基于遗传算法的铜闪速熔炼过程控制优化

基于已建立的铜闪速熔炼神经网络模型,以能耗费用最低为目标,在工艺指标控制范围内,采用遗传算法对铜闪速熔炼过程的工艺参数进行了仿真优化计算。结果表明,当空气、分配风、工艺氧和中央氧的市场价格折合比值分别为0.05、0.1、0.4和0.45,精矿量为128 t,其成分(质量分数)为Cu 20.61%、S 27.59%、Fe 24.72%、SiO2 11.64%和MgO 1.39%时,铜闪速熔炼工艺参数的遗传优化值为空气15 011 m3、分配风1 302 m3、工艺氧17 359 m3、中央氧1 000 m3、熔剂13.6 t;与实践平均值相比,若采用优化工艺参数控制,熔炼能耗费用可降低4.6%。     

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.     

Numerical simulation analysis of Guixi copper flash smelting furnace

A numerical simulation analysis for reactions of chalcopyrite and pyrite particles coupled with momentum,heat and mass transfer between the particle and gas in a flash smelting furnace is presented.In the simulation.the equations governing the gas flow are solved numerically by Eular method.The particle phase is introduced into the gas flow by the particle-source-in-cell technique(PSIC),Predictions including the fluid flow field,temperature field,concentration field of gas phase and the tracks of particles have been obtained by the numerical simulation.The visualized results show that the reaction of sulfide particles is almost completed in the upper zone of the shaft within 1.5m far from the central jet distributor (CJD)type concentrate burner,The simulation results are in good agreement with data obtained from a series of experiments and tests in the plant and the error is less than 2%.     

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.     

铜闪速熔炼渣中砷的赋存状态和浸出毒性（英文）

铜冶炼含砷炉渣的高效安全处置取决于对其含砷物相及其浸出毒性的准确认识。采用X射线荧光光谱、X射线衍射、电子探针显微分析、扫描电子显微术和选择性逐级提取法对铜熔炼渣中的含砷物相进行鉴定,并基于对炉渣中不同含砷物相的选择性逐级提取结果探讨渣中砷浸出毒性的可能来源。结果表明,砷以水溶性砷、铜砷金属间化合物、铜砷硫化物以及固化在铁橄榄石和硅酸盐玻璃相中的砷等形式赋存在熔炼渣中。浮选过程可以去除熔炼渣中的水溶性砷并回收铜砷金属间化合物,降低渣尾矿的砷浸出毒性,使其符合USEPA和SEPA标准要求。     

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。     

Combustion in flash smelting furnaces

The reaction shaft is the heart of a flash smelter. Current knowledge of the combustion of concentrate and ancillary fuels (coal, oil, and gas) in flash smelter shafts comes from laboratory studies, plant measurements, and physical and mathematical modeling. The latter is particularly useful when considering the complications of two-phase flow of particles and gas and chemical reactions; however, uncertainty as to effective particle size requires validation to establish confidence in the model outcomes. Those issues are addressed in the paper, together with the importance of the burner in achieving good mixing and dispersion. Simulations, which may be viewed on the web, show the consequences of poor mixing. For more information, contact Frank Jorgensen, CSIRO Division of Minerals, Box 312, Clayton South, VIC 3169, Australia; +61-3-9545-8531; fax +61-3-9562-8919; e-mail frank.jorgensen@minerals.csiro.au.     

基于数值模拟的闪速连续炼铜炉型结构研究

分析4种闪速连续炼铜炉型的本质特性,提出将闪速连续炼铜过程视为由相对独立的闪速造锍熔炼过程和连续吹炼造铜过程构成,分别建立闪速造锍熔炼多相平衡数学模型和连续吹炼造铜局域平衡数学模型,并通过中间物料的传递将两模型有机结合,从而构建完整的闪速连续炼铜过程热力学模型。运用此模型,考察炉型结构对闪速连续炼铜过程的粗铜生成条件、Fe3O4行为、铜在渣中损失以及铜直收率等因素的影响。结果表明：相对于其他3种炉型,甩渣吹炼双烟道D型炉是比较理想的连续炼铜炉体;对于闪速连续炼铜,造锍熔炼段和铜锍吹炼段宜在相对独立的分区进行,各自炉渣和烟气也应分开排出炉体。     

基于投影寻踪回归的铜闪速熔炼过程关键工艺指标预测

针对数据量庞大引起模型参数更新时样本选择困难及训练速度慢的缺陷,提出基于投影寻踪回归的铜闪速熔炼过程关键工艺指标预测方法。首先采用机器学习方式提取用于建模所需的相似样本集,借助投影寻踪回归思想,建立铜闪速熔炼过程关键工艺指标预测模型;然后利用基于实数编码的加速遗传算法进行模型参数的实时更新。训练样本的机器选择可以避免人工选择带来的主观性和盲目性缺陷,模型参数的更新训练只在相似样本集中进行,可有效提高模型参数更新速度。实际生产数据仿真结果验证了所提方法的有效性和可行性。     

铜闪速炉沉淀池渣中锍液滴沉降机理及其影响因素

通过分析沉淀池内锍液滴的沉降机理,导出了渣中最大锍液滴直径的计算公式。根据闪速炉的实际生产条件,计算出渣中最大锍液滴直径的理论值为0.063 mm,并用矿相显微镜对沉淀池出口处的渣样进行了观察,渣中最大锍颗粒粒径为0.06 mm,两者结果一致。由此证明了沉降机理分析的正确性。在此基础上,进一步分析渣中锍夹带损失影响因素。结果表明:增大熔体中离散态分布的锍液滴直径是降低渣中铜夹带损失的重要措施;其次是升高渣温度有助于渣中锍的沉降;减小渣层厚度等措施对降低渣中铜夹带损失作用不大。     

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。     

硫化铅矿闪速熔炼过程的热力学分析

基于最小吉布斯自由能原理,建立硫化铅矿闪速熔炼过程多相平衡热力学模型,考察熔炼温度(T)、吨矿氧量(VOVPTO)对粗铅含硫量、炉渣含铅量、烟气含铅量及铅在各平衡相中分配比的影响。结果表明:对一定用量和一定成分的硫化铅矿,随着T和VOVPTO的增大,粗铅含硫量可降至0.1%(质量分数)以下,但过高的VOVPTO会使渣含铅量升至60%(质量分数)以上,铅在粗铅中的分配比低于30%(质量分数);烟气中的铅主要以PbS形式存在,其含量随着T的升高及VOVPTO降低而增高。综合考虑铅的直收率及产物处理的难易程度,闪速炉直接炼铅应采取分区分步熔炼方式,先在氧化区制低硫铅,然后在还原区造低铅渣,且氧化区熔炼温度宜较低。     

改进的混沌遗传算法及其在炼铜转炉操作优化中的应用

利用混沌优化的遍历性和遗传算法优化的反演性,提出了混沌遗传算法(CGA),其基本思想是把混沌变量加载于遗传算法的变量群体中,利用混沌变量对子代群体进行微小扰动,随着搜索过程的进行逐渐调整扰动幅度.结果表明,该方法优化效果与前人的优化结果相比,优化效率明显提高.由炼铜转炉造渣期与造铜期操作参数(样本采集、数据预处理、PLS(偏最小二乘法)空间变换、BPN神经网络建模及CGA)的优化和造渣期适应度函数与造铜期适应度函数的变换,使操作参数变量在训练集给出的数据范围的基础上延伸±10%,得到最优点对应的工艺条件,并用于生产中.经过3个多月的试运行,粗铜产量提高6.0%,冷料处理量提高8%,平均炉寿从原来的213炉提高到235炉.     

Oxidation leaching of copper smelting dust by controlling potential

A study was conducted for metal extraction from copper smelting dust using the oxidation leaching and control of potential technology. The effects of H₂O₂ dosage, H₂O₂ feeding speed, initial HCl concentration, leaching temperature, liquid-to-solid ratio and leaching time on metals leaching efficiencies were investigated. The following optimized leaching conditions were obtained: H₂O₂ dosage of 0.8 mL/g (redox potential of 429 mV), H₂O₂ feeding speed of 1.0 mL/min, initial H₂SO₄ concentration of 1.0 mol/L, initial HCl concentration of 1.0 mol/L, leaching temperature of 80 °C, initial liquid-to-solid ratio of 5:1 mL/g and leaching time of 1.5 h. Under the optimized conditions, copper and arsenic can be effectively leached from copper smelting dust, leaving residue as a suitable lead resource. The average leaching efficiencies of copper, arsenic and iron are 95.27%, 96.82% and 46.65%, respectively.     

基于遗传算法的无头轧制技术闪光焊机行走系统

介绍了无头轧制闪光焊机的行走系统的组成及其工作原理,建立了闪光焊机行走系统的数学模型.提出了一种基于遗传算法和神经网络PID相结合的控制方法,该算法用GA(遗传算法)优化BP网络的初始连接权系数,得到一组较佳的BP网络初始权值的参数组合,再通过BP算法,实现PID参数的在线调整.仿真结果表明,经过GA对网络初始权值优化后,闪光焊机行走系统的输出响应能够快速的跟踪输入的信号,使系统具有精确的同步性能.     

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。     

Current refractory practice as applied in copper smelting

Present indications are that the highest speeds of copper smelting have not yet been achieved. Although refractories are available which permit reasonable or satisfactory smelting costs, extensive research continues in an effort to develop refractories which will be capable of withstanding even more severe treatment.     

The oxidation mechanism in copper smelting and converting

The oxidation mechanism of copper-sulfide concentrates is of fundamental interest in an understanding of flash smelting and converting. The compositions of mattes follow simple, well-defined relationships, and the progression of iron and sulfur oxidation in smelting and converting occurs in such a manner that generates mattes of these compositions. J.W. Matousek earned his Ph.D. in metallurgical engineering at Queens University. He is currently an independent consulting engineer. Dr. Matousek is also a member of TMS.     

Modeling and control of copper loss in smelting slag

A series of technical improvements have been implemented to address the issue of high copper losses in rotary holding furnace (RHF) slag, which were experienced at the Xstrata Copper Smelter at Mount Isa in 2007 and 2008. The copper losses in smelting slag in the RHF were more than 3% in 2006 and 2007. Thermodynamic models and viscosity models have been applied in the operation of Xstrata Copper Smelter in Australia. The theory of RHF key performance indicators has also been developed to reduce the copper losses in RHF slag. The RHF KPIs Theory has been applied in Mount Isa Copper Smelter. The copper losses in RHF slag dropped from 3.1% in 2007 to 0.76% in April 2009. The average copper loss in RHF slag in 2009 and 2010 was about 0.9%.