Efficient energy-saving continuous melting method

Abstract

The invention discloses an efficient and energy-saving continuous melting method. The method comprises the following steps that S1, the temperature of fuel gas and the temperature of air tend to be balanced; the pretreatment comprises preliminary heating of air and preliminary heat exchange of fuel gas and air; s2, the fuel gas and the air which are subjected to temperature balance in the step S1 are guided into a premixing mechanism, the fuel gas and the air are fully mixed through the premixing mechanism, and uniform premixed gas is obtained; s3, the premixed gas obtained in the step S2 is guided into a burner, the burner sprays out the premixed gas and then combusts the premixed gas, and the copper raw material in the smelting furnace is continuously smelted; and S4, combustion state parameters in the smelting furnace are collected in real time through analysis monitoring equipment, the oxygen-enriched state or the oxygen-deficient state in the furnace is judged based on the combustion state parameters, the proportion of the fuel gas to the air is intelligently adjusted, and the combustion atmosphere in the smelting furnace is controlled. According to the method, energy consumption in the melting process of the copper raw material is remarkably reduced through energy recovery, and the technical effects of high efficiency and energy conservation are achieved.

Description

Technical Field

[0001] This invention relates to the field of copper raw material melting technology, specifically to a highly efficient and energy-saving continuous melting method. Background Technology

[0002] In the copper raw material melting process, traditional technology typically uses burners as mixers for fuel gas and air, meaning that the fuel gas and air are directly mixed inside the burner before combustion. However, this mixing method has significant drawbacks: on the one hand, the mixing time between fuel gas and air inside the burner is short, resulting in insufficient contact, and uneven mixing is often caused by large initial temperature differences, leading to low fuel gas utilization and high energy consumption; on the other hand, the mixed gas has poor uniformity, easily resulting in localized oxygen enrichment or oxygen deficiency, leading to unstable combustion, affecting the combustion atmosphere inside the furnace, making it difficult to ensure stable oxygen content in copper products, and ultimately affecting product quality.

[0003] In addition, traditional technologies use a single method for pre-treating the temperature of gas and air, which does not fully utilize the system's own energy (such as waste heat from fans and combustion flue gas), resulting in energy waste and further limiting the improvement of combustion efficiency.

[0004] Therefore, there is an urgent need for a melting method that can integrate energy recovery and is highly energy-efficient. Summary of the Invention

[0005] The main objective of this invention is to provide a highly efficient and energy-saving continuous melting method, aiming to solve the technical problems of low effective utilization rate of gas and high energy consumption in the prior art.

[0006] To achieve the above objectives, the present invention proposes a highly efficient and energy-saving continuous melting method, comprising the following steps: S1. Pre-treat the fuel gas and air used for melting copper raw materials to bring the temperatures of the fuel gas and air to a near-equilibrium; the pre-treatment includes preheating the fuel gas and air using the combustion flue gas discharged from the furnace. S2. The gas and air after temperature equilibration in step S1 are introduced into the premixing mechanism, and the gas and air are fully mixed through the premixing mechanism to obtain a uniform premixed gas. S3. The premixed gas obtained in step S2 is introduced into the burner. After the premixed gas is ejected from the burner, it is burned to continuously melt the copper raw materials in the furnace. S4. By analyzing and monitoring the combustion state parameters in the furnace in real time, the oxygen-rich or oxygen-deficient state in the furnace is determined based on the combustion state parameters, and the ratio of the fuel gas to air is intelligently adjusted to control the combustion atmosphere in the furnace, so as to ensure that the oxygen content of the product is stable during the melting of copper raw materials.

[0007] Preferably, the temperature balancing process includes preliminary heating of the air and preliminary heat exchange between the fuel gas and the air, specifically: Natural air is drawn in by a fan. The air is slightly heated during the compression and transportation process by the fan before being sent into the gas mixing pretreatment system. The gas and air heated by a fan are introduced into a buffer tank, where preliminary heat exchange takes place through the heat exchange structure inside the buffer tank, reducing the temperature difference between the gas and the air.

[0008] Preferably, the temperature balancing process further includes a preheating step: introducing the gas and air, which have undergone preliminary heat exchange in the buffer tank, into the preheating tank, using the combustion flue gas from the furnace as a heat source to preheat the gas and air, and further balancing the temperature between the gas and air.

[0009] Preferably, the preheating tank is provided with a flue gas passage and a medium passage. The combustion flue gas flows through the flue gas passage, and the fuel gas and air flow through the medium passage. Through heat exchange, the temperature of the fuel gas and air is increased by 5-30°C, and the final temperature difference between the two is controlled within ±3°C.

[0010] Preferably, the premixing mechanism includes a mixing chamber with a stirring component, in which the gas and air are stirred and mixed by the stirring component for 5-30 seconds, and the component uniformity of the mixed gas is ≥95%.

[0011] Preferably, the combustion state parameters include the oxygen content in the furnace, combustion temperature, remaining fuel gas, flow rate of premixed gas, and temperature of combustion flue gas.

[0012] Preferably, the analysis and monitoring equipment includes a hydrogen analyzer, an infrared temperature sensor, a flow sensor, and a flue gas temperature sensor. The flue gas temperature sensor is used to detect the temperature of the combustion flue gas in order to regulate the heat exchange efficiency of the preheating tank.

[0013] Preferably, the pretreatment further includes filtering the gas and air to remove impurity particles, wherein the filtration accuracy of the impurity particles is ≤10μm.

[0014] Preferably, the intelligent adjustment specifically involves: when the analysis and monitoring equipment detects that the furnace is in an oxygen-rich state, reducing the air input or increasing the gas input; when it detects that the furnace is in an oxygen-deficient state, increasing the air input or decreasing the gas input, until the combustion atmosphere meets the preset oxygen content range.

[0015] Preferably, the continuous melting of copper raw materials in the furnace specifically includes the following steps: S31. The copper raw material is fed into the feeding zone of the furnace through a continuous feeding device according to the melting rate of the copper raw material. The feeding rate of the continuous feeding device is adjusted in a timely manner according to different production capacity requirements. S32. The furnace is divided into a preheating zone and a melting zone along the material flow direction. The burner sprays out the premixed gas and burns it to each zone. The temperature of the preheating zone is controlled at 500-800℃ to initially heat up the copper raw material. The temperature of the melting zone is controlled at 1100-1300℃ to completely melt the copper raw material. S33. The molten copper flows towards the holding furnace along the guide slope of the discharge port in the furnace and is continuously discharged through the liquid level control device at the discharge port. The discharge rate is matched with the feeding rate and melting rate to maintain a stable liquid level of copper in the furnace and achieve continuous melting operation. The temperature of the holding furnace is controlled at 1100-1200℃ to maintain the temperature of the molten copper.

[0016] In the technical solution of this invention, by using the combustion flue gas to preheat the fuel gas and air and the initial heat exchange between the fuel gas and air in step S1, the waste heat of the system itself (such as the waste heat of the combustion flue gas, the temperature difference energy between the fuel gas and air, etc.) is fully recovered and utilized, avoiding the direct emission and waste of these energies in traditional technologies. This efficient utilization of the circulating energy within the system reduces dependence on external energy sources (such as additional heating energy), reduces energy consumption from the energy source, and achieves significant energy-saving effects.

[0017] The temperature balancing process in step S1 brings the initial temperatures of the gas and air closer together, eliminating the mixing resistance caused by large temperature differences in traditional technologies. Combined with the thorough mixing by the premixing mechanism in step S2, this significantly extends the contact time between the gas and air, improves mixing uniformity, and solves the problem of insufficient mixing in traditional burners. The uniformly mixed premixed gas burns more completely, avoiding incomplete combustion caused by localized oxygen deficiency (where incompletely burned gas is directly wasted in traditional technologies). This significantly improves the effective utilization rate of the gas, resulting in a substantial reduction in the amount of gas required to melt a unit of copper raw material, directly reducing gas energy consumption.

[0018] Step S4, by monitoring the combustion status in real time and intelligently adjusting the ratio of fuel gas to air, avoids the localized oxygen-rich (excessive air carries away heat) or localized oxygen-deficient (fuel gas waste) phenomena caused by uneven mixing in traditional technologies. A stable combustion atmosphere ensures that the combustion heat is more concentrated for melting copper raw materials, reducing ineffective heat loss due to unstable combustion (such as excess air carrying heat out of the furnace), further improving energy utilization efficiency and reducing the overall energy consumption of the melting process.

[0019] In summary, this method addresses the energy consumption deficiencies of traditional technologies by focusing on three dimensions: energy recovery, improved gas utilization, and optimized combustion process. It significantly reduces energy consumption during the copper raw material melting process and achieves highly efficient and energy-saving technical results. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the efficient and energy-saving continuous melting method of the present invention.

[0022] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0024] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0025] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" can explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0026] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two elements or the interaction between two elements, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible to those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0028] This invention proposes a highly efficient and energy-saving continuous melting method.

[0029] Please refer to Figure 1 This efficient and energy-saving continuous melting method includes the following steps: S1. Pre-treat the fuel gas and air used for melting copper raw materials to bring the temperatures of the fuel gas and air to a near-equilibrium; the pre-treatment includes preheating the fuel gas and air using the combustion flue gas discharged from the furnace. S2. The gas and air after temperature equilibration in step S1 are introduced into the premixing mechanism, and the gas and air are fully mixed through the premixing mechanism to obtain a uniform premixed gas. S3. The premixed gas obtained in step S2 is introduced into the burner. After the premixed gas is ejected from the burner, it is burned to continuously melt the copper raw materials in the furnace. S4. By analyzing and monitoring the combustion state parameters in the furnace in real time, the oxygen-rich or oxygen-deficient state in the furnace is determined based on the combustion state parameters, and the ratio of the fuel gas to air is intelligently adjusted to control the combustion atmosphere in the furnace, so as to ensure that the oxygen content of the product is stable during the melting of copper raw materials.

[0030] In the technical solution of this invention, by using the combustion flue gas to preheat the fuel gas and air and the initial heat exchange between the fuel gas and air in step S1, the waste heat of the system itself (such as the waste heat of the combustion flue gas, the temperature difference energy between the fuel gas and air, etc.) is fully recovered and utilized, avoiding the direct emission and waste of these energies in traditional technologies. This efficient utilization of the circulating energy within the system reduces dependence on external energy sources (such as additional heating energy), reduces energy consumption from the energy source, and achieves significant energy-saving effects.

[0031] The temperature balancing process in step S1 brings the initial temperatures of the gas and air closer together, eliminating the mixing resistance caused by large temperature differences in traditional technologies. Combined with the thorough mixing by the premixing mechanism in step S2, this significantly extends the contact time between the gas and air, improves mixing uniformity, and solves the problem of insufficient mixing in traditional burners. The uniformly mixed premixed gas burns more completely, avoiding incomplete combustion caused by localized oxygen deficiency (where incompletely burned gas is directly wasted in traditional technologies). This significantly improves the effective utilization rate of the gas, resulting in a substantial reduction in the amount of gas required to melt a unit of copper raw material, directly reducing gas energy consumption.

[0032] Step S4, by monitoring the combustion status in real time and intelligently adjusting the ratio of fuel gas to air, avoids the localized oxygen-rich (excessive air carries away heat) or localized oxygen-deficient (fuel gas waste) phenomena caused by uneven mixing in traditional technologies. A stable combustion atmosphere ensures that the combustion heat is more concentrated for melting copper raw materials, reducing ineffective heat loss due to unstable combustion (such as excess air carrying heat out of the furnace), further improving energy utilization efficiency and reducing the overall energy consumption of the melting process.

[0033] In summary, this method addresses the energy consumption deficiencies of traditional technologies by focusing on three dimensions: energy recovery, improved gas utilization, and optimized combustion process. It significantly reduces energy consumption during the copper raw material melting process and achieves highly efficient and energy-saving technical results.

[0034] Please refer to the appendix. Figure 1 The temperature balancing process includes preliminary heating of the air and preliminary heat exchange between the fuel gas and the air, specifically: Natural air is drawn in by a fan. The air is slightly heated during the compression and transportation process by the fan before being sent into the gas mixing pretreatment system. The gas and air heated by a fan are introduced into a buffer tank, where preliminary heat exchange takes place through the heat exchange structure inside the buffer tank, reducing the temperature difference between the gas and the air.

[0035] By utilizing the small amount of heating generated during the compression and delivery of air by the fan, the air is preheated without the need for additional external energy consumption, thus achieving effective energy recovery within the system itself. This direct utilization of the fan's waste heat avoids the idle waste of this energy, reduces energy loss from the perspective of internal energy circulation, significantly improves energy utilization efficiency, and achieves energy-saving effects.

[0036] By utilizing the heat exchange structure within the buffer tank, the air and gas, initially heated by the fan, undergo preliminary heat exchange, effectively reducing the temperature difference between them. This solves the problems of high mixing resistance and insufficient contact caused by the large initial temperature difference between gas and air in traditional technologies. Gas and air, with their temperatures approaching equilibrium, are more easily and uniformly mixed in subsequent premixing processes, reducing mixing "barriers" caused by temperature differences. This lays the foundation for thorough mixing in subsequent premixing mechanisms, thereby reducing incomplete combustion of gas due to uneven mixing, improving the effective utilization rate of gas, reducing gas consumption per unit melting volume, and further enhancing energy-saving effects.

[0037] Please refer to the appendix. Figure 1 The temperature balancing process also includes a preheating step: the gas and air that have undergone preliminary heat exchange in the buffer tank are introduced into the preheating tank, and the combustion flue gas of the furnace is used as a heat source to preheat the gas and air, further balancing the temperature between the gas and air.

[0038] By using the combustion flue gas from the furnace as a heat source to preheat the fuel gas and air, the waste heat from the flue gas (which is part of the system's own energy) that is directly emitted in traditional technologies is fully utilized, avoiding the waste of this high-grade thermal energy. This deep recovery of waste heat from the flue gas reduces dependence on external heating energy, realizing "turning waste into treasure" from an energy cycle perspective, significantly reducing the overall energy consumption of the system, and enhancing the energy-saving effect.

[0039] Building upon the initial heat exchange in step 2, a preheating step further reduces the temperature difference between the gas and air, bringing their initial temperatures closer together. This solves the problems of high mixing resistance and insufficient contact caused by large temperature differences in traditional technologies, creating better conditions for thorough mixing in the subsequent premixing mechanism. It significantly improves the uniformity of gas-air mixing, thereby avoiding incomplete combustion due to localized oxygen deficiency (reducing gas waste), increasing the effective utilization rate of gas, and lowering gas consumption per unit melting volume.

[0040] Please refer to the appendix. Figure 1 The preheating tank is equipped with a flue gas passage and a medium passage. The combustion flue gas flows through the flue gas passage, and the fuel gas and air flow through the medium passage. Through heat exchange, the temperature of the fuel gas and air is increased by 5-30°C, and the final temperature difference between the two is controlled within ±3°C.

[0041] The preheating tank, through its structural design of flue gas and medium channels, achieves efficient heat exchange between combustion flue gas, fuel gas, and air. It also precisely raises the temperature of fuel gas and air by 5-30°C. This specific temperature increase range quantifies the recovery effect of flue gas waste heat. This avoids energy waste caused by insufficient waste heat recovery and ensures the economy of the heat exchange process through a reasonable temperature increase range (not overheating). It enables the precise and effective utilization of the heat from the flue gas that would otherwise be directly emitted, reducing dependence on external heating energy and achieving targeted energy saving from the waste heat recovery stage.

[0042] By strictly controlling the final temperature difference between the gas and air within ±3℃, this precise temperature control completely solves the mixing resistance problem caused by large temperature differences in traditional technologies. The extremely small temperature difference makes the physical states of the gas and air more similar, resulting in higher molecular coordination. This allows for rapid and thorough contact and mixing in the subsequent premixing mechanism, significantly reducing localized oxygen-rich or oxygen-poor phenomena. The uniformly mixed premixed gas burns more completely, avoiding incomplete combustion and waste caused by uneven mixing, significantly improving the effective utilization rate of the gas, reducing the gas consumption per unit of copper raw material melting, and directly enhancing energy-saving effects.

[0043] Please refer to the appendix. Figure 1The premixing mechanism includes a mixing chamber with a stirring component. The gas and air are stirred and mixed in the mixing chamber by the stirring component. The mixing time is 5-30 seconds, and the component uniformity of the mixed gas is ≥95%.

[0044] The stirring component generates turbulence in the mixing chamber (as in the design of the premixing chamber in Abstract 5), which fully disperses the gas and air molecules, achieving a mixing uniformity of ≥95%, thus solving the problem of uneven local concentration caused by traditional laminar flow mixing.

[0045] A mixing time of 5-30 seconds ensures that gas molecules complete the diffusion process, improving mixing efficiency by more than 20 times compared to the millisecond-level mixing in traditional burners.

[0046] Uniform premixed gas combustion results in a more stable flame, reducing flame flickering and localized overheating caused by uneven mixing, protecting the furnace lining and extending burner life.

[0047] Please refer to the appendix. Figure 1 The combustion state parameters include the oxygen content in the furnace, combustion temperature, remaining fuel gas, flow rate of premixed gas, and temperature of combustion flue gas.

[0048] By incorporating oxygen content, combustion temperature, residual fuel gas, premixed gas flow rate, and flue gas temperature into the monitoring parameters, a multi-dimensional monitoring system covering the core combustion process has been constructed. Compared to the potential problems of single or incomplete monitoring parameters in traditional technologies, these parameters comprehensively reflect whether combustion is complete (residual fuel gas), whether heat utilization is efficient (combustion temperature, flue gas temperature), and whether the mixing ratio is reasonable (oxygen content, premixed gas flow rate). This provides accurate and comprehensive data for subsequent parameter adjustments, avoiding blind adjustments due to incomplete information and laying the foundation for energy-saving optimization from the source of monitoring.

[0049] Please refer to the appendix. Figure 1 The analysis and monitoring equipment includes a hydrogen analyzer, an infrared temperature sensor, a flow sensor, and a flue gas temperature sensor. The flue gas temperature sensor is used to detect the temperature of the combustion flue gas in order to regulate the heat exchange efficiency of the preheating tank.

[0050] By specifically configuring a hydrogen analyzer, infrared temperature sensor, flow sensor, and flue gas temperature sensor, direct and accurate detection of core combustion parameters (oxygen content, combustion temperature, premixed gas flow rate, and flue gas temperature) is achieved. Compared to the potential problems of ambiguous monitoring parameters or insufficient detection accuracy in traditional technologies, this configuration ensures that the data of each parameter truly reflects the actual combustion state, avoiding misjudgments or ineffective adjustments due to data errors. This provides a precise basis for subsequent energy optimization and control, reducing energy waste caused by blind operation from the monitoring stage.

[0051] A hydrogen analyzer is an instrument that can test the actual oxygen content, but it is not limited to hydrogen analyzers; it can also be a carbon monoxide analyzer or similar equipment.

[0052] Please refer to the appendix. Figure 1 The pretreatment also includes filtering the gas and air to remove impurity particles, with the filtration accuracy of the impurity particles being ≤10μm.

[0053] By filtering the fuel gas and air (filtration accuracy ≤10μm), tiny impurity particles are effectively removed, preventing them from hindering the full contact between fuel gas and air molecules. Clean gas is more easily and uniformly mixed in the premixing mechanism, reducing localized incomplete mixing caused by impurities. This ensures efficient reaction and complete combustion of the fuel gas and air, avoiding incomplete combustion and waste caused by impurities hindering mixing in traditional technologies. This significantly improves fuel gas utilization, reduces fuel gas consumption per unit of copper raw material melt, and directly enhances energy-saving effects.

[0054] Please refer to the appendix. Figure 1 The intelligent adjustment specifically refers to the following: when the analysis and monitoring equipment detects that the furnace is in an oxygen-rich state, the air input is reduced or the gas input is increased; when an oxygen-deficient state is detected, the air input is increased or the gas input is reduced until the combustion atmosphere meets the preset oxygen content range.

[0055] For oxygen-rich conditions, by reducing the air input or increasing the gas input, the problem of excessive air carrying combustion heat with the flue gas in traditional technologies can be avoided (excessive air, as a "heat carrier," will carry away a large amount of heat that is not effectively utilized), reducing the ineffective loss of heat, and making the heat energy generated by combustion more concentrated for melting copper raw materials, directly improving heat utilization efficiency. In the case of oxygen-deficient conditions, increasing the air input or decreasing the gas input can solve the problem of incomplete combustion of gas due to insufficient oxygen (unburned gas cannot release all heat energy, which is a direct waste of energy), ensure that the gas releases heat fully, increase the heat output per unit of gas, reduce the gas consumption per unit of melting, and achieve significant energy saving from the perspective of combustion efficiency.

[0056] Please refer to the appendix. Figure 1 The continuous melting of copper raw materials in the furnace specifically includes the following steps: S31. The copper raw material is fed into the feeding zone of the furnace through a continuous feeding device according to the melting rate of the copper raw material. The feeding rate of the continuous feeding device is adjusted in a timely manner according to different production capacity requirements. S32. The furnace is divided into a preheating zone and a melting zone along the material flow direction. The burner sprays out the premixed gas and burns it to each zone. The temperature of the preheating zone is controlled at 500-800℃ to initially heat up the copper raw material. The temperature of the melting zone is controlled at 1100-1300℃ to completely melt the copper raw material. S33. The molten copper flows towards the holding furnace along the guide slope of the discharge port in the furnace and is continuously discharged through the liquid level control device at the discharge port. The discharge rate is matched with the feeding rate and melting rate to maintain a stable liquid level of copper in the furnace and achieve continuous melting operation. The temperature of the holding furnace is controlled at 1100-1200℃ to maintain the temperature of the molten copper.

[0057] Adjusting the feeding rate in a timely manner according to different production capacity requirements enables continuous output and 24-hour uninterrupted production, increasing production capacity by 50%-100% compared to intermittent furnaces.

[0058] The zoned design of the preheating zone (500-800℃) and the melting zone (1100-1300℃) allows the copper material to heat up gradually, reducing cracking caused by thermal stress and improving the utilization rate of thermal energy.

[0059] Liquid level stability control By using a liquid level sensor and a guide slope design, the copper liquid discharge rate is ensured to match the feeding and melting rates, thus avoiding the impact of liquid level fluctuations on temperature distribution and melting efficiency.

[0060] Co-operation with the holding furnace: The temperature of the holding furnace is controlled at 1100-1200℃ to maintain the fluidity of the molten copper, which facilitates continuous operation of subsequent casting processes.

[0061] The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural transformations made under the concept of the present invention using the description and drawings of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A highly efficient and energy-saving continuous melting method, characterized in that, Includes the following steps: S1. Pre-treat the fuel gas and air used for melting copper raw materials to bring the temperatures of the fuel gas and air to a near-equilibrium; the pre-treatment includes preheating the fuel gas and air using the combustion flue gas discharged from the furnace. S2. The gas and air after temperature equilibration in step S1 are introduced into the premixing mechanism, and the gas and air are fully mixed through the premixing mechanism to obtain a uniform premixed gas. S3. The premixed gas obtained in step S2 is introduced into the burner. After the premixed gas is ejected from the burner, it is burned to continuously melt the copper raw materials in the furnace. S4. By analyzing and monitoring the combustion state parameters in the furnace in real time, the oxygen-rich or oxygen-deficient state in the furnace is determined based on the combustion state parameters, and the ratio of fuel gas to air is intelligently adjusted to control the combustion atmosphere in the furnace, so as to ensure that the oxygen content of the product is stable during the melting of copper raw materials.

2. The efficient and energy-saving continuous melting method according to claim 1, characterized in that, The temperature balancing process includes preliminary heating of the air and preliminary heat exchange between the fuel gas and the air, specifically: Natural air is drawn in by a fan. The air is slightly heated during the compression and transportation process by the fan before being sent into the gas mixing pretreatment system. The gas and air heated by a fan are introduced into a buffer tank, where preliminary heat exchange takes place through the heat exchange structure inside the buffer tank, reducing the temperature difference between the gas and the air.

3. The high-efficiency and energy-saving continuous melting method according to claim 2, characterized in that, The temperature balancing process also includes a preheating step: the gas and air that have undergone preliminary heat exchange in the buffer tank are introduced into the preheating tank, and the combustion flue gas of the furnace is used as a heat source to preheat the gas and air, further balancing the temperature between the gas and air.

4. The high-efficiency and energy-saving continuous melting method according to claim 3, characterized in that, The preheating tank is equipped with a flue gas passage and a medium passage. Combustion flue gas flows through the flue gas passage, while fuel gas and air flow through the medium passage. Through heat exchange, the temperature of the fuel gas and air is increased by 5-30°C, and the final temperature difference between the two is controlled within ±3°C.

5. The efficient and energy-saving continuous melting method according to claim 1, characterized in that, The premixing mechanism includes a mixing chamber with a stirring component. The gas and air are stirred and mixed in the mixing chamber by the stirring component for 5-30 seconds. The component uniformity of the mixed gas is ≥95%.

6. The high-efficiency and energy-saving continuous melting method according to claim 1, characterized in that, The combustion state parameters include the oxygen content in the furnace, combustion temperature, remaining fuel gas, flow rate of premixed gas, and temperature of combustion flue gas.

7. The high-efficiency and energy-saving continuous melting method according to claim 6, characterized in that, The analysis and monitoring equipment includes a hydrogen analyzer, an infrared temperature sensor, a flow sensor, and a flue gas temperature sensor. The flue gas temperature sensor is used to detect the temperature of the combustion flue gas in order to regulate the heat exchange efficiency of the preheating tank.

8. The efficient and energy-saving continuous melting method according to claim 1, characterized in that, The pretreatment also includes filtering the gas and air to remove impurity particles, with the filtration accuracy of the impurity particles being ≤10μm.

9. The high-efficiency and energy-saving continuous melting method according to claim 1, characterized in that, The intelligent adjustment specifically involves: when the analysis and monitoring equipment detects that the furnace is in an oxygen-rich state, reducing the air input or increasing the gas input; when it detects that the furnace is in an oxygen-deficient state, increasing the air input or decreasing the gas input, until the combustion atmosphere meets the preset oxygen content range.

10. The high-efficiency and energy-saving continuous melting method according to claim 1, characterized in that, The continuous melting of copper raw materials in the furnace specifically includes the following steps: S31. The copper raw material is fed into the feeding zone of the furnace through a continuous feeding device according to the melting rate of the copper raw material. The feeding rate of the continuous feeding device is adjusted in a timely manner according to different production capacity requirements. S32. The furnace is divided into a preheating zone and a melting zone along the material flow direction. The burner sprays out the premixed gas and burns it to each zone. The temperature of the preheating zone is controlled at 500-800℃ to initially heat up the copper raw material. The temperature of the melting zone is controlled at 1100-1300℃ to completely melt the copper raw material. S33. The molten copper flows towards the holding furnace along the guide slope of the discharge port in the furnace and is continuously discharged through the liquid level control device at the discharge port. The discharge rate is matched with the feeding rate and melting rate to maintain a stable liquid level of copper in the furnace and achieve continuous melting operation. The temperature of the holding furnace is controlled at 1100-1200℃ to maintain the temperature of the molten copper.

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