The Numerical Analysis And Optimization On Process In Copper Flash Furnace

Copper flash smelting is a complicated process with strong coupling multiple operation parameters. In this process, the material composition of ore, chemical composition of fuel and the operation parameters are changed with time, on the other hand, there are causations and influences among the flowing gas and melt, heat absorption and generation, heat transfer and chemical reaction in single phase or multiple phases. With the development of flash smelting, it shows more and more importance of the numerical analysis and optimization of flash furnace. The purpose of the analysis and optimization is to improve the productivity, decrease the dust generation ratio and the fuel consumption.Through detailed research on copper flash smelting system and process, according to the characteristics of the metallurgy process in copper flash furnace, with the knowledge of computational fluid dynamics, computational combustion, numerical heat transfer, a model including fluid flow, heat transfer, combustion, mass transfer and the track, temperature and chemical reaction of concentration was set up, and a flash furnace simulation system based on commercial software CFX was developed.Simulation has been done for copper flash furnace with a 2-D during developing the simulation system of copper flash furnace. The results including temperature, concentrate and particle track are obtained. The temperature of particles with different diameters and position distributions are analyzed and the influences of particle are obtained. At the same time, multiple strategies have been put forward in order to increase the speed of convergence.Guixi flash furnace, the first copper flash furnace in China, was simulated and a serial of data are obtained which can be used to instruct the operation. From these data, the reason of the flash furnace roof damage, the influence of particle distribution, particle temperature, oxidations are analyzed. At the same time, concentration flow rate 110 t-h"1 and 125 t-h'1 be compared and the influence of different high temperature zone was obtained. It ensures the safe production and decreases the dust generation ratio.With the help of simulation system of copper flash furnace, Jinlong flash furnace is also simulated. Via the simulation and factory test, the system is proved to be reliable. At same time, a forecast was done for increasing the product capacity from 65 t-h"1 to 80 t-h"1 concentration and the best operating parameters such as oxygen concentrate of process air, velocity of distribution air and proportion of oxygen in central oxygen were resulted.