型.在此基础上,以某弯板机为例,研发了大型板材卷制数控系统及数控程序,并结合实际工程样件完成了大型板材的卷制加工,验证了提出的大型板材卷制工艺流程数学模型的正确性.研究内容不仅对同类装备方案设...     

基夫赛特式炉闪速炉功能区冶炼过程的同时平衡

基于硫化铅矿在闪速炉功能区冶炼过程的多相同时平衡原理，利用平衡摩尔量法分析和讨论熔炼温度、初始氧量和初始硫化铅量对平衡后各凝聚态产出量的影响。结果表明：在较高温度下，初始氧量的增加会使硫酸铅的产量增加，而硫化铅的产量降低；低氧量条件下不生成硫酸铅而生成硫化铅。考虑产物的后续碳还原处理，在冶炼过程中应选择高氧气输入量以生成容易处理的硫酸铅，而不是较难处理的硫化铅。     

楔横轧内直角台阶成形过程的数学模型

楔横轧内直角台阶成形过程非常复杂，导致数学模型也很复杂。在符合实际情况的几何模型基础上，分析建立了内直角台阶成形过程的数学模型，求解得到各曲面的边界条件。     

井式炉渗碳工艺过程控制SE-607系统的应用

以德国斯坦格电气有限公司设计制造的SE-607井式炉渗碳工艺过程控制系统在杭州前进齿轮箱厂的项目应用为实例,对该过程控制系统的软硬件结构、渗碳工艺、碳势控制原理、渗碳扩散模拟模块及上位机监控系统的组成进行介绍。     

Microprocessor based protecting and monitoring system for transformer of electric furnace in nickel smelting process

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等温CVD制备炭/炭复合材料过程中气体滞留时间的数模分析

在化学气相沉积（CVD）制备炭/炭复合材料的过程中,对采用强制通过毛坯的特定装炉方式下的碳源气体的流动动力学及其反应机理进行系统的理论分析。在一系列的计算基础上,得到毛坯内部空腔压强、毛坯外部空腔压强和毛坯的孔隙度随时间变化的微分方程模型,求出气体在炉体的滞留时间以及渗透毛坯的时间。该理论计算所得的CVD过程中毛坯孔隙度变化与实际生产过程中的孔隙度变化趋势一致,表明该研究理论分析结果具有较高的可信度。     

蓄热式铝熔炼炉熔炼过程的数值模拟

为了更好地研究和优化铝熔炼炉的性能,针对现有的蓄热式圆形铝熔炼炉,在建立合理的铝熔炼炉基本模型的基础上,通过耦合用户自定义熔化模型和氧化烧损模型,运用计算流体力学软件FLUENT实现燃烧空间和熔池的耦合物理场的数值模拟。着重研究不同固液区和不同孔隙率对铝及铝合金熔炼过程的影响。结果表明,该模型较好地反映铝熔炼炉的熔炼现象,可运用该模型进行铝熔炼炉熔炼过程工艺参数的优化研究。同时获得了固液区和孔隙率对熔炼参数影响规律:铝液温度在固液区上升缓慢,而离开固液相线时,铝液温度上升速度加快,炉膛温度和氧化层质量随着熔炼时间分别呈周期性增加和呈抛物线增加;随着氧化层厚度的增加,铝液温度随着孔隙率的增加而增加变得缓慢。     

高投料量下炼铜闪速炉内熔炼过程的数值模拟

以FLUENT 6.3为计算平台,建立了铜闪速炉熔炼过程数值模型,并针对高投料量下反应塔气粒两相变物理场信息分布变化特点展开仿真研究。结果表明:工艺风入炉后迅速膨胀,并在反应塔中心形成轮廓明显的主体气流柱;主体气流柱内外的温度和氧浓分布梯度变化较大;局部低温出现在精矿喷嘴下方,而高温反应核心区域则下移至反应塔中下部。综合多场耦合仿真结果可知:高投料量条件下精矿粒子与反应配风之间混合力度欠佳是造成高投料量反应塔内熔炼过程反应效率降低的主要原因。     

大功率密闭直流电弧炉冶炼钛渣烟气净化工艺研究

根据国内引进的第一台30MW密闭直流电弧炉钛渣生产线的工艺流程,对采用云南省钛铁矿冶炼钛渣过程中产生的烟气进行了气体及烟尘的流量、含量、化学成分等分析。由于产生的烟气具有温度高、含尘量大(1.75%~9.60%)、SO2含量低、CO含量高的特点,选择烟气净化设备时,除了处理能力要符合生产要求,还需要考虑粉尘粒径和烟气温度这两个因素,以实现烟气回收利用的目的。经过研究,烟气净化工艺首先对烟气进行直接水冷使烟气降温,然后选用德国进口涤气机对烟气进行精处理,除尘效率可以达到99.983%。处理净化后的烟气,热值高,气体性质稳定,净化后可安全用于无烟煤/钛渣干燥及渣包/铁包的烘烤,实现节能减排的目标;烟尘可以回收利用。     

粉末注射成形溶剂脱脂过程的数学模型

从宏观的角度出发 ,仅考虑脱脂预成形坯的体积、粘结剂含量对脱脂过程的影响 ,将预成形坯几何形状等其他因素的影响合理地归结到扩散系数函数中。根据浓度扩散原理建立了描述粉末注射成形溶剂脱脂过程中预成形坯粘结剂含量随时间变化的数学模型 ,避免了求解用Fick第二定律描述的偏微分方程 ,得出了一种预测脱脂量与脱脂时间的有效方法。根据模型求出了脱脂速度函数 ,给出了一种控制溶剂脱脂过程产生缺陷的分段升温优化方法。用该模型对硬质合金注射成形溶剂脱脂过程进行了模拟和预测 ,预测结果与实验结果吻合较好     

Experiment and numerical simulation of two-phase flow in oxygen enriched side-blown furnace

Taking an oxygen enriched side-blown furnace as the prototype, a hydraulic model was established according to the similarity principle. The influence of three factors on the gas—liquid two-phase flow was analyzed, i.e. the airflow speed, the submerged depth and the downward angle of the nozzle. A numerical simulation of the hydraulic model was carried out trying to find the suitable turbulence model which can describe the side-blown two-phase flow correctly by comparing the simulation results with the experimental data. The experiment shows that the airflow speed has a great influence on the flow of the water. The submerged depth of the nozzle has a relatively smaller influence on the penetration depth and the surface fluctuation height in the liquid phase. When the nozzle is at a downward angle of 15°, the penetration depth and the surface fluctuation height are reduced. It is concluded that the numerical results with the realizable k–ɛ turbulence model are the closest to the experiment for the penetration depth, the surface fluctuation height and the bubble scale.     

球形封头自动堆焊数学模型的建立

为实现大型封头自动堆焊,提出了对变位器、操作机进行技术改造,组合使用并进行柔性控制的方案。建立了球形封头自动堆焊的数学模型,讨论了堆焊过程焊枪与工件的相对位置和运动关系,给出了过渡段堆焊空间曲线形成的控制原理。并进行了计算机仿真和堆焊试验,试验结果表明,封头自动堆焊方案可行,数学模型正确。