Modeling and simulation method and system of submerged top-blown smelting furnace based on key field coupling

Abstract

The present invention provides a modeling and simulation method and system for a submerged top-blown smelting furnace based on key field coupling, which relates to the technical field of simulation and simulation of non-ferrous metal smelting processes, including: analyzing the different fields of the submerged top-blown smelting process, and breaking down the multi-field coupling process into six links; extracting key fields from the six links and weakening non-key fields; performing coupling calculations on the key fields of the six links, obtaining key field information of different links, and completing the modeling and simulation of the submerged top-blown smelting furnace based on key field coupling. The present invention analyzes the different fields of the submerged top-blown smelting process, extracts key fields for different links, weakens or simplifies non-critical fields, and only performs coupling calculations on key fields, thereby achieving efficient and accurate analysis of key field information in different links.

Description

Technical Field

[0001] The present invention relates to the technical field of simulation technology for nonferrous metal smelting processes, and in particular to a modeling and simulation method and system for a submerged top-blown smelting furnace based on key field coupling. Background Art

[0002] Submerged lance top-blowing molten pool smelting technology uses a lance to forcibly inject oxygen-enriched air into the molten pool, creating intense agitation between the melt, gas, and charge. This enhances mass and heat transfer, accelerates chemical reactions, and fully utilizes the heat released by the oxidation of iron and sulfur in the concentrate during the smelting process, producing high-grade matte. Due to its advantages of low investment, fast smelting speed, wide raw material adaptability, high productivity, and low energy consumption, it is currently widely used in the extraction and smelting of sulfide ores such as copper and nickel, as well as secondary resources such as scrap circuit boards. However, with decreasing raw material grade, increasing proportions of complex ores and secondary resources, and increasing production requirements, top-blowing smelting processes have encountered a series of urgent problems, including incomplete smelting, sublimated sulfur, liquid surface splashing, lance bending, and short furnace life.

[0003] Submerged top-blown molten pool smelting involves multiphase chemical reactions, mass transfer, and heat transfer in a complex gas-liquid-solid system. During the smelting process, the molten pool is subjected to intense agitation. Interfacial reactions between the gas and liquid, oxygen distribution, and melt temperature significantly impact production performance, including gas utilization, slagging efficiency, matte grade, and furnace life. However, because top-blown smelting often occurs at temperatures exceeding 1300°C, direct observation of the agitation and multiphase fluid motion within the furnace is impossible, making accurate quantitative characterization difficult using existing measurement techniques.

[0004] Numerical modeling and simulation technologies based on computational fluid dynamics (CFD) have rapidly developed in the metallurgical industry and are an indispensable component of the design and optimization of various metallurgical reactors. In particular, for the high-temperature, highly turbulent, multiphase, and multifield systems involved in top-blown smelting, numerical simulation is an effective means of predicting and optimizing process parameters, equipment structure, and production indicators. Submerged top-blown smelting involves a complex multiphase flow and transport system involving concentrate particles, oxygen-enriched air, matte, and slag. Current software and hardware requirements are insufficient for high-precision and efficient simulation of this process. While the use of comprehensive multi-field coupling models theoretically yields relatively more accurate simulation results, solving multiple strongly coupled equations requires significant computational resources and significantly reduces the convergence of the results. Furthermore, since submerged top-blown smelting is a highly exothermic, autothermal reaction, analyzing the multiphase reaction flow, thermal, and component fields within the furnace requires complex coupled governing equations. Therefore, current simulation calculations for the above processes are mostly focused on the simulation of their flow fields, and there are few reports on modeling and simulation of smelting reactions, component diffusion, particle motion, etc. Summary of the Invention

[0005] The present invention provides a modeling and simulation method and system for a submerged top-blown smelting furnace based on key field coupling, which solves the problems of complex model, difficult convergence and long calculation time encountered in the modeling and simulation of top-blown smelting multi-field strong coupling system in the prior art.

[0006] To solve the above-mentioned purpose, the present invention provides the following technical solution: a modeling and simulation method for a submerged top-blown smelting furnace based on key field coupling, characterized in that the steps include:

[0007] S1. Analyze the different fields in the submerged top-blowing smelting process and decompose the multi-field coupling process; decompose the submerged top-blowing smelting process into six steps: compressible gas injection in the top-blowing lance, multiphase movement of gas-matte-slag in the top-blowing process, component mixing in the top-blowing process, exothermic heterogeneous reaction in the top-blowing process, concentrate particle feeding in the top-blowing furnace, and stress and strain in the top-blowing lance;

[0008] S2. Extract key fields from the six links and weaken non-key fields;

[0009] S3. Carry out coupling calculation on the key fields of the six links, obtain the key field information of different links, and complete the modeling and simulation of the submerged top-blown smelting furnace based on key field coupling.

[0010] Preferably, in step S2, extracting key fields from multiple links includes:

[0011] Extract the key fields of the compressible gas injection link in the top-blowing lance, including the single-phase flow field of the injection gas in the lance and the temperature field inside the lance;

[0012] Extract the key fields of the multiphase movement of gas, matte and slag in the top-blowing process, including the multiphase flow fields of gas, matte and slag;

[0013] Extract the key fields of the component mixing link in the top blowing process, including: gas-matte-slag multiphase flow field and the component fields in each phase;

[0014] Extract the key fields of the exothermic heterogeneous reaction link in the top-blowing process, including: gas-matte-slag multiphase flow field and component field of heterogeneous reaction;

[0015] Extract the key fields of the top-blown furnace concentrate particle feeding link, including: gas matte slag multiphase flow field and particle movement field;

[0016] The key fields of the stress and strain link of the top-blowing spray gun are extracted. The key fields include: the structural field of the spray gun and the stress field of the fluid.

[0017] Preferably, in step S3, coupling calculation is performed on key fields of multiple links to obtain key field information of different links, including:

[0018] Calculate the coupling between the single-phase flow field of the compressed gas in the top-blowing lance and the temperature field inside the lance;

[0019] Calculate the coupling between the gas, matte and slag multiphase flow fields in the gas-matte-slag multiphase motion process during the top blowing process;

[0020] Calculate the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase during the component mixing stage of the top-blowing process;

[0021] Calculate the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process;

[0022] Calculate the coupling between the gas-matte-slag multiphase flow field and the particle motion field during the feed process of concentrate particles in a top-blown furnace;

[0023] Calculate the coupling between the structural field of the top-blowing spray gun and the stress field of the fluid in the stress and strain link of the top-blowing spray gun.

[0024] Preferably, calculating the coupling between the single-phase flow field of the blowing gas in the top-blowing lance and the temperature field in the lance during the compressible gas blowing link in the top-blowing lance includes:

[0025] Establish a top-blowing spray gun model;

[0026] Use compressible gas for single-phase flow field calculation;

[0027] Steady-state calculation or transient calculation is used to converge the residuals, and the nozzle outlet velocity, velocity vector distribution results, and nozzle outlet gas density and viscosity distribution results under different wall temperatures, gas compositions, and inlet pressures are obtained.

[0028] Preferably, the calculation of the coupling between the multiphase flow fields of gas, matte and slag in the multiphase movement link of gas, matte and slag in the top blowing process includes:

[0029] Establish a model of the top-blown furnace molten pool area;

[0030] Use VOF incompressible multiphase flow to calculate the multiphase flow field;

[0031] The velocity inlet boundary is used for the gun inlet section, and the size of the gun inlet in three orthogonal coordinate systems is the size of the gun outlet velocity;

[0032] Transient calculation is used to converge the residuals, and the results of the changes in the velocity field, turbulence field, and gas-matte-slag phase field distribution in the furnace with respect to the injection time are obtained under different injection parameters, gas-matte-slag dosage ratio, liquid level, and melt properties.

[0033] Preferably, the calculation of the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase in the component mixing link of the top blowing process includes:

[0034] Based on the regional model of the top-blown furnace melt pool, the time statistics method is used to calculate the average values ​​of the velocities in three orthogonal directions, the gas-matte-slag phase distribution, the turbulent kinetic energy, and the turbulent dissipation rate during the multiphase movement of the gas-matte-slag during the top-blowing process. The statistical time is 5-20 seconds after the flow field stabilizes, and the average flow field is obtained.

[0035] The transient flow field in the molten pool is modified to the statistical average flow field, and a component of a certain concentration is added at a certain position in the molten pool. The calculation of the flow field equation is turned off, and the concentration diffusion equation of the component is solved only under the average flow field.

[0036] Transient calculation is used to converge the residuals, and the diffusion and concentration distribution results of any component in the phase where the component is located under different injection conditions are obtained, and then the mixing time results at different positions are obtained.

[0037] Preferably, the calculation of the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process includes:

[0038] The average flow field obtained by statistics;

[0039] Establish the kinetic equations for the reactions between different phases in the smelting process, combine the reaction exotherm, turn off the flow field calculation, and turn on the calculation of the component equation and energy equation;

[0040] Transient calculation is used to converge the residuals, and the concentration distribution of different reaction components, reaction rate, reaction heat release and furnace temperature distribution under different injection conditions are obtained.

[0041] Preferably, the calculation of the coupling between the gas-matte-slag multiphase flow field and the particle motion field in the top-blown furnace concentrate particle feeding process includes:

[0042] The steady-state calculation of the flow field in the top-blown furnace molten pool area model is converted to a transient calculation, where the calculation time interval is 5-10s of the melting time;

[0043] The particle motion and its interaction with the gas-matte-slag multiphase flow are calculated by coupling discrete element method with VOF multiphase flow. The concentrate particle motion is calculated by discrete element modeling. The particles and fluid are related through drag coupling in the momentum equation.

[0044] The volume fraction of particles was calculated by Monte Carlo method;

[0045] By performing residual convergence through transient calculation, the movement and distribution results of particles in the gas-matte-slag multiphase flow field under different injection conditions are obtained, and the pressure and stress distribution at the wall of the injection gun can be obtained.

[0046] Preferably, in the process of calculating the stress and strain of the top-blowing lance, the coupling between the structural field of the lance and the stress field of the fluid includes:

[0047] Establish the finite element model of the spray gun by finite element calculation method;

[0048] The results of pressure and stress on the gun wall are loaded into the gun finite element model;

[0049] Through transient calculations to achieve residual convergence, the strain results caused by uneven force on the spray gun after feeding are obtained. The movement and distribution of particles in the gas-matte-slag multiphase flow field under different spraying conditions are obtained, and the pressure and stress distribution on the spray gun wall can be obtained.

[0050] A modeling and simulation system for a submerged top-blown smelting furnace based on key field coupling is provided. The system is used for the above-mentioned modeling and simulation method for a submerged top-blown smelting furnace based on key field coupling. The system comprises:

[0051] The coupled process decomposition module 210 is used to analyze the different fields of the submerged top-blowing smelting process and decompose the multi-field coupled process. The submerged top-blowing smelting process is decomposed into six steps: compressible gas injection in the top-blowing lance, multiphase movement of gas-matte-slag in the top-blowing process, component mixing in the top-blowing process, exothermic heterogeneous reaction in the top-blowing process, concentrate particle feeding in the top-blowing furnace, and stress and strain in the top-blowing lance.

[0052] A key field extraction module 220 is used to extract key fields from the six links and weaken non-key fields;

[0053] The modeling and simulation module 230 is used to perform coupling calculations on the key fields of the six links, obtain key field information of different links, and complete modeling and simulation of the submerged top-blown smelting furnace based on key field coupling.

[0054] On the one hand, an electronic device is provided, which includes a processor and a memory, wherein the memory stores at least one instruction, and the at least one instruction is loaded and executed by the processor to implement the above-mentioned submerged top-blown smelting furnace modeling and simulation method based on key field coupling.

[0055] On the one hand, a computer-readable storage medium is provided, in which at least one instruction is stored. The at least one instruction is loaded and executed by a processor to implement the above-mentioned submerged top-blown smelting furnace modeling and simulation method based on key field coupling.

[0056] Compared with the prior art, the above technical solution has at least the following beneficial effects:

[0057] The above scheme proposes a coupled modeling and simulation method based on key fields. (1) The multi-field coupling process is disassembled. For different links, only the key fields involved are coupled and solved, which greatly reduces the difficulty of modeling. (2) The convergence is good. Since the model has been appropriately simplified, the convergence of the solution process is greatly improved. At the same time, the results obtained by solving the key fields that play a major role are still relatively accurate. (3) The computational cost is greatly reduced. Due to the processing of the coupling method of the key fields, it can avoid the concentration field and temperature field being too time-consuming to couple and solve during the flow field calculation. The time step can be increased by 1-2 orders of magnitude, and the computational time can be greatly reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0059] Figure 1 1 is a schematic flow chart of a modeling and simulation method for a submerged top-blown smelting furnace based on key field coupling provided by an embodiment of the present invention;

[0060] Figure 2 This is a modeling simulation effect diagram of a submerged top-blown smelting furnace provided by an embodiment of the present invention;

[0061] Figure 3This is a block diagram of a modeling and simulation system for a submerged top-blown smelting furnace based on key field coupling provided by an embodiment of the present invention;

[0062] Figure 4 It is a structural diagram of an electronic device provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0063] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the described embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0064] The present invention addresses the problems of complex models, difficult convergence and long calculation time encountered in the modeling and simulation of multi-field strong coupling systems of top-blown smelting in the existing technology, and provides a modeling and simulation method and system for a submerged top-blown smelting furnace based on key field coupling.

[0065] like Figure 1 As shown, the embodiment of the present invention provides a modeling and simulation method for a submerged top-blown smelting furnace based on key field coupling, which can be implemented by electronic equipment. Figure 1 The flowchart of the modeling and simulation method of a submerged top-blown smelting furnace based on key field coupling is shown. The processing flow of the method may include the following steps:

[0066] S101. Analyze the different fields of the submerged top-blowing smelting process and decompose the multi-field coupling process; decompose the submerged top-blowing smelting process into six links: compressible gas injection in the top-blowing lance, multiphase movement of gas-matte-slag in the top-blowing process, component mixing in the top-blowing process, exothermic heterogeneous reaction in the top-blowing process, concentrate particle feeding in the top-blowing furnace, and stress and strain of the top-blowing lance.

[0067] In a feasible implementation method, the submerged top-blown smelting process involves a complex coupling system of four phases, namely gas-matte-slag-ore particles, and five fields, namely flow field, particle field, component field, thermal field, and structural field. The above fields are solved simultaneously. (1) Modeling is difficult. Multiple control equations must be coupled and associated. The mutual influence mechanism between multiple fields is not clear, and the accuracy of the model cannot be guaranteed. (2) Convergence is difficult. When multiple control equations are coupled and solved, if the model is not set up properly, it is easy to cause divergence of the results, and correct results are often not obtained. (3) The calculation is time-consuming. The time step for coupling and solving the above equations is often controlled within 10 -5 ~10 -6 s, the time cost required to solve the example is huge.

[0068] In a feasible implementation method, the complex multi-phase and multi-field coupling process in top-blowing smelting is decomposed into multiple links, the key fields involved in the characteristics of different links are extracted, and specific methods are used to perform coupling calculations on the key fields of different links to achieve efficient and accurate analysis of the top-blowing smelting process.

[0069] S102, extracting key fields from the six links and weakening non-key fields;

[0070] In a feasible implementation, in step S102, extracting key fields from multiple links includes:

[0071] Extract the key fields of the compressible gas injection link in the top-blowing lance, including the single-phase flow field of the injection gas in the lance and the temperature field inside the lance;

[0072] Extract the key fields of the multiphase movement of gas, matte and slag in the top-blowing process, including the multiphase flow fields of gas, matte and slag;

[0073] Extract the key fields of the component mixing link in the top blowing process, including: gas-matte-slag multiphase flow field and the component fields in each phase;

[0074] Extract the key fields of the exothermic heterogeneous reaction link in the top-blowing process, including: gas-matte-slag multiphase flow field and component field of heterogeneous reaction;

[0075] Extract the key fields of the top-blown furnace concentrate particle feeding link, including: gas matte slag multiphase flow field and particle movement field;

[0076] The key fields of the stress and strain link of the top-blowing spray gun are extracted. The key fields include: the structural field of the spray gun and the stress field of the fluid.

[0077] S103. Perform coupling calculation on the key fields of the six links, obtain key field information of different links, and complete modeling and simulation of the submerged top-blown smelting furnace based on key field coupling.

[0078] In a feasible implementation, in step S103, coupling calculation is performed on key fields of multiple links to obtain key field information of different links, including:

[0079] Calculate the coupling between the single-phase flow field of the compressed gas in the top-blowing lance and the temperature field inside the lance;

[0080] Calculate the coupling between the gas, matte and slag multiphase flow fields in the gas-matte-slag multiphase motion process during the top blowing process;

[0081] Calculate the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase during the component mixing stage of the top-blowing process;

[0082] Calculate the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process;

[0083] Calculate the coupling between the gas-matte-slag multiphase flow field and the particle motion field during the feed process of concentrate particles in a top-blown furnace;

[0084] Calculate the coupling between the structural field of the top-blowing spray gun and the stress field of the fluid in the stress and strain link of the top-blowing spray gun.

[0085] In a feasible implementation, calculating the coupling between the single-phase flow field of the compressed gas in the top-blowing lance and the temperature field in the lance during the injection process of the compressible gas in the top-blowing lance includes:

[0086] Establish a top-blowing spray gun model;

[0087] Use compressible gas for single-phase flow field calculation;

[0088] Steady-state calculation or transient calculation is used to converge the residuals, and the nozzle outlet velocity, velocity vector distribution results, and nozzle outlet gas density and viscosity distribution results under different wall temperatures, gas compositions, and inlet pressures are obtained.

[0089] In a feasible implementation, the first link after decomposition is the injection of compressible gas in the top-blowing lance, which involves the coupling between the single-phase flow field of the injected gas in the lance and the temperature field inside the lance. For the above process, only the top-blowing lance model is established, including the lance wall, the flow channel inside the lance and the end swirl plate structure. The single-phase flow field calculation of compressible gas is adopted, the temperature boundary condition is given on the lance wall, the pressure inlet boundary condition is adopted for the gas inlet, and the pressure outlet boundary condition is adopted for the gas outlet. Steady-state calculation can be adopted, and all residuals converge to 10 -4 ~10 -5 ; Transient calculation can also be used, with a time step of 10 -3 ~10 -4 s, all residuals converge to 10 -3 ~10 -4 The final results of steady-state and transient calculations do not vary by more than ±1%. Using the above calculation method, we can obtain the nozzle outlet velocity, velocity vector distribution results, and nozzle outlet gas density and viscosity distribution results under different wall temperatures, gas compositions, and inlet pressures.

[0090] In a feasible implementation, the calculation of the coupling between the multiphase flow fields of gas, matte, and slag in the multiphase motion link of gas, matte, and slag in the top-blowing process includes:

[0091] Establish a model of the top-blown furnace molten pool area;

[0092] Use VOF incompressible multiphase flow to calculate the multiphase flow field;

[0093] The velocity inlet boundary is used for the gun inlet section, and the size of the gun inlet in three orthogonal coordinate systems is the size of the gun outlet velocity;

[0094] Transient calculation is used to converge the residuals, and the results of the changes in the velocity field, turbulence field, and gas-matte-slag phase field distribution in the furnace with respect to the injection time are obtained under different injection parameters, gas-matte-slag dosage ratio, liquid level, and melt properties.

[0095] In a feasible implementation, the second link after the split is the multiphase movement of gas, matte and slag in the top-blowing process, which involves the coupling between the multiphase flow fields of gas, matte and slag. For the above process, only the regional model of the top-blown furnace molten pool is established, including the furnace wall and the molten pool structure in the furnace. The spray gun model is simplified, and only the gas inlet section of the spray gun is retained. The multiphase flow field is calculated using VOF incompressible multiphase flow, and the surface tension between gas, matte and slag is considered; the velocity inlet boundary is used for the spray gun inlet section, and its size in the three orthogonal coordinate systems is input by the calculation result of the velocity at the spray gun outlet in the first link; the density and viscosity of the gas are obtained by the average value of the gas density and viscosity at the spray gun outlet calculated in the first link. Transient calculation is used, and the time step is 10 -3 ~10 -4 s, all residuals converge to 10 -3 ~10 -4 ; The above calculation can be used to obtain the changes in the velocity field, turbulence field, and gas-matte-slag phase field distribution in the furnace with respect to the injection time under different injection parameters, gas-matte-slag dosage ratio, liquid level, and melt physical properties.

[0096] In a feasible implementation, the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase in the component mixing step of the top-blowing process is calculated, including:

[0097] Based on the regional model of the top-blown furnace melt pool, the time statistics method is used to calculate the average values ​​of the velocities in three orthogonal directions, the gas-matte-slag phase distribution, the turbulent kinetic energy, and the turbulent dissipation rate during the multiphase movement of the gas-matte-slag during the top-blowing process. The statistical time is 5-20 seconds after the flow field stabilizes, and the average flow field is obtained.

[0098] The transient flow field in the molten pool is modified to the statistical average flow field, and a component of a certain concentration is added at a certain position in the molten pool. The calculation of the flow field equation is turned off, and the concentration diffusion equation of the component is solved only under the average flow field.

[0099] Transient calculation is used to converge the residuals, and the diffusion and concentration distribution results of any component in the phase where the component is located under different injection conditions are obtained, and then the mixing time results at different positions are obtained.

[0100] In a feasible implementation, the third link after the split is the mixing of components in the top blowing process, which involves the coupling between the multiphase flow field of gas-matte-slag and the component fields in each phase. For the above process, the established model remains unchanged from the model established in the second link. First, the time statistics method is used to calculate the average values ​​of the velocity, gas-matte-slag phase distribution, turbulent kinetic energy and turbulent dissipation rate in the three orthogonal directions in the second link under the statistical time. The statistical time is 5-20s after the flow field stabilizes to obtain the average flow field; then the transient flow field in the molten pool is modified to the statistical average flow field, and a certain concentration of components is added at a certain position in the molten pool, and the calculation of the flow field equations (continuity equation, momentum equation and turbulence equation) is closed. The concentration diffusion equation of the components is only solved under the average flow field; transient calculation is used, and the time step is 10 -1 ~10 2 s, all residuals converge to 10 -4 ~10 -5 ; The above calculation can be used to obtain the diffusion and concentration distribution results of a certain component in its phase under different injection conditions, and then the mixing time results at different positions can be obtained.

[0101] In a feasible implementation, the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process is calculated, including:

[0102] The average flow field obtained by statistics;

[0103] Establish the kinetic equations for the reactions between different phases in the smelting process, combine the reaction exotherm, turn off the flow field calculation, and turn on the calculation of the component equation and energy equation;

[0104] Transient calculation is used to converge the residuals, and the concentration distribution of different reaction components, reaction rate, reaction heat release and furnace temperature distribution under different injection conditions are obtained.

[0105] In a feasible implementation, the fourth link after the split is the exothermic heterogeneous reaction of the blowing process, which involves the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction. For the above process, the model built remains unchanged from the third link, and the average flow field is first obtained by statistics. The kinetic equation of the reaction between different phases in the smelting process is established, and the reaction exotherm is taken into account. The flow field calculation is turned off, and the calculation of the component equation and the energy equation is turned on at the same time. Transient calculation is used, and the time step is 10 -3 ~10 -1 s, all residuals converge to 10 -4 ~10 -5 ; The above calculation can be used to obtain the concentration distribution, reaction rate, reaction heat release and furnace temperature distribution of different reaction components under different injection conditions.

[0106] In a feasible implementation, the coupling between the gas-matte-slag multiphase flow field and the particle motion field in the top-blown furnace concentrate particle feeding process is calculated, including:

[0107] The steady-state calculation of the flow field in the top-blown furnace molten pool area model is converted to a transient calculation, where the calculation time interval is 5-10s of the melting time;

[0108] The particle motion and its interaction with the gas-matte-slag multiphase flow are calculated by coupling discrete element method with VOF multiphase flow. The concentrate particle motion is calculated by discrete element modeling. The particles and fluid are related through drag coupling in the momentum equation.

[0109] The volume fraction of particles was calculated by Monte Carlo method;

[0110] By performing residual convergence through transient calculation, the movement and distribution results of particles in the gas-matte-slag multiphase flow field under different injection conditions are obtained, and the pressure and stress distribution at the wall of the injection gun can be obtained.

[0111] In a feasible implementation, the fifth link after the split is the feeding of concentrate particles into the top-blown furnace, which involves the coupling between the multiphase flow field of gas-matte slag and the particle motion field. For the above process, the established model remains unchanged from the second link. First, the flow field is calculated based on the regional model of the top-blown furnace molten pool established in the second link, so that it is calculated from steady-state calculation to transient calculation, usually to the smelting time of 5-10s. Then, the discrete element and VOF multiphase flow coupling method are used to calculate the particle motion and its interaction with the gas-matte slag multiphase flow. The concentrate particle motion is calculated using discrete element modeling. The particles and the fluid are coupled through the drag in the momentum equation, and the volume fraction of the particles is calculated using the Monte Carlo method. Transient calculation is used, and the multiphase fluid time step is 10 -3 ~10 -4 s, all residuals converge to 10 -3 ~10 -4 ; The time step of particle calculation is 10 -5 ~10 -4 s, the fluid calculation time step is an integer multiple of the particle calculation time step. The above calculation can be used to obtain the movement and distribution results of particles in the gas-matte-slag multiphase flow field under different injection conditions, and the pressure and stress distribution at the injection gun wall can be obtained.

[0112] In a feasible implementation, the coupling between the structural field of the top-blowing lance and the stress field of the fluid in the stress and strain calculation of the top-blowing lance includes:

[0113] Establish the finite element model of the spray gun by finite element calculation method;

[0114] The results of pressure and stress on the gun wall are loaded into the gun finite element model;

[0115] Through transient calculations to achieve residual convergence, the strain results caused by uneven force on the spray gun after feeding are obtained. The movement and distribution of particles in the gas-matte-slag multiphase flow field under different spraying conditions are obtained, and the pressure and stress distribution on the spray gun wall can be obtained.

[0116] In a feasible implementation, the sixth link after decomposition is the stress and strain of the top-blowing lance, which involves the coupling between the structural field of the lance and the stress field of the fluid. For the above process, a finite element calculation method is used to establish a lance model, and then the pressure and stress on the lance wall calculated in the fifth link are loaded into the finite element model. Steady-state calculation is used, and all residuals converge to 10 -4 ~10 -5 The above calculations can be used to obtain the strain results caused by the uneven force on the spray gun after feeding. The movement and distribution of particles in the gas-matte-slag multiphase flow field under different spraying conditions can be obtained, and the pressure and stress distribution on the spray gun wall can be obtained.

[0117] Through the key field coupling calculations of the above six links, we can obtain relatively accurate simulation calculation results of different field information relatively efficiently, such as Figure 2 shown.

[0118] In the embodiment of the present invention, the coupled modeling and simulation method based on key fields proposed in the present invention is adopted. (1) The multi-field coupling process is disassembled. For different links, only the key fields involved are coupled and solved, which greatly reduces the difficulty of modeling; (2) The convergence is good. Since the model is appropriately simplified, the convergence of the solution process is greatly improved. At the same time, the results obtained by solving the key fields that play a major role still have relatively good accuracy; (3) The computational cost is greatly reduced. Since the coupling method of the key fields is processed, it can be avoided that the time spent on the coupled solution of the concentration field and the temperature field during the flow field calculation is too long. The time step can be increased by 1-2 orders of magnitude, and the computational time can be greatly reduced.

[0119] This method decomposes the complex multiphase, multifield system of submerged top-blown smelting into multiple links. Based on the characteristics of the fields involved in each link, different coupling calculation methods are used. This significantly reduces the difficulty of solving the computational model, improves model convergence, and increases solution efficiency. The calculation results are also relatively accurate. The decomposition method of the six links and the coupling calculation methods of the different links are protected.

[0120] Figure 3 Schematic diagram of a submerged top-blown smelting furnace modeling and simulation system based on key field coupling according to the present invention. The system 200 is used for the above-mentioned submerged top-blown smelting furnace modeling and simulation method based on key field coupling. The system 200 includes:

[0121] The coupled process decomposition module 210 is used to analyze the different fields of the submerged top-blowing smelting process and decompose the multi-field coupled process. The submerged top-blowing smelting process is decomposed into six steps: compressible gas injection in the top-blowing lance, multiphase movement of gas-matte-slag in the top-blowing process, component mixing in the top-blowing process, exothermic heterogeneous reaction in the top-blowing process, concentrate particle feeding in the top-blowing furnace, and stress and strain in the top-blowing lance.

[0122] A key field extraction module 220 is used to extract key fields from the six links and weaken non-key fields;

[0123] The modeling and simulation module 230 is used to perform coupling calculations on the key fields of the six links, obtain key field information of different links, and complete modeling and simulation of the submerged top-blown smelting furnace based on key field coupling.

[0124] Preferably, the key field extraction module 220 is used to extract the key fields of the compressible gas blowing link in the top-blowing lance, and the key fields include: the single-phase flow field of the blowing gas in the lance and the temperature field in the lance;

[0125] Extract the key fields of the multiphase movement of gas, matte and slag in the top-blowing process, including the multiphase flow fields of gas, matte and slag;

[0126] Extract the key fields of the component mixing link in the top blowing process, including: gas-matte-slag multiphase flow field and the component fields in each phase;

[0127] Extract the key fields of the exothermic heterogeneous reaction link in the top-blowing process, including: gas-matte-slag multiphase flow field and component field of heterogeneous reaction;

[0128] Extract the key fields of the top-blown furnace concentrate particle feeding link, including: gas matte slag multiphase flow field and particle movement field;

[0129] The key fields of the stress and strain link of the top-blowing spray gun are extracted. The key fields include: the structural field of the spray gun and the stress field of the fluid.

[0130] Preferably, the modeling and simulation module 230 is used to calculate the coupling between the single-phase flow field of the blowing gas in the top-blowing spray gun and the temperature field in the spray gun during the compressible gas blowing process in the top-blowing spray gun;

[0131] Calculate the coupling between the gas, matte and slag multiphase flow fields in the gas-matte-slag multiphase motion process during the top blowing process;

[0132] Calculate the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase during the component mixing stage of the top-blowing process;

[0133] Calculate the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process;

[0134] Calculate the coupling between the gas-matte-slag multiphase flow field and the particle motion field during the feed process of concentrate particles in a top-blown furnace;

[0135] Calculate the coupling between the structural field of the top-blowing spray gun and the stress field of the fluid in the stress and strain link of the top-blowing spray gun.

[0136] Preferably, calculating the coupling between the single-phase flow field of the blowing gas in the top-blowing lance and the temperature field in the lance during the compressible gas blowing link in the top-blowing lance includes:

[0137] Establish a top-blowing spray gun model;

[0138] Use compressible gas for single-phase flow field calculation;

[0139] Steady-state calculation or transient calculation is used to converge the residuals, and the nozzle outlet velocity, velocity vector distribution results, and nozzle outlet gas density and viscosity distribution results under different wall temperatures, gas compositions, and inlet pressures are obtained.

[0140] Preferably, the calculation of the coupling between the multiphase flow fields of gas, matte and slag in the multiphase movement link of gas, matte and slag in the top blowing process includes:

[0141] Establish a model of the top-blown furnace molten pool area;

[0142] Use VOF incompressible multiphase flow to calculate the multiphase flow field;

[0143] The velocity inlet boundary is used for the gun inlet section, and the size of the gun inlet in three orthogonal coordinate systems is the size of the gun outlet velocity;

[0144] Transient calculation is used to converge the residuals, and the results of the changes in the velocity field, turbulence field, and gas-matte-slag phase field distribution in the furnace with respect to the injection time are obtained under different injection parameters, gas-matte-slag dosage ratio, liquid level, and melt properties.

[0145] Preferably, the calculation of the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase in the component mixing link of the top blowing process includes:

[0146] Based on the regional model of the top-blown furnace melt pool, the time statistics method is used to calculate the average values ​​of the velocities in three orthogonal directions, the gas-matte-slag phase distribution, the turbulent kinetic energy, and the turbulent dissipation rate during the multiphase movement of the gas-matte-slag during the top-blowing process. The statistical time is 5-20 seconds after the flow field stabilizes, and the average flow field is obtained.

[0147] The transient flow field in the molten pool is modified to the statistical average flow field, and a component of a certain concentration is added at a certain position in the molten pool. The calculation of the flow field equation is turned off, and the concentration diffusion equation of the component is solved only under the average flow field.

[0148] Transient calculation is used to converge the residuals, and the diffusion and concentration distribution results of any component in the phase where the component is located under different injection conditions are obtained, and then the mixing time results at different positions are obtained.

[0149] Preferably, the calculation of the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process includes:

[0150] The average flow field obtained by statistics;

[0151] Establish the kinetic equations for the reactions between different phases in the smelting process, combine the reaction exotherm, turn off the flow field calculation, and turn on the calculation of the component equation and energy equation;

[0152] Transient calculation is used to converge the residuals, and the concentration distribution of different reaction components, reaction rate, reaction heat release and furnace temperature distribution under different injection conditions are obtained.

[0153] Preferably, the calculation of the coupling between the gas-matte-slag multiphase flow field and the particle motion field in the top-blown furnace concentrate particle feeding link includes:

[0154] The steady-state calculation of the flow field in the top-blown furnace molten pool area model is converted to a transient calculation, where the calculation time interval is 5-10s of the melting time;

[0155] The particle motion and its interaction with the gas-matte-slag multiphase flow are calculated by coupling discrete element method with VOF multiphase flow. The concentrate particle motion is calculated by discrete element modeling. The particles and fluid are related through drag coupling in the momentum equation.

[0156] The volume fraction of particles was calculated by Monte Carlo method;

[0157] By performing residual convergence through transient calculation, the movement and distribution results of particles in the gas-matte-slag multiphase flow field under different injection conditions are obtained, and the pressure and stress distribution at the wall of the injection gun can be obtained.

[0158] Preferably, in the process of calculating the stress and strain of the top-blowing lance, the coupling between the structural field of the lance and the stress field of the fluid includes:

[0159] Establish the finite element model of the spray gun by finite element calculation method;

[0160] The results of pressure and stress on the gun wall are loaded into the gun finite element model;

[0161] Through transient calculations to achieve residual convergence, the strain results caused by uneven force on the spray gun after feeding are obtained. The movement and distribution of particles in the gas-matte-slag multiphase flow field under different spraying conditions are obtained, and the pressure and stress distribution on the spray gun wall can be obtained.

[0162] In the embodiment of the present invention, the coupled modeling and simulation method based on key fields proposed in the present invention is adopted. (1) The multi-field coupling process is disassembled. For different links, only the key fields involved are coupled and solved, which greatly reduces the difficulty of modeling; (2) The convergence is good. Since the model is appropriately simplified, the convergence of the solution process is greatly improved. At the same time, the results obtained by solving the key fields that play a major role still have relatively good accuracy; (3) The computational cost is greatly reduced. Since the coupling method of the key fields is processed, it can be avoided that the time spent on the coupled solution of the concentration field and the temperature field during the flow field calculation is too long. The time step can be increased by 1-2 orders of magnitude, and the computational time can be greatly reduced.

[0163] Figure 4 3 is a schematic structural diagram of an electronic device 300 provided in an embodiment of the present invention. The electronic device 300 may vary significantly due to different configurations or performances, and may include one or more processors (central processing units, CPUs) 301 and one or more memories 302. The memories 302 store at least one instruction, which is loaded and executed by the processor 301 to implement the following steps of the modeling and simulation method for a submerged top-blown smelting furnace based on key field coupling:

[0164] S1. Analyze the different fields in the submerged top-blowing smelting process and decompose the multi-field coupling process; decompose the submerged top-blowing smelting process into six steps: compressible gas injection in the top-blowing lance, multiphase movement of gas-matte-slag in the top-blowing process, component mixing in the top-blowing process, exothermic heterogeneous reaction in the top-blowing process, concentrate particle feeding in the top-blowing furnace, and stress and strain in the top-blowing lance;

[0165] S2. Extract key fields from the six links and weaken non-key fields;

[0166] S3. Carry out coupling calculation on the key fields of the six links, obtain the key field information of different links, and complete the modeling and simulation of the submerged top-blown smelting furnace based on key field coupling.

[0167] In an exemplary embodiment, a computer-readable storage medium is also provided, such as a memory including instructions. The instructions are executable by a processor in a terminal to implement the aforementioned method for modeling and simulating a submerged top-blown smelting furnace based on key field coupling. For example, the computer-readable storage medium may be a ROM, random access memory (RAM), CD-ROM, magnetic tape, floppy disk, or optical data storage device.

[0168] Those skilled in the art will understand that all or part of the steps to implement the above embodiments may be accomplished by hardware, or by a program to instruct the relevant hardware, and the program may be stored in a computer-readable storage medium, which may be a read-only memory, a disk, or an optical disk, etc.

Claims

1. A modeling and simulation method for a submerged top-blown smelting furnace based on key field coupling, characterized in that: The method steps include: S1. Analyze the different fields in the submerged top-blowing smelting process and decompose the multi-field coupling process; decompose the submerged top-blowing smelting process into six steps: compressible gas injection in the top-blowing lance, multiphase movement of gas-matte-slag in the top-blowing process, component mixing in the top-blowing process, exothermic heterogeneous reaction in the top-blowing process, concentrate particle feeding in the top-blowing furnace, and stress and strain in the top-blowing lance; S2. extracting key fields from the six links and weakening non-key fields; In step S2, key fields are extracted from the six links, including: Extracting key fields of the compressible gas injection link in the top-blowing lance, the key fields including: the single-phase flow field of the injection gas in the lance and the temperature field in the lance; Extracting the key fields of the multiphase movement link of gas-matte-slag in the top-blowing process, the key fields include: gas, matte, and slag multiphase flow fields; Extract the key fields of the component mixing link in the top blowing process, which include: the gas-matte-slag multiphase flow field and the component fields in each phase; Extracting the key fields of the exothermic heterogeneous reaction link in the top-blowing process, the key fields include: the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction; Extract the key fields of the top-blown furnace concentrate particle feeding link, which include: gas-matte-slag multiphase flow field and particle movement field; Extracting the key fields of the stress and strain link of the top-blowing lance, the key fields including: the structural field of the lance and the stress field of the fluid; S3. Perform coupling calculation on the key fields of the six links, obtain key field information of different links, and complete modeling and simulation of the submerged top-blown smelting furnace based on key field coupling.

2. The method according to claim 1, characterized in that In step S3, coupling calculation is performed on the key fields of the six links to obtain key field information of different links, including: Calculating the coupling between the single-phase flow field of the compressed gas in the top-blowing lance and the temperature field in the lance during the lance injection process; Calculating the coupling between the multiphase flow fields of gas, matte and slag in the multiphase movement link of gas, matte and slag in the top blowing process; Calculating the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase during the component mixing step of the top-blowing process; Calculating the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process; Calculating the coupling between the gas-matte-slag multiphase flow field and the particle motion field during the top-blown furnace concentrate particle feeding process; The coupling between the structural field of the top-blowing lance and the stress field of the fluid is calculated in the stress-strain link of the top-blowing lance.

3. The method according to claim 2, characterized in that The calculation of the coupling between the single-phase flow field of the blowing gas in the top-blowing lance and the temperature field in the lance during the compressible gas blowing link in the top-blowing lance includes: Establish a top-blowing spray gun model; Use compressible gas for single-phase flow field calculation; Steady-state calculation or transient calculation is used to converge the residuals, and the nozzle outlet velocity, velocity vector distribution results, and nozzle outlet gas density and viscosity distribution results under different wall temperatures, gas compositions, and inlet pressures are obtained.

4. The method according to claim 3, characterized in that The calculation of the coupling between the multiphase flow fields of gas, matte and slag in the multiphase movement link of gas, matte and slag in the top blowing process includes: Establish a model of the top-blown furnace molten pool area; Use VOF incompressible multiphase flow to calculate the multiphase flow field; The velocity inlet boundary is used as the cross section of the spray gun inlet, and the size of the spray gun inlet in three orthogonal coordinate systems is the size of the spray gun outlet velocity; Transient calculation is used to converge the residuals, and the results of the changes in the velocity field, turbulence field, and gas-matte-slag multiphase flow field distribution in the furnace with respect to the injection time are obtained under different injection parameters, gas-matte-slag dosage ratio, liquid level, and melt properties.

5. The method according to claim 4, characterized in that The calculation of the coupling between the gas-matte-slag multiphase flow field and the component fields in each phase in the component mixing link of the top blowing process includes: Based on the regional model of the top-blown furnace molten pool, the average values ​​of the velocities in three orthogonal directions, the gas-matte-slag phase distribution, the turbulent kinetic energy, and the turbulent dissipation rate in the gas-matte-slag multiphase movement during the top-blowing process are calculated using a time statistics method; the average flow field is obtained from the statistical time of 5-20 seconds after the flow field stabilizes; The transient flow field in the molten pool is modified to the statistical average flow field, and a component of a certain concentration is added at a certain position in the molten pool. The calculation of the flow field equation is turned off, and the concentration diffusion equation of the component is solved only under the average flow field. Transient calculation is used to converge the residuals, and the diffusion and concentration distribution results of any component in the phase where the component is located under different injection conditions are obtained, and then the mixing time results at different positions are obtained.

6. The method according to claim 5, characterized in that The calculation of the coupling between the gas-matte-slag multiphase flow field and the component field of the heterogeneous reaction in the exothermic heterogeneous reaction link of the top-blowing process includes: The average flow field obtained by statistics; Establish the kinetic equations for the reactions between different phases in the smelting process, combine the reaction exotherm, turn off the flow field calculation, and turn on the calculation of the component equation and energy equation; Transient calculation is used to converge the residuals, and the concentration distribution of different reaction components, reaction rate, reaction heat release and furnace temperature distribution results under different injection conditions are obtained.

7. The method according to claim 6, characterized in that The calculation of the coupling between the gas-matte-slag multiphase flow field and the particle motion field in the top-blown furnace concentrate particle feeding link includes: Convert the steady-state calculation of the flow field in the top-blown furnace molten pool area model into a transient calculation, where the calculation time interval is 5-10s of the melting time; The particle motion and its interaction with the gas-matte-slag multiphase flow are calculated by coupling discrete element method with VOF multiphase flow. The concentrate particle motion is calculated by discrete element modeling. The particles and fluid are related through drag coupling in the momentum equation. The volume fraction of particles was calculated by Monte Carlo method; By performing residual convergence through transient calculation, the movement and distribution results of particles in the gas-matte-slag multiphase flow field under different injection conditions are obtained, and the pressure and stress distribution at the wall of the spray gun can be obtained.

8. The method according to claim 7, characterized in that The coupling between the structural field of the top-blowing lance and the stress field of the fluid in the step of calculating the stress and strain of the top-blowing lance includes: Establish the finite element model of the spray gun by finite element calculation method; Loading the results of the pressure and stress on the wall of the spray gun into the finite element model of the spray gun; By performing residual convergence through transient calculation, the strain results caused by uneven force on the spray gun after feeding are obtained, the movement and distribution results of particles in the gas-matte-slag multiphase flow field under different spraying conditions are obtained, and the pressure and stress distribution at the spray gun wall can be obtained.

9. A modeling and simulation system for a submerged top-blown smelting furnace based on key field coupling, characterized in that: The system is used for the modeling and simulation method of a submerged top-blown smelting furnace based on key field coupling according to any one of claims 1 to 8, and the system comprises: The coupled process decomposition module is used to analyze the different fields of the submerged top-blowing smelting process and decompose the multi-field coupled process. It decomposes the submerged top-blowing smelting process into six links: compressible gas injection in the top-blowing lance, multiphase movement of gas-matte-slag in the top-blowing process, component mixing in the top-blowing process, exothermic heterogeneous reaction in the top-blowing process, concentrate particle feeding in the top-blowing furnace, and stress and strain in the top-blowing lance. A key field extraction module is used to extract key fields from the six links and weaken non-key fields; The modeling and simulation module is used to perform coupling calculations on the key fields of the six links, obtain key field information of different links, and complete the modeling and simulation of the submerged top-blown smelting furnace based on key field coupling.

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