铜锍底吹连续吹炼的运行实践

从铜锍品位、冷热态铜锍、氧浓、废杂铜品位及加入量、"三相"厚度、杂质元素对铜锍底吹连续吹炼的影响进行分析探讨,总结了试产一年来不同条件下铜锍底吹连续吹炼的运行实践。     

铜熔池熔炼渣锍沉降分离变化过程的分析

艾萨炉造锍熔炼产生的铜渣锍在沉降电炉中进行沉降分离，其铜渣分离效果的好坏，直接影响铜的直收率，对铜产品产量和经济效益都有很大的影响。本文通过对铜渣锍沉降分离过程中艾萨炉渣、沉降电炉渣、沉降铜锍三者进行全面微观检测，鉴定查明三者的主要铜矿物及脉石矿物的组成、产出形式、结构分布、粒度大小、粒度分布等微观结构，分析铜渣锍在沉降分离过程中矿物结构的微观变化过程及元素分布，为沉降分离措施的深入及细化研究摸索提供参考和指导。     

铜闪速熔炼影响规律的神经网络分析

基于已建立的神经网络模型,研究了富化率、吨矿氧量、熔剂率以及铜精矿主要成分对铜闪速熔炼过程的影响。结果表明:富化率的增大会使铜锍品位降低、铜锍温度升高,而对渣含Fe/SiO2影响不大;吨矿氧量的增加会使铜锍品位、铜锍温度及渣含Fe/SiO2都升高;熔剂率的增加会使渣含Fe/SiO2明显下降;精矿中Cu含量的增大会使铜锍品位升高,铜锍温度稍微降低;而Fe的影响与Cu相反;S/Cu一般控制在1.0±0.2,自热熔炼应控制在1.34以上。     

温度控制对大型转炉铜锍吹炼的影响

转炉铜锍吹炼是个自热过程,温度过高、过低对炉龄、单炉产量及产品质量控制有至关重要的影响。通过对大型转炉铜锍吹炼过程造渣和造铜阶段的温度统计,结合现场实际炉况表现,总结得出温度控制对铜锍吹炼的影响及温度控制的具体措施。实验结果表明:造渣初期、中期及末期温度温度分别控制在1110~1160℃、1150~1210℃和1195~1260℃时,造渣效果最佳;造铜前期和末期温度控制在1160~1210℃和1180~1200℃时,造铜效果最好。同时为转炉铜锍吹炼更好的利用自身余热增加冷料处理量、保护炉衬及确保渣型提高粗铜质量提供借鉴意义。     

碘量法测定铜锍及含铜烧结物料中铜

根据铜锍及含铜烧结物料的基体成分特点,提出了用碘量法测定其中铜含量的方法,重点讨论了铁、硫、硅等干扰元素对铜含量分析的影响及消除,并对滴定酸度、介质、速度、盐酸浓度等条件进行了分析,为深入探讨试验方法的可靠性提供了依据。本方法经验证：相对标准偏差在1%之内,不同实验室测定样品结果的绝对误差小于0.3%。该方法能够较好地解决铜锍及含铜烧结物中铜含量测定难的问题     

杂质元素在铜锍吹炼过程中的行为分析

简述铜锍吹炼原理,重点分析铜锍吹炼过程中镍、锌、铅、铋、砷、锑、硒、碲等杂质元素的反应原理及脱除方法,同时提出降低粗铜中杂质元素的控制方法。     

铜底吹熔池熔炼炉多相流数值模拟

在铜的富氧底吹熔池熔炼过程中,熔池内的多相流动决定了颗粒下料、传热传质及化学反应速率。本文建立了包含气泡、铜锍、渣的三相数学模型,并通过水力学模型实验对数学模型进行了验证。对不同气流速度、铜锍深度、渣层厚度进行了数值模拟,研究炉内渣眼尺寸、旋流强度及漩涡位置等情况。结果表明,随着气流速度增大,气泡流对熔池的搅拌程度逐渐强烈,气泡弥散程度降低,但气流速度过大容易造成熔体喷溅。铜锍深度越大,旋涡搅拌面积越大,旋流强度越大,渣层变短变厚,有利于排渣,但熔池深度增大到一定程度时渣眼直径急剧减小,并且铜锍卷渣程度增大。随着渣层厚度增加,铜锍层内气泡尺寸增大,渣眼尺寸急剧减小,甚至消失,漩涡同时出现在铜锍和渣层内,导致卷渣严重。     

闪速炉沉淀池中的冶金过程与炉况控制

在高强度熔炼的工业闪速炉生产条件下,从反应塔出口和沉淀池的不同位置提取悬浮粒子、炉渣和铜锍熔体试样,进行各种化学成分检测和仪器分析,研究了沉淀池中的冶金过程及特点、炉渣和铜锍的形成过程、炉渣含Fe3O4和渣含铜降低的过程等,提出了强化沉淀池中冶金过程、改善闪速炉炉况控制、优化闪速炉设计的有效途径;通过对渣含铜物相形态及渣含铜变化的研究,分析并探讨了降低渣含铜的有效方法。     

基于MetCal的双底吹连续炼铜工艺全流程模拟计算

以"底吹造锍熔炼-底吹铜锍吹炼"铜冶炼工艺为设计计算对象,基于冶金工艺流程计算系统开发平台(MetCal),运用化学平衡、质量守恒、热量守恒、元素分配约束等原理建立了底吹熔炼配料、底吹造锍熔炼、底吹熔炼余热锅炉、底吹铜锍吹炼、铜锍吹炼余热锅炉等冶金单元数学模型.开发了双底吹炼铜工艺全流程模拟系统,通过计算得到了全流程物...     

提高铜浮渣反射炉生产指标的措施

某厂采用反射炉处理铜浮渣,但一直存在铜锍铜铅比太低,铅金属损失极大;通过调整生产节奏、原料配比、辅料种类及用量等措施,铜锍中铜铅比稳定在3.3以上,取得了良好的生产指标。     

炉渣缓冷爆炸分析及研究

缓冷场转炉渣渣包自投人使用后，连续发生多次爆炸事故。通过深入研究，查出爆炸原因主要为转炉渣局部带人大量白冰铜，高温熔体未完全凝固而进水而引起的。通过加强操作过程控制减少冰铜量，利用红外装置监测异常渣包及使用便携式测温仪，事故得到有效扼制，一年半的时间里，未发生渣包缓冷爆炸事故。     

不同渣型缓冷制度下铜渣的热场仿真与分析

为了明晰不同渣型缓冷制度下铜渣温度分布,以ANSYS有限元软件为基础,建立3D模型,对其进行热场仿真研究,得出闪速炉和转炉铜渣缓冷制度下温度分布。结果表明,闪速炉和转炉铜渣前期温度下降比较缓慢,此后温度下降速度增加,在水冷前2 h内温度下降速度达到最大,随后下降速度减缓。在初期0 h时,渣包温差达到851.51 ℃,此时渣包承受热应力最大,影响渣包使用寿命,需对渣包进行预热处理。在冷却水缓冷初期2 h内,铜渣温度下降速度快,为了使含铜颗粒充分聚集,需减缓降温速度。在冷却水缓冷2~50 h阶段,铜渣已经凝固,应增加降温速度,减小渣缓冷时间,节约生产成本。     

170 t钢水罐的热 结构应力耦合分析

以武钢第一炼钢厂170 t钢水罐为研究对象,采用参数化有限元法、借助有限元前后处理软件HyperMesh和计算软件ANSYS,对其不同工况下的热 结构耦合应力进行仿真,得出钢水罐的温度场和热应力场分布,为钢水罐的设计和使用提供了依据。     

170 t钢水罐的热 结构应力耦合分析

以武钢第一炼钢厂170 t钢水罐为研究对象,采用参数化有限元法、借助有限元前后处理软件HyperMesh和计算软件ANSYS,对其不同工况下的热 结构耦合应力进行仿真,得出钢水罐的温度场和热应力场分布,为钢水罐的设计和使用提供了依据。     

钢包车焊接车架结构有限元分析与研究

利用三维机械设计软件SolidWorks,结合实际对钢包车进行设计,建立了有限元分析模型。根据钢包车工作状态模拟施加载荷和约束,采用有限元分析软件COSMOS／Works对焊接车架进行静态分析,最终得出钢包车的应力和应变云图,确定了危险点和危险截面。     

Thermodynamics of Copper Matte Converting: Part II. Distribution of Au,Ag, Pb,Zn, Ni,Se, Te,Bi, Sb and As Between Copper,Matte and Slag in the Noranda Process

The solubility of minor elements in fayalitic slags was assessed thermodynamically assuming exclusively oxidic dissolution for Pb, Zn and Ni, metallic dissolution for Au and Ag, molecular and monatomic dissolution for Se and Te, and monatomic dissolution for Bi, Sb and As. Based on these assumptions as well as the thermochemical data in the literature, an analytical method was developed to calculate the distribution equilibria of minor elements between copper, matte and slag phases. As an example of the application, the method was demonstrated for the analysis of behavior of minor elements in the Noranda Process producing metallic copper or high grade matte. The distribution of minor elements was expressed in terms of concentration ratios of an element for copper/matte, copper/slag and matte/slag phases. Using the concentration ratios and also formulae compensating for mechanical suspension, apparent distribution coefficients of the minor elements in the actual process were calculated as a function of the process parameters: temperature, partial pressure of SO₂, magnetite activity and matte grade. An excellent agreement was observed between the calculated and observed data, thus providing logical basis for interpreting operating data of the Noranda Process. The behavior of minor elements under various operating conditions can also be predicted by the present model.     

Mathematical modeling of sulfide flash smelting process: Part III. Volatilization of minor elements

The mathematical model described in Part I^[14] was extended to include the minor element behavior inside a flash-furnace shaft during flash smelting of copper concentrate. The volatilization of As, Sb, Bi, and Pb was computed, and experiments were carried out for Sb and Pb in a laboratory flash furnace. Satisfactory agreement between the predicted and measured results was obtained for antimony and lead. From the computational results, the behavior of each minor element was predicted for various target matte grades. The model predictions show that the elimination of As and Bi to the gas phase increases sharply at about 0.3 m from the burner; however, that of the Sb increases gradually along the flash-furnace shaft, and that of lead occurs suddenly at about 0.6 m from the burner. The predicted results also show that the elimination increases for Bi and Pb as the target matte grade increases; however, it is relatively independent of the target matte grade between 50 and 60 pet Cu for As and Sb. At higher target matte grades above 60 pet Cu, the elimination of As and Sb decreases as matte grade increases. formerly Graduate Student, Department of Chemical Engineering, University of Utah,     

Finite Element Analysis of 100 t Hot Metal Ladle in Process of Tipping

 Hot-metal ladle is an important part in continuous casting production line and its stress distribution has direct influence on its life. In the process of design and calibration of the large sized hot-metal ladle, it’s of great significance to determine the stress distribution of each part of the ladle for safely and reliably running the device. Based on 100t hot-metal ladle which is designed by Baotou Iron &; Steel Group, a simulation of stress field was made by finite element software ANSYS 10.0 in the different dumping angles. Through modeling, loading, restricting and calculating, strain and stress field distribution of the hot-metal ladle were acquired. Finally, an assessment of strength and stiffness was made on the hot-metal ladle. The results show that in the process of tipping for the hot-metal ladle, maximum stress is 137MPa, maximum strain is only 0.681‰, maximum stress and strain have appeared in the stiffener plate which is located at the bottom of the trunnion, and strength and stiffness are qualified. The method which is convenient and practical, reasonable and reliable provides theoretical evidence for checking analysis and further optimal design of the hot-metal ladle.     

Studies on the anodic dissolution of copper matte

Anodic polarisation studies on copper matte revealed that a copper matte electrode polariess abruptly in H,SO, solution but not in HCl solution. Anodic dissolution of copper matte was studied at various anodic potentials in 2 N solutions of HCl and H,SO,. It was found that at lower anodic potential (around 0.4 volt vs. saturated calomel electrode) copper dissolves preferentially (at 90% current efficiency) over iron (8–10% C.E.), in both the acid solutions. It was further observed that this preferential dissolution of copper takes place over a longer period (about 6 h) in HCl than in H₂SO₄ solution (about 3 h). Preferential dissolution of copper from copper matte was found to be independent of HCl concentration (0.5 N to 4 N). From the X-ray diffraction analysis of the original copper matte and electrolysed copper matte, it was established that digenite and bornite phases of copper matte dissolved causing preferential dissolution of copper.     

Selenium partitioning between slag and matte during smelting

Copper concentrates usually contain a number of minor as well as precious elements, the control of which in copper smelting processes is often a key to the quality of the anode copper produced and may also have a bearing on the overall economics of the process. During copper smelting, the copper concentrates are partially oxidized to form slag and matte. The molten slag and matte are separated from each other in the settler. The matte being heavier in density settles at the bottom of the furnace and slag being lighter in density floats over the matte and is eventually discarded off. During the separation, selenium is distributed between slag and matte. Selenium is a value added by-product of copper process. The lower recovery of selenium from the copper process is attributed to the high loss of selenium to the discarded slag. Knowledge of the distribution and form of selenium in slag and matte is very important in the control of the selenium loss, although to date very little is known regarding their distribution. The samples of slag and matte were collected from the smelter exit before their separation. Selenium was added in different proportions in the sample. The experiments involving slag-matte separation were performed at 1250°C for 4 hours of soaking time under inert atmosphere in a vertical tubular furnace. The distribution of selenium and the mechanism by which selenium is dissolved in matte and slag have been established by this study.