A non-submerged high-efficiency molten bath smelting daughter-mother furnace and a smelting process method thereof

Abstract

The present application relates to non-ferrous pyrometallurgical technology field, specifically disclose a kind of sub-mother furnace of immersion-free efficient molten pool smelting and smelting process method, the sub-mother furnace is made of mother furnace and sub-furnace, melt passage is equipped between the lower part of mother furnace and sub-furnace, partition is equipped between waist, and flue is equipped between upper part;Several gas beam lances that pass into mother furnace cavity are evenly distributed in the circumferential direction of mother furnace along its furnace body;The top of mother furnace is equipped with mother furnace flat top, and feeding port is equipped on the top of mother furnace flat top, and the side of mother furnace flat top away from sub-furnace is smoke outlet;The top of sub-furnace is equipped with sub-furnace flat top, and sampling port, burner port are equipped on the top of sub-furnace flat top;Metal discharge port, tap hole, slag overflow port are equipped on the furnace body of sub-furnace.The present application can use the reaction gas of any oxygen concentration, and sub-furnace provides continuous layered discharge space, so as to realize efficient molten pool smelting, and the present application is not immersed in molten pool, and does not need to worry about the erosion of molten pool to spray gun, and the service life of spray gun is longer.

Description

Technical Field

[0001] This invention relates to the field of pyrometallurgical technology for non-ferrous metals, and more specifically, to a non-immersion high-efficiency molten pool furnace and its smelting process. Background Technology

[0002] The most commonly used technologies in non-ferrous metal pyrometallurgical processes are pool smelting and flash smelting. In the case of copper smelting, although the rapid development of flash smelting has achieved high oxygen enrichment and high efficiency, its extremely demanding batching process and high-quality raw materials require a large investment and high infrastructure costs.

[0003] Traditional molten pool smelting technology has the following problems:

[0004] ①. Traditional molten pool smelting technology can be divided into three processes: side blowing, top blowing, and bottom blowing. In all three processes, the spray gun is immersed in the molten pool and sprays the reaction gas. The spray gun is subjected to the erosion and scouring of the high temperature melt for a long time, which makes it easy to be damaged. Replacing or repairing the spray gun will take up a lot of operation time, resulting in low operation efficiency.

[0005] ②. Traditional smelting technology results in relatively low oxygen concentrations in the reaction gas, low smelting efficiency, and the generation of a large amount of smelting flue gas. A large amount of heat is lost in the flue gas, and the SO2 concentration in the smelting flue gas is relatively low, which is not conducive to the production of acid from smelting flue gas.

[0006] ③. Traditional molten pool smelting technology suffers from poor metal and slag settling and separation because the reaction zone is constantly agitated. During continuous operation, either stratified discharge is difficult to achieve, or the poor settling and separation results in a high metal content in the slag. To improve settling and separation, copper smelting typically adds a settling electric furnace at the rear of the smelting furnace to provide a settling space for the metal. However, this design adds an extra settling electric furnace system, resulting in a longer process time and significantly higher energy consumption.

[0007] Therefore, there is a need to provide a molten pool smelting technology to address the shortcomings of existing smelting technologies and achieve efficient, low-consumption, and clean production of non-ferrous metals. Summary of the Invention

[0008] In view of this, the present invention proposes a non-immersion high-efficiency molten pool smelting furnace and its smelting process, the specific technical solution of which is as follows:

[0009] This invention provides a non-immersion high-efficiency smelting furnace consisting of a mother furnace and a daughter furnace, which are two parallel upright columns. A molten material channel connecting the two furnace chambers is located between their lower parts, a partition wall is installed between their middle sections, and a sloping daughter furnace flue is located between their upper sections, connecting the daughter furnace flue to the upper part of the mother furnace chamber. Several gas jet nozzles are evenly distributed around the circumference of the mother furnace, all pointing downwards towards the centerline of the mother furnace. The mother furnace has a flat top with a charging port, and a flue outlet on the side of the flat top furthest from the daughter furnace. The daughter furnace top... The furnace is equipped with a sub-furnace flat top, which has a sampling port and a burner port. On the upper surface of the sub-furnace flat top near the mother furnace, there is a flue wall with its top end lower than the mother furnace flat top. The mother furnace flat top and the flue wall are connected by the inclined furnace top of the mother and daughter furnaces. The melt channel, the sub-furnace flue, and the partition wall are all located below the inclined furnace top of the mother and daughter furnaces. The furnace body of the sub-furnace is equipped with a metal outlet and a slag overflow outlet, and the bottom of the partition wall is located below the slag overflow outlet. The metal outlet is lower than the upper edge of the melt channel. If the mother and daughter furnaces are matte smelting furnaces, the furnace body of the sub-furnace is also equipped with a matte outlet, which is also lower than the upper edge of the melt channel.

[0010] By adopting the above technical solution, the present invention provides a non-immersion high-efficiency molten pool smelting mother-daughter furnace comprising two complementary and connected smelting spaces. The mother furnace provides the molten pool smelting reaction field, and the daughter furnace provides the settling and stratification discharge space. The reaction gas required for smelting in the mother-daughter furnace is directly injected into the molten pool by a gas jet nozzle on the mother furnace body. The reaction gas ejected by the gas jet nozzle is a high-pressure, hypersonic gas flow. Because the nozzle is not immersed in the molten pool, the ejected gas flow resembles a laser beam, hence it is named a gas jet nozzle. The gas jet penetrates deep into the molten pool and reacts with the melt. The incompletely reacted melt and reaction gas rise upwards and complete the metallurgical physicochemical reaction with the falling concentrate.

[0011] This invention can use reaction gas of any oxygen concentration, and the sub-furnace provides a continuous stratified discharge space, thereby achieving efficient molten pool smelting. Furthermore, the spray gun of this invention is not immersed in the molten pool, so there is no need to worry about the molten pool scouring and corroding the spray gun, resulting in a longer service life for the spray gun.

[0012] Preferably, in the above-mentioned non-immersion high-efficiency molten pool smelting mother furnace, the mother furnace and the daughter furnace are two parallel standing cylinders or two regular polygonal cylinders, and the mother furnace and the daughter furnace are reinforced by a clamp.

[0013] Preferably, in the above-mentioned non-immersion high-efficiency molten pool smelting mother furnace, the mother furnace is provided with 3 to 10 evenly distributed gas jet spray guns at a distance of 2 / 3 to 4 / 5 of the height from the bottom of its cavity; the gas jets sprayed by the gas jet spray guns form an angle of 30 to 45° with the center line of the mother furnace.

[0014] Preferably, in the above-mentioned non-immersion high-efficiency molten pool smelting mother furnace, a charging port is provided on the top of the mother furnace corresponding to the center line of the mother furnace, and the charging port is a circular charging port with an inner diameter of 500mm to 1000mm. The exhaust port located on one side of the top of the mother furnace is connected to the downstream flue gas treatment process.

[0015] Preferably, in the above-mentioned non-immersion high-efficiency smelting furnace, the vertical distance between the flue wall and the center line of the furnace is 1 / 2 of the radius of the furnace cavity; the burner is located on the top of the furnace and away from the mother furnace, and the vertical distance between the burner and the center line of the furnace is 1 / 2 of the radius of the furnace cavity; the lower outlet end of the burner gradually tilts towards the side closer to the mother furnace within the furnace cavity.

[0016] Preferably, in the above-mentioned non-immersion high-efficiency molten pool smelting mother furnace, the bottom of the cavities of the mother furnace and the daughter furnace are on the same horizontal plane, the metal outlet is 0mm away from the bottom of the daughter furnace cavity, the matte outlet is 300-600mm away from the bottom of the daughter furnace cavity, the slag overflow outlet is 1600-2500mm away from the bottom of the daughter furnace cavity, and the bottom of the partition wall between the mother furnace and the daughter furnace is located 100-200mm below the plane of the slag overflow outlet.

[0017] Preferably, in the above-mentioned non-immersion high-efficiency molten pool smelting mother-daughter furnace, the size of the mother furnace cavity is: The dimensions of the sub-furnace cavity are The melt channel between the lower parts of the mother furnace and the daughter furnace is 250mm to 500mm wide; the bottom of the partition wall is parallel to the furnace bottom, the thickness of the partition wall at its widest point is 500 to 1000mm, the top of the partition wall is parallel to the inclined furnace top of the mother and daughter furnaces, and a daughter furnace flue with a width of 250mm to 500mm is formed between the top of the partition wall and the inclined furnace top of the mother and daughter furnaces.

[0018] This invention also provides a smelting process method for a non-immersion high-efficiency molten pool smelting furnace, comprising the following steps:

[0019] S1. The concentrate falls from the charging port on the top of the mother furnace into the mother furnace molten pool. After receiving the charging signal, the control system uses the metallurgical calculation model to calculate the amount of reaction gas required for the reaction. Under the protection of the outer protective gas, the reaction gas jet is directly injected into the depth of the mother furnace molten pool through the gas jet spray gun after the pressure and speed are adjusted.

[0020] S2. The reactant gas and the melt undergo a smelting reaction, forming a turbulent field. The unreacted melt and reactant gas rise upwards and come into contact with the falling concentrate, thus completing the metallurgical physicochemical reaction.

[0021] S3. After the reaction, the melt flows from the mother furnace through the melt channel to the daughter furnace, where it settles and stratifies. The slag is continuously discharged from the slag overflow port, and the bottom matte layer or metal layer is discharged from the furnace body through the corresponding matte outlet or metal outlet. The smelting flue gas in the daughter furnace enters the mother furnace through the daughter furnace flue, merges with the flue gas in the mother furnace, and is discharged through the exhaust port.

[0022] Preferably, in the above-mentioned smelting process of a non-immersion high-efficiency molten pool smelting mother-daughter furnace, as the smelting reaction continues, matte or metal is intermittently discharged from the matte outlet or metal outlet, and the height of the matte layer or metal layer is controlled to be lower than the upper edge of the melt channel; during the smelting operation, the thickness of the matte layer or metal layer needs to be measured every 30 min to 60 min, the sampling ruler is inserted into the bottom of the molten pool of the daughter furnace from the sampling port, and removed after standing for 2 to 3 min. The height of the thinner slag layer at the lower end of the sampling ruler is the thickness of the matte layer or metal layer, and the sampling and testing results are used to supplement the process control.

[0023] Preferably, in the above-mentioned smelting process of a non-immersion high-efficiency molten pool smelting mother-daughter furnace, all gas jet spray guns can be used simultaneously, or three or more spray guns can be used evenly distributed. The gas jets sprayed by the gas jet spray guns are one or more of air, nitrogen, oxygen, and carbon dioxide, with an oxygen concentration of 0-100%. The protective gas carried on the surface of the gas jets wraps around the reactive gas jets. The protective gas is used to protect the reactive gas jets to have sufficient impact strength and to protect the reactive gas jets from chemical changes and deterioration during their passage. The reactive gas pressure at the front end of the gas jet spray gun is 0.5-1.5 MPa, and the gas jet velocity is 340-600 m / s.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The smelting reaction gas has a high oxygen concentration, making the smelting operation very efficient. The smelting flue gas has a high SO2 concentration, resulting in a high acid production rate. The total amount of flue gas produced is small, heat loss is low, energy consumption is low, and the smelting environment is clean.

[0026] 2. The gas jet spray gun is not immersed in the high-temperature molten pool, so there is no need to worry about the molten pool eroding and corroding the spray gun, resulting in a longer service life. The mother-daughter furnace is equipped with multiple gas jet spray guns, so even if a spray gun is damaged, maintenance can be carried out directly on the damaged spray gun, and stopping one or two spray guns will not affect the normal production order.

[0027] 3. This invention is a molten pool smelting technology with strong raw material adaptability. The oxidation-reduction atmosphere can be controlled by adjusting the ratio of oxidizing gas and reducing gas. It can be used for both oxidation smelting and reduction smelting. The gas jet lance can also be used for furnace heat preservation. Using this mother-daughter furnace, there is no need to add a heat preservation device to the mother furnace. It can be widely used in the smelting of non-ferrous metals such as copper, nickel, cobalt, tin, and lead.

[0028] 4. When this invention is used in matte smelting, the reaction gas is directly injected into the matte layer at the bottom of the molten pool, the oxygen utilization rate is very high, the amount of magnetic iron generated which is more harmful to smelting is relatively small, the slag has good fluidity, and the slag and matte are clearly separated in the sub-furnace.

[0029] 5. The sub-furnace replaces the traditional settling electric furnace, providing a relatively static space for the settling and separation of the melt. The slag has a low metal content, and the slag is continuously overflowed and discharged. The bottom metal layer is discharged through intermittent burners.

[0030] 6. During the smelting process, the high-temperature melt tumbles up and down without spiraling in the molten pool, resulting in less erosion and corrosion of the refractory materials and a longer-lasting furnace lining compared to traditional molten pool smelting technology. Attached Figure Description

[0031] 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 embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0032] Figure 1 This is a schematic diagram of the overall structure of a high-efficiency molten pool furnace without immersion according to the present invention.

[0033] Figure 2 This is a top view schematic diagram of a high-efficiency molten pool furnace for non-immersion smelting according to the present invention.

[0034] Figure 3 This is a front view schematic diagram of a high-efficiency molten pool furnace for non-immersion smelting according to the present invention.

[0035] Figure 4 This is a left view of a high-efficiency molten pool furnace for non-immersion smelting according to the present invention.

[0036] Figure 5 This is a cross-sectional view of the mother furnace and daughter furnace obtained by cutting along the center line of the mother furnace and daughter furnace of the present invention, which is a high-efficiency molten pool smelting furnace without immersion.

[0037] In the diagram: 1-Main furnace flat top, 2-Sloping top of mother and daughter furnaces, 3-Daughter furnace flat top, 4-Burner inlet, 5-Sampling inlet, 6-Slag overflow inlet, 7-Daughter furnace, 8-Mattress outlet, 9-Metal outlet, 10-Main furnace, 11-Gas jet lance, 12-Charging inlet, 13-Clamping hoop, 14-Flue outlet, 15-Gas jet, 16-Burner, 17-Daughter furnace flue, 18-Partition wall, 19-Melted material channel, 20-Flue vertical wall. Detailed Implementation

[0038] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0039] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0040] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0041] like Figures 1-5 As shown, the present invention provides a high-efficiency molten pool smelting furnace without immersion, which consists of a mother furnace 10 and a daughter furnace 7. The mother furnace 10 and the daughter furnace 7 are two parallel standing cylinders or two regular polygonal cylinders, and the mother furnace 10 and the daughter furnace 7 are reinforced as a whole by a clamp 13.

[0042] There is a melt channel 19 connecting the two furnace chambers between the lower parts of the mother furnace 10 and the daughter furnace 7, a partition wall 18 between the middle parts, and a sloping daughter furnace flue 17 between the upper parts, which is connected to the upper part of the cavity of the mother furnace 10.

[0043] The mother furnace 10 has several gas jet nozzles 11 evenly distributed around its circumference, which enter the mother furnace cavity, and the nozzles of the gas jet nozzles 11 all point obliquely downwards toward the center line of the mother furnace.

[0044] More specifically, the mother furnace 10 has 3 to 10 evenly distributed gas jet spray guns 11 arranged circumferentially at a distance of 2 / 3 to 4 / 5 of its cavity bottom; the gas jet spray guns 11 spray out gas jets ( Figure 2 , Figure 3 , Figure 5 The reference number 15 indicates an angle of 30-45° with the center line of the mother furnace.

[0045] The top of the mother furnace 10 is provided with a mother furnace flat furnace top 1, and a feeding port 12 is provided on the mother furnace flat furnace top 1. The feeding port 12 is a circular feeding port with an inner diameter of 500mm to 1000mm. The side of the mother furnace flat furnace top 1 away from the daughter furnace 7 is the flue gas outlet 14, which is connected to the downstream flue gas treatment process.

[0046] The top of the sub-furnace 7 is provided with a sub-furnace flat top 3. The sub-furnace flat top 3 is provided with a sampling port 5 and a burner port 4. On the upper surface of the sub-furnace flat top 3 near the mother furnace 10, a flue wall 20 with its top end lower than the mother furnace flat top 1 is vertically fixed. The mother furnace flat top 1 and the flue wall 20 are connected by the sub-furnace inclined top 2. The melt channel 19, the sub-furnace flue 17 and the partition wall 18 are all located below the sub-furnace inclined top 2.

[0047] More specifically, the vertical distance between the flue wall 20 and the center line of the sub-furnace is 1 / 2 of the radius of the sub-furnace cavity; the burner opening 4 is located on the top of the sub-furnace flat furnace 3 at the end away from the mother furnace 10, and the vertical distance between the burner opening 4 and the center line of the sub-furnace is 1 / 2 of the radius of the sub-furnace cavity; the lower outlet end of the burner 16 gradually tilts towards the side closer to the mother furnace 10 within the sub-furnace cavity.

[0048] The furnace body of the slave furnace 7 is equipped with a metal outlet 9 and a slag overflow outlet 6, and the bottom of the partition wall 18 is located below the slag overflow outlet 6. The metal outlet 9 is lower than the upper edge of the melt channel 19. If the master furnace 10 is a matte smelting furnace, the furnace body of the slave furnace 7 is also equipped with a matte outlet 8, which is also lower than the upper edge of the melt channel 19. Generally, only matte smelting furnaces are equipped with matte outlet 8, and other smelting processes do not have this outlet.

[0049] More specifically, the bottom of the chambers of the mother furnace 10 and the daughter furnace 7 are on the same horizontal plane. The metal outlet 9 is 0mm away from the bottom of the daughter furnace chamber (i.e., the metal outlet 9 is flush with the bottom of the daughter furnace chamber). The matte outlet 8 is 300-600mm away from the bottom of the daughter furnace chamber. The slag overflow outlet 6 is 1600-2500mm away from the bottom of the daughter furnace chamber. The bottom of the partition wall between the mother furnace 10 and the daughter furnace 7 is located 100-200mm below the plane of the slag overflow outlet.

[0050] In a specific embodiment, the dimensions of the mother furnace cavity are: The dimensions of the sub-furnace cavity are The melt channel 19 between the lower parts of the mother furnace 10 and the daughter furnace 7 is 250mm to 500mm wide; the bottom of the partition wall 18 is parallel to the furnace bottom, the thickness of the partition wall 18 at its widest point is 500 to 1000mm (i.e. the length of the melt channel), the top of the partition wall 18 is parallel to the inclined furnace top 2 of the mother and daughter furnaces, and a daughter furnace flue 17 with a width of 250mm to 500mm is formed between the top of the partition wall 18 and the inclined furnace top 2 of the mother and daughter furnaces.

[0051] This invention also discloses a process method for smelting using the above-mentioned non-immersion high-efficiency molten pool smelting furnace, comprising the following steps:

[0052] S1. During smelting, the concentrate falls from the charging port 12 on the top of the mother furnace open furnace 1 into the mother furnace molten pool. After receiving the charging signal, the control system uses the metallurgical calculation model to calculate the amount of reaction gas required for the reaction. Under the protection of the outer protective gas, the reaction gas jet is directly injected into the depth of the mother furnace molten pool through the gas jet spray gun 11 after the pressure and speed are adjusted.

[0053] S2. The reactant gas and the melt undergo a smelting reaction, forming a turbulent field. The unreacted melt and reactant gas rise upwards and come into contact with the falling concentrate, thus completing the metallurgical physicochemical reaction.

[0054] S3. The reacted melt flows from the mother furnace 10 through the melt channel 19 to the daughter furnace 7. Settling and stratification are completed in the daughter furnace 7. The slag is continuously discharged from the slag overflow port 6. The bottom matte layer or metal layer is discharged from the furnace body from the corresponding matte discharge port 8 or metal discharge port 9. The smelting flue gas in the daughter furnace 7 enters the mother furnace 10 through the daughter furnace flue 17. After merging with the flue gas in the mother furnace 10, it is discharged through the flue gas outlet 14.

[0055] In the above smelting process, the mother furnace 10 and the daughter furnace 7 are connected vertically. The lower opening is the melt channel 19, which provides a passage for the melt to pass through. The upper opening is the daughter furnace flue 17, which allows the daughter furnace flue gas and the mother furnace flue gas to be combined and discharged through the exhaust port 14. The partition wall 18 separates the floating molten pool space in the reaction zone from the daughter furnace 7.

[0056] In the above smelting process, as the smelting reaction continues, matte or metal is intermittently discharged from matte outlet 8 or metal outlet 9, controlling the height of the matte or metal layer to be lower than the upper edge of the melt channel 19; during the smelting operation, the thickness of the matte or metal layer needs to be measured every 30 min to 60 min. The sampling ruler is inserted into the bottom of the sub-furnace molten pool from the sampling port 5, left to stand for 2 to 3 min and then removed. The height of the thinner slag layer at the lower end of the sampling ruler is the thickness of the matte or metal layer. The sampling and testing results are used to supplement the process control.

[0057] In the above-mentioned smelting process, all gas jet spray guns 11 can be used simultaneously, or three or more spray guns can be used evenly distributed. The gas jet sprayed by the gas jet spray gun 11 can be one or more of the smelting gases such as air, nitrogen, oxygen, and carbon dioxide, with an oxygen concentration of 0-100%. The protective gas (carbon monoxide, H2, natural gas, air, oxygen-enriched air, and other fuel gases and combustion-supporting gases) carried on the surface of the gas jet wraps around the reaction gas jet. The protective gas is used to ensure that the reaction gas jet has sufficient impact strength and to prevent the reaction gas jet from undergoing chemical changes and deterioration during its passage. The reaction gas pressure at the front end of the gas jet spray gun 11 is 0.5-1.5 MPa, and the gas jet velocity is 340-600 m / s.

[0058] This invention is a molten pool smelting technology that differs significantly from traditional molten pool smelting techniques. The reactant gas is injected into the molten pool from the top, resembling top-blowing smelting but not actually top-blowing; the gas jet nozzle is positioned on the side wall of the furnace, resembling side-blowing smelting but not actually side-blowing; the reactant gas jet is directly injected into the matte layer at the bottom of the molten pool (used in matte-making smelting) for the smelting reaction, resembling bottom-blowing smelting but not actually bottom-blowing. This invention combines the advantages of flash smelting and traditional molten pool smelting techniques, achieving highly efficient smelting while exhibiting strong adaptability to raw materials. The unique mother-daughter furnace design simplifies and simplifies layered discharge, resulting in energy savings and environmental cleanliness.

[0059] Example 1:

[0060] A copper smelter with an annual output of 20 tons of cathode copper uses the non-immersion high-efficiency molten pool smelting furnace of this invention to smelt copper matte. The dimensions and specifications of this furnace are as follows: furnace cavity Partition wall thickness 800mm; melt channel length 800mm × width 400mm × height 1800mm; sub-furnace flue 400mm × 400mm; sub-furnace cavity Feed port matte Metal outlet The slag overflow outlet is 2000mm high; the angle between the jet gas stream and the centerline of the mother furnace is 35°; there are 7 gas stream spray guns, the gas stream pressure is controllable within the range of 0.8 to 1.2 MPa, the flow rate is controllable within the range of 360 to 560 m / s, and the oxygen concentration of the reaction gas stream is controllable within the range of 50% to 98%.

[0061] After copper concentrate and flux are batched, they are transported by belt and fed into the molten pool from the charging port on the top of the mother furnace. After receiving the charging signal, the control system uses a metallurgical calculation model to calculate the amount of reaction gas (oxygen and compressed air) required for the reaction. Under the protection of the outer protective gas (natural gas and oxygen-enriched air), the reaction gas jet is directly injected into the depth of the molten pool (h300mm) after pressure and speed regulation.

[0062] The reactant gas reacts with the matte at the bottom of the mother furnace, creating a turbulent area. Unreacted melt and reactant gas rise and come into contact with the falling copper concentrate, thus completing the metallurgical physicochemical reaction. The resulting slag and matte mixture travels from the mother furnace through the melt channel to the daughter furnace, where it settles and stratifies. The slag is continuously discharged from the slag overflow outlet, and the bottom matte layer is discharged from the matte outlet. The smelting flue gas is discharged from the daughter furnace flue and exhaust outlet.

[0063] After the reactive gas stream reaches the copper matte layer, it undergoes intense oxidation, slag formation, and matte formation reactions with the copper matte.

[0064] 2Cu₂S + 3O₂ = 2Cu₂O + 2SO₂↑

[0065] 2FeS + 3O2 = 2FeO + 2SO2↑

[0066] FeS + Cu₂O = Cu₂S + FeO

[0067] 2FeO + SiO2 = 2FeO·SiO2 (ferroolitic)

[0068] Cu₂S + FeS → Copper matte

[0069] The concentrate added to the molten pool decomposes at high temperatures, undergoing oxidation, slag formation, and matte formation reactions with the upward-rolling melt and oxygen.

[0070] CuFeS2=Cu2S+2FeS+1 / 2S2↑

[0071] 2Cu₂S + 3O₂ = 2Cu₂O + 2SO₂↑

[0072] 2FeS + 3O2 = 2FeO + 2SO2↑

[0073] FeS + Cu₂O = Cu₂S + FeO

[0074] Cu2S+3Fe3O4=Cu2O+9FeO+SO2↑

[0075] FeS + 3Fe3O4 = 10FeO + SO2↑

[0076] Before reaching the matte layer, the oxygen jet is enveloped by a protective gas (a mixture of natural gas and oxygen-enriched air). The combustion of the protective gas releases heat to replenish the heat for the matte smelting of copper concentrate. The oxygen jet does not directly contact the slag layer, which can effectively control the formation of magnetic iron.

[0077] As the smelting reaction continues, matte is intermittently discharged from the matte outlet, and slag is continuously discharged from the furnace through the slag overflow outlet. During the smelting operation, the height of the matte layer is controlled to be lower than the upper edge of the melt channel (1800mm). During the smelting operation, the metal layer thickness needs to be measured every 30 min to 60 min. The sampling ruler is inserted into the bottom of the molten pool from the sampling port, left to stand for 2 to 3 min, and then removed. The height of the thinner slag layer at the lower end of the sampling ruler is the metal layer thickness. The sampling and testing results are used to supplement the process control.

[0078] Example 2:

[0079] A 20-ton-per-year cathode copper smelter uses copper matte as raw material and employs a high-efficiency smelting pool and mother-daughter furnace to smelt crude copper. The dimensions and specifications of this mother-daughter furnace are as follows: Mother furnace cavity... Partition wall thickness 700mm; melt channel length 700mm × width 400mm × height 1800mm; sub-furnace flue 400mm × 400mm; sub-furnace cavity Feed port crude copper outlet The slag overflow port is 2000mm high; the angle between the jet gas stream and the center line of the mother furnace is 40°; there are 7 gas stream spray guns, the gas stream pressure is controllable within the range of 0.8 to 1.4 MPa, the flow rate is controllable within the range of 360 to 560 m / s, and the oxygen concentration of the reaction gas stream is controllable within the range of 30% to 65%.

[0080] After the copper matte and flux are mixed, they are transported by belt and fed into the molten pool from the charging port on the top of the mother furnace. After receiving the charging signal, the control system uses a metallurgical calculation model to calculate the amount of reaction gas (oxygen and compressed air) required for the reaction. Under the protection of the outer protective gas (natural gas and oxygen-enriched air), the reaction gas jet is directly injected into the depth of the molten pool (h800~1300mm) after pressure and speed regulation.

[0081] The reactant gas reacts with the molten metal and matte in the mother furnace, creating a turbulent environment. Unreacted molten metal and reactant gas rise and come into contact with the falling copper matte, thus completing the metallurgical physicochemical reaction. The resulting slag and crude copper mixture travels from the mother furnace through the molten metal channel to the daughter furnace, where it settles and stratifies. The slag is continuously discharged from the slag overflow outlet, and the bottom layers of crude copper are discharged from the crude copper outlet. The smelting flue gas is discharged from the daughter furnace flue and exhaust outlet.

[0082] After the reactive gas stream is injected into the melt, it undergoes a strong oxidation, slag formation, and copper formation reaction with the matte.

[0083] Oxidative desulfurization:

[0084] Cu₂S + O₂ = Cu₂O + SO₂↑

[0085] 2FeS + 3O2 = 2FeO + 2SO2↑

[0086] FeS + Cu₂O = Cu₂S + FeO

[0087] Slag formation:

[0088] 2FeO + SiO2 = 2FeO·SiO2 (ferroolitic)

[0089] Desulfurization for copper production:

[0090] FeS + Cu₂O = Cu₂S + FeO

[0091] Cu2S+3Fe3O4=Cu2O+9FeO+SO2↑

[0092] FeS + 3Fe3O4 = 10FeO + SO2↑

[0093] Cu₂S + 2Cu₂O = 6Cu + SO₂↑

[0094] Before reaching the lowest point, the oxygen jet is enveloped by a protective gas (a mixture of natural gas and oxygen-enriched air), and the heat released by the combustion of the protective gas provides heat replenishment for the smelting of copper matte.

[0095] As the smelting reaction continues, crude copper is intermittently discharged from the crude copper outlet, and slag is continuously discharged from the furnace through the slag overflow outlet. During the smelting operation, the height of the matte layer is controlled to be lower than the upper edge of the melt channel (1800mm). During the smelting operation, the thickness of the crude copper layer needs to be measured every 30 min to 60 min. The sampling ruler is inserted into the bottom of the molten pool from the sampling port, left to stand for 2 to 3 min, and then removed. The height of the thinner slag layer at the lower end of the sampling ruler is the thickness of the crude copper layer. The sampling and testing results are used to supplement the process control.

[0096] Example 3:

[0097] A nickel smelter uses a high-efficiency molten pool smelting furnace to smelt nickel matte. The dimensions and specifications of this furnace are as follows: furnace chamber... Partition wall thickness 700mm; melt channel length 700mm × width 400mm × height 1800mm; sub-furnace flue 400mm × 400mm; sub-furnace cavity Feed port Metal exhaust outlet Metal outlet The slag overflow port is 2000mm; the angle between the jet gas stream and the center line of the mother furnace is 32°; there are 9 gas stream spray guns, the gas stream pressure is controllable within the range of 0.8 to 1.3 MPa, the flow rate is controllable within the range of 360 to 560 m / s, and the oxygen concentration of the reaction gas stream is controllable within the range of 60% to 90%.

[0098] Nickel concentrate and flux are mixed and transported by belt through the charging port on the top of the mother furnace into the molten pool. After receiving the charging signal, the control system uses a metallurgical calculation model to calculate the amount of reaction gas (oxygen and compressed air) required for the reaction. Under the protection of the outer protective gas (natural gas and oxygen-enriched air), the reaction gas jet is directly injected into the matte layer (h300mm) deep in the molten pool after pressure and speed regulation.

[0099] The reactant gas reacts with the matte at the bottom of the mother furnace, creating a turbulent area. Unreacted melt and reactant gas rise and come into contact with the falling nickel concentrate, thus completing the metallurgical physicochemical reaction. The reacted slag and matte mixture travels from the mother furnace through the melt channel to the daughter furnace, where it settles and stratifies. The slag is continuously discharged from the slag overflow outlet, and the bottom matte layer is discharged from the matte outlet. The smelting flue gas is discharged from the daughter furnace flue and exhaust outlet.

[0100] After the reactive gas stream reaches the copper matte layer, it undergoes intense oxidation, slag formation, and matte formation reactions with the copper matte.

[0101] Oxidation

[0102] 2Cu₂S + 3O₂ = 2Cu₂O + 2SO₂↑

[0103] 2FeS + 3O2 = 2FeO + 3SO2↑

[0104] 2Ni3S2 + 7O2 = 6NiO + 4SO2↑

[0105] Slag formation:

[0106] 2FeO + SiO2 = 2FeO·SiO2 (ferroolitic)

[0107] matte reaction

[0108] FeS + Cu₂O = Cu₂S + FeO

[0109] 2FeS+2NiO=2 / 3Ni3S2+2FeO+1 / 3S2↑

[0110] Cu₂S + FeS + Ni₃S₂ → Nickel matte (copper matte)

[0111] The concentrate added to the molten pool decomposes at high temperatures, undergoing oxidation, slag formation, and matte formation reactions with the upward-rolling melt and oxygen.

[0112] Decomposition of high-valent sulfides:

[0113] CuFeS2=Cu2S+2FeS+1 / 2S2↑

[0114] Fe7S8=7FeS+1 / 2S2↑

[0115] 3NiS·FeS2=Ni3S2+FeS+S2↑

[0116] (Ni,Fe)9S8=2Ni3S2+3FeS+1 / 2S2↑

[0117] 3NiS=Ni3S2+1 / 2S2↑

[0118] FeS2=FeS+1 / 2S2↑

[0119] Oxidation reaction:

[0120] 2CuFeS2+5 / 2O2=Cu2S·FeS+FeO+SO2↑

[0121] 2Ni3S2 + 7O2 = 6NiO + 4SO2↑

[0122] 2FeS + 3O2 = 2FeO + 2SO2↑

[0123] 2Cu₂S + 3O₂ = 2Cu₂O + 2SO₂↑

[0124] FeS + 3Fe3O4 = 10FeO + SO2↑

[0125] Cu2S+3Fe3O4=Cu2O+9FeO+SO2↑

[0126] Slag-forming reaction:

[0127] 2FeO + SiO2 = 2FeO·SiO2 (ferroolitic)

[0128] Making matte:

[0129] 2FeS+2NiO=2 / 3Ni3S2+2FeO+1 / 3S2↑

[0130] FeS + Cu₂O = Cu₂S + FeO

[0131] Cu₂S + FeS + Ni₃S₂ → Nickel matte (nickel copper matte)

[0132] Before the oxygen jet enters the nickel matte layer, it is enveloped by a protective gas (a mixture of natural gas and oxygen-enriched air). The heat released by the combustion of the protective gas provides heat for the smelting of nickel concentrate. The oxygen jet does not directly contact the slag layer, which can effectively suppress the formation of magnetic iron.

[0133] As the smelting reaction continues, matte is intermittently discharged from the matte outlet, and slag is continuously discharged from the furnace through the slag overflow outlet. During the smelting operation, the height of the matte layer is controlled to be lower than the upper edge of the melt channel (1800mm). During the smelting operation, the thickness of the matte layer needs to be measured every 30 min to 60 min. The sampling ruler is inserted into the bottom of the molten pool from the sampling port, left to stand for 2 to 3 min, and then removed. The height of the thinner slag layer at the lower end of the sampling ruler is the thickness of the nickel matte layer. The sampling and testing results are used to supplement the process control.

[0134] Example 4:

[0135] A tin smelter with an annual output of 7 tons uses a high-efficiency molten pool furnace to smelt crude tin. The dimensions and specifications of this furnace are as follows: furnace chamber... Partition wall thickness 800mm; melt channel length 800mm × width 300mm × height 1400mm; sub-furnace flue 300mm × 400mm; sub-furnace cavity Feed port Coarse tin outlet The slag overflow outlet is 1800mm; the angle between the jet gas stream and the center line of the mother furnace is 35°; there are 7 gas stream spray guns, the gas stream pressure is controllable within the range of 0.8 to 1.2 MPa, the flow rate is controllable within the range of 360 to 560 m / s, the oxygen concentration of the reaction gas stream is controllable within the range of 25% to 60%, and the ratio of natural gas to oxygen is 1:2 to 10:1.

[0136] Tin concentrate, flux, and return materials are batched and transported by belt conveyor from the charging port on the top of the mother furnace into the molten pool. After receiving the charging signal, the control system uses a metallurgical calculation model to calculate the required amount of reaction gas (air, oxygen, natural gas). Under the protection of the outer protective gas (natural gas, oxygen-enriched air), the reaction gas jet is directly injected into the depth of the molten pool (h500~1400mm) after pressure and speed regulation.

[0137] The reactant gas reacts with the molten slag and tin concentrate in the mother furnace, creating a turbulent environment. Unreacted melt and reactant gas rise and come into contact with the falling tin concentrate, thus completing the metallurgical physicochemical reaction. The reacted slag and crude tin mixture travel from the mother furnace through the melt channel to the daughter furnace, where it settles and stratifies. The slag is continuously discharged from the slag overflow port, and the bottom crude tin layer is discharged from the tin discharge port. The smelting flue gas is discharged from the daughter furnace flue and exhaust port.

[0138] After the reactive gas stream enters the melt, it undergoes a strong reduction and slagging reaction with the tin concentrate:

[0139] SnO2 + C = SnO (slag) + CO (gas)

[0140] Fe₂O₃ + C = 2FeO (slag) + CO (gas)

[0141] SnO (slag) + C = Sn (metal) + CO (gas)

[0142] FeO (slag) + C = Fe (metal) + CO (gas)

[0143] CO (gas) + 1 / 2 O2 (gas) = ​​CO2 (gas)

[0144] 2FeO + SiO2 = 2FeO·SiO2 (ferroolitic)

[0145] Before reaching the lowest point, the reactive gas stream is enveloped by a protective gas (a mixture of natural gas and oxygen-enriched air). The heat released by the combustion of the reactive gas and the protective gas provides supplemental heat for the reduction and smelting of tin concentrate.

[0146] As the smelting reaction continues, crude tin is intermittently discharged from the crude tin outlet, and slag is continuously discharged from the furnace from the slag overflow outlet. During the smelting operation, the height of the crude tin layer is controlled to be lower than the upper edge of the melt channel (1400mm). During the smelting operation, the thickness of the metal layer needs to be measured every 30 min to 60 min. The sampling ruler is inserted into the bottom of the molten pool from the sampling port, left to stand for 2 to 3 min, and then removed. The height of the thinner slag layer at the lower end of the sampling ruler is the thickness of the crude tin layer. The sampling and testing results are used to supplement the process control.

[0147] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0148] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A high-efficiency, non-immersion smelting furnace, characterized in that, It consists of a mother furnace and a daughter furnace, which are two parallel, upright columns. A molten metal channel connects the lower parts of the mother furnace and the daughter furnace, and a partition wall is installed between their middle sections. A sloping daughter furnace flue connects the upper part of the mother furnace cavity. Several gas jet nozzles are evenly distributed around the circumference of the mother furnace, all pointing downwards towards the center line of the mother furnace. The mother furnace has a flat top with a charging port, and the side of the flat top furthest from the daughter furnace is the exhaust port. The daughter furnace has a flat top with a sampling port and burner inlet. A flue wall, with its top lower than the mother furnace flat top, is vertically fixed to the upper surface of the daughter furnace flat top near the mother furnace. The flat furnace top and the flue wall are connected by a mother-daughter furnace inclined top. The melt channel, the daughter furnace flue, and the partition wall are all located below the mother-daughter furnace inclined top. The daughter furnace body is equipped with a metal outlet and a slag overflow outlet, and the bottom of the partition wall is located below the slag overflow outlet. The metal outlet is lower than the upper edge of the melt channel. If the mother-daughter furnace is a matte smelting furnace, the daughter furnace body is also equipped with a matte outlet, which is also lower than the upper edge of the melt channel. The mother furnace and the daughter furnace are two parallel standing cylinders or two regular polygonal cylinders, and the mother furnace and the daughter furnace are reinforced by a clamp. The mother furnace is equipped with 3 to 10 evenly distributed gas jet lances at a distance of 2 / 3 to 4 / 5 of the height from the bottom of its cavity. The gas jets sprayed by the gas jet lances form an angle of 30 to 45° with the center line of the mother furnace.

2. The non-immersion high-efficiency smelting furnace according to claim 1, characterized in that, A charging port is provided on the top of the mother furnace at a position corresponding to the center line of the mother furnace. The charging port is a circular charging port with an inner diameter of 500mm~1000mm. The exhaust port located on one side of the top of the mother furnace is connected to the downstream flue gas treatment process.

3. The non-immersion high-efficiency smelting furnace according to claim 1, characterized in that, The vertical distance between the flue wall and the center line of the sub-furnace is 1 / 2 of the radius of the sub-furnace cavity; the burner opening is located on the top of the sub-furnace flat furnace at the end away from the mother furnace, and the vertical distance between the burner opening and the center line of the sub-furnace is 1 / 2 of the radius of the sub-furnace cavity. The lower outlet end of the burner gradually tilts towards the side closer to the mother furnace within the sub-furnace cavity.

4. The non-immersion high-efficiency smelting furnace according to claim 1, characterized in that, The bottom of the chambers of the mother furnace and the daughter furnace are on the same horizontal plane. The metal outlet is 0mm away from the bottom of the daughter furnace chamber, the matte outlet is 300~600mm away from the bottom of the daughter furnace chamber, the slag overflow outlet is 1600~2500mm away from the bottom of the daughter furnace chamber, and the bottom of the partition wall between the mother furnace and the daughter furnace is located 100~200mm below the plane of the slag overflow outlet.

5. A high-efficiency, non-immersion smelting furnace according to any one of claims 1-4, characterized in that, The dimensions of the mother furnace cavity are h4000mm~8000mm×Ø3000mm~8500mm, and the dimensions of the daughter furnace cavity are h2000mm~3500mm×Ø500mm~2500mm; the width of the melt channel between the lower parts of the mother furnace and the daughter furnace is 250mm~500mm; the bottom of the partition wall is parallel to the furnace bottom, the thickness of the partition wall at its widest point is 500~1000mm, the top of the partition wall is parallel to the inclined furnace top of the mother and daughter furnaces, and a daughter furnace flue with a width of 250mm~500mm is formed between the top of the partition wall and the inclined furnace top of the mother and daughter furnaces.

6. A smelting process method for a non-immersion high-efficiency molten pool smelting furnace, characterized in that, The application of any one of the immersion-free high-efficiency molten pool smelting master furnaces according to any one of claims 1-5 includes the following steps: S1. The concentrate falls from the charging port on the top of the mother furnace into the mother furnace molten pool. After receiving the charging signal, the control system uses the metallurgical calculation model to calculate the amount of reaction gas required for the reaction. Under the protection of the outer protective gas, the reaction gas jet is directly injected into the depth of the mother furnace molten pool through the gas jet spray gun after the pressure and speed are adjusted. S2. The reactant gas and the melt undergo a smelting reaction, forming a turbulent field. The unreacted melt and reactant gas rise upwards and come into contact with the falling concentrate, thus completing the metallurgical physicochemical reaction. S3. After the reaction, the melt flows from the mother furnace through the melt channel to the daughter furnace, where it settles and stratifies. The slag is continuously discharged from the slag overflow port, and the bottom matte layer or metal layer is discharged from the furnace body through the corresponding matte outlet or metal outlet. The smelting flue gas in the daughter furnace enters the mother furnace through the daughter furnace flue, merges with the flue gas in the mother furnace, and is discharged through the exhaust port.

7. The smelting process method of a non-immersion high-efficiency molten pool smelting furnace according to claim 6, characterized in that, As the smelting reaction continues, matte or metal is intermittently discharged from the matte outlet or metal outlet, controlling the height of the matte or metal layer to be lower than the upper edge of the melt channel. During the smelting operation, the thickness of the matte or metal layer needs to be measured every 30 to 60 minutes. The sampling ruler is inserted into the bottom of the sub-furnace molten pool from the sampling port, left to stand for 2 to 3 minutes, and then removed. The height of the thinner slag layer at the lower end of the sampling ruler is the thickness of the matte or metal layer. The sampling and testing results are used to supplement the process control.

8. The smelting process method of a non-immersion high-efficiency molten pool smelting mother-daughter furnace according to claim 6, characterized in that, All gas jet spray guns can be used simultaneously, or three or more spray guns can be used evenly distributed. The gas jet sprayed by the gas jet spray gun is one or more of air, nitrogen, oxygen, and carbon dioxide, with an oxygen concentration of 0~100%. The protective gas carried on the surface of the gas jet wraps around the reactive gas jet. The protective gas is used to ensure that the reactive gas jet has sufficient impact strength and to prevent the reactive gas jet from undergoing chemical changes and deteriorating during its passage. The reactive gas pressure at the front end of the air jet spray gun is 0.5~1.5MPa, and the air jet velocity is 340~600m / s.

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