Material flow and energy flow bi-directional coupling tin smelting automatic batching method and material flow and energy flow bi-directional coupling tin smelting automatic batching system

Abstract

The invention relates to the technical field of batching automatic control, and discloses a material flow and energy flow bidirectional coupling tin smelting automatic batching method and system. Carrying out automatic calculation to carry out material balance, energy balance calculation and material-energy coupling optimization configuration, and determining a decision variable value of production optimization batching, namely a batching scheme; a batching scheme and target parameters are displayed through a window and are transmitted to a DCS (Distributed Control System) through an OPC (Optical Product Control) server, and the feeding amount of a feeder and hardware instrument equipment are controlled by the DCS; the current crude tin grade, the Fe / SiO2 ratio in slag and the melt temperature are analyzed and compared with target values. The system comprises a batching calculation module, a distribution control module and a parameter correction module. Through material and energy flow analysis, precise smelting burdening, process optimization, energy conservation and emission reduction are achieved, and the production efficiency and environmental friendliness are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of automatic batching control, and in particular to an automatic batching method and system for tin smelting with bidirectional coupling of material flow and energy flow. Background Art

[0002] Nonferrous metal tin is widely used in the manufacture of electronic products, building materials and chemical products; the tin smelting industry provides raw materials for various industries and promotes the development of related industries; with the development of industrial production and the improvement of environmental protection requirements, the traditional tin smelting process faces problems such as low energy efficiency and environmental pollution; in addition, due to the instantaneous nature of smelting technology and process and the complexity of the composition of the incoming ore, it is difficult to flexibly control the process parameters. In the face of the high temperature and multiphase reaction process of nonferrous smelting, the current production adjustment and input of process control parameters are only set by personal experience, and the extensive regulation is limited by the level of personal experience and the lag of smelting process monitoring, which brings uncontrollable factors to smelting production, resulting in large fluctuations in the top-blown tin smelting conditions and crude tin grades, which not only affects the production of the next process, but also affects the normal service life of metallurgical furnaces and other equipment, bringing many unstable factors to production. In addition, in the smelting process, there is a complex symbiotic relationship in which energy flow and material flow are coupled and affect each other. However, in the past, the usual practice was to consider production scheduling and energy systems separately, which resulted in limitations such as low energy efficiency, unreasonable batching and production scheduling. In order to accelerate the development and layout of new quality productivity, tin smelters have put forward higher requirements for production planning, cycle scheduling, material ratio, etc.; the top-blowing submerged smelting process is the link with the largest energy consumption and the most complex reaction mechanism in the entire tin smelting process. The relevant furnace charge ratio and energy flow and material flow direction play a key role in the direct recovery rate and grade of tin metal; the production scheduling optimization of the tin smelting submerged top-blowing molten pool smelting system can be summarized as follows: on the basis of fully considering the grade of the raw ore entering the furnace, the production capacity of the smelting furnace, and the quality and output requirements of the tin smelting products, with the optimization of energy utilization and ore ratio economic benefits as the objective function, under the condition of meeting the constraints, supervise the fluctuation of the material composition of various types of materials entering the furnace, provide the best operation strategy for the ratio of various types of raw materials, and make dynamic overall scheduling arrangements.

[0003] Prior art 1, Chinese patent, application number 202010667861.0 discloses a crude tin smelting system and process, the system comprising a top-blown furnace, a condensate pot, a water quenching system, a waste heat boiler, a roasting furnace, a cooling flue, an electrostatic precipitator, a quencher, a bag-type dust collector and a desulfurization and acid-making system; the dust-containing flue gas produced by the top-blown furnace enters the waste heat boiler through the smoke exhaust port at the top of the top-blown furnace; the condensate pot is arranged below the top-blown furnace; the smoke exhaust port arranged on the top of the roasting furnace is connected to the cooling flue; the water quenching system is connected to the slag discharge port of the top-blown furnace; the electrostatic precipitator, the quencher and the bag-type dust collector are connected in sequence; the electrostatic precipitator, the quencher and the bag-type dust collector are provided with two groups, the electrostatic precipitator in one group is connected to the waste heat boiler, and the electrostatic precipitator in the other group is connected to the cooling flue; the bag-type dust collectors are all connected to the desulfurization and acid-making system. Although the equipment configuration is small, the investment is small, and the smelting, reduction and fuming processes are completed continuously in the same circuit, reducing the turnover of intermediate materials and reducing material losses, the equipment is highly complex, the installation and maintenance costs are high, and the ingredients and production scheduling are unreasonable.

[0004] Prior art 2, Chinese patent, application number 202310447300.3 discloses a smelting device and smelting method for shortening the smelting time of indium tin, the smelting device includes a furnace body and a furnace cover, the top of the furnace cover is provided with a feed part, and three crushing rollers are equidistantly arranged inside the feed part, and one side of the three crushing rollers is fixedly sleeved with a transmission shaft; the smelting method of the smelting device is adopted, through the crushing rollers, transmission shafts, semicircular cavity screens and drive components, when the raw materials are put in, by opening the drive component, under the transmission action of the transmission shaft, the crushing rollers can be driven to rotate, and then the raw materials placed in the feed part can be crushed, and the crushed raw materials pass through the feed port and fall onto the semicircular cavity screen, and the crushed raw materials can be dispersed to various positions on the receiving bottom plate through the semicircular cavity screen. Although the problem of long smelting time caused by uneven distribution of raw materials can be avoided. However, the production scheduling and energy system are considered separately, which leads to the limitation of low energy utilization efficiency.

[0005] Prior art three, Chinese patent, application number 202310175861.2 discloses a recyclable concentrate smelting device, including a charging box, the front and rear sides of the top of the charging box are provided with slide grooves, the front and rear sides of the bottom of the charging box are laterally plugged with first slides, the connection between the charging box and the first slide is sleeved with a bearing lock sleeve, the bottoms of the front and rear sides of the charging box are provided with slide rails, and the inner sides of the two slide rails facing each other are provided with baffles. Although a charging box is provided, and the first slide at the bottom of the charging box on both sides is suspended in the air, the internal liquid and moisture are prevented from damaging the bottom of the charging box during long-term use, thereby increasing its service life, and the charging box can be well protected, and at the same time, the leak-proof cover provided on the side of the charging box can collect the leaked material on the side. However, it has problems such as low energy efficiency and easy to cause environmental pollution.

[0006] At present, the existing technologies 1, 2 and 3 have the problems of low energy efficiency, environmental pollution, and separate production scheduling from energy system, which results in low energy utilization efficiency, unreasonable batching and production scheduling, etc. Therefore, the present invention provides a method and system for automatic batching of tin smelting with bidirectional coupling of material flow and energy flow. In order to improve smelting efficiency and ensure product quality, it is necessary to design a concise and accurate material flow-energy flow measurement, calculation and management method and a high-efficiency intelligent batching and production scheduling system to solve these challenges. Summary of the invention

[0007] The main purpose of the present invention is to provide a method and system for automatic batching of tin smelting with bidirectional coupling of material flow and energy flow, so as to solve the problems in the prior art of low energy efficiency, environmental pollution, and separation of production scheduling and energy system, resulting in low energy utilization efficiency and unreasonable batching and production scheduling.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] An automated batching method for tin smelting by bidirectionally coupling material flow and energy flow, the automated batching method for tin smelting by bidirectionally coupling material flow and energy flow comprises:

[0010] Input the information of ore and fuel composition, set the top blowing air volume, oxygen concentration and three target parameter values; based on the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting, automatically calculate the material balance, energy balance calculation and material-energy coupling optimization configuration, and determine the decision variable value of production optimization batching, that is, the precise batching plan;

[0011] The batching plan and target parameters are displayed in the window and transmitted to the distributed control system DCS through the OPC server. The distributed control system DCS controls the feeder discharge amount and hardware instrument equipment;

[0012] The current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature are analyzed and compared with the target values. If the deviation exceeds the allowable range, feedback is automatically triggered, and the correction amount and feedforward output value are calculated to obtain the corrected target parameters. After confirmation by the operator, the calculated target parameters are transmitted to the distributed control system DCS through the transmission subsystem of the OPC server for terminal control.

[0013] As a further improvement of the present invention, the construction of a nonlinear energy flow-material flow coupling mathematical model based on oxygen-enriched top-blown tin smelting includes:

[0014] A material balance model is established based on the input materials in the tin smelting process of the oxygen-enriched top-blown smelting system; at the same time, based on the input and output data in the tin smelting process, the data that cannot be directly measured are calculated, and the data that can be directly measured include flue gas composition and flow rate;

[0015] Calculate the material balance results according to the energy balance equation, analyze the flow of various substances and energy in the tin smelting process, and the energy flow includes heat income and heat expenditure; through the material balance model and energy balance equation, perform mathematical calculations to obtain the flow direction, quantity, utilization efficiency, theoretical smelting end point temperature and material component parameters of various substances and energy, and realize the mathematical modeling of multi-energy loads and dynamic prediction of related energy-quality networks for large-scale oxygen-enriched top-blown smelting processes;

[0016] The heat income and heat expenditure are expressed in a weighted form by the mass of each input and output material, and a nonlinear energy flow-material flow coupling mathematical model is obtained.

[0017] As a further improvement of the present invention, the material balance equation:

[0018] ∑G 投入 =∑G 产出

[0019] ∑G 投入 =g1+g2+g3+g4

[0020] ∑G 产出 =g5+g6+g7+g8+g9

[0021] Where: ∑G 投入、产出 Indicates the total mass of input and output materials of top-blown smelting furnace, t / h; g 1、2、3、4 Indicates the feeding amount of tin concentrate, slag-making agent, coal and oxygen-enriched air, t / h; g 5、6、7、8、9 Indicates the output of tin A, tin B, slag, smoke and flue gas, t / h;

[0022] Among them, in the oxygen-enriched top-blown molten pool smelting process, the J element flow balance equation before and after smelting is:

[0023] G j,投入 =G j,产出

[0024]

[0025] Where: G j,投入、产出 It represents the total input and output of element j in the tin smelting process, t / h; η 1,j、2,j、3,j、4,j represents the proportion of element j in the tin concentrate, slag-making agent, coal and oxygen-enriched air entering the furnace; η 5,j、6,j、7,j、8,j、9,j It indicates the proportion of element j in tin A, tin B, slag, smoke and flue gas in the smelting products;

[0026] Energy balance equation takes historical smelting data to calculate the unquantifiable heat loss The mean Calculate and according to the law of conservation of energy:

[0027] ∑Q 收入 =∑Q 支出

[0028] ∑Q 收入 =q1+q2+q3+q4+q5+q6

[0029]

[0030] Where: ∑Q 收入、支出 Indicates the heat entering the top-blowing smelting reaction zone; ∑Q 收入、支出 Indicates the heat expenditure from the top-blowing smelting reaction zone; q 1、2、3、4、5、6 It represents the heat released by oxidation of free sulfur generated by FeS2 dissociation, heat released by slag making, heat released by coal combustion, sensible heat of charge, sensible heat of coal and sensible heat of air entering the furnace, MJ / h; q 7、8、9、10、11、12、13、14 It means that FeS2 dissociation absorbs heat, SnO2 and Fe3O4 reduction takes away heat, crude tin takes away heat, slag takes away heat, smoke takes away heat, water evaporation absorbs heat, flue gas takes away heat, and water cooling jacket takes away heat, MJ / h.

[0031] As a further improvement of the present invention, the theoretical air leakage / gas volume of the material balance equation is:

[0032] in is the historical statistical data of furnace air leakage u * The mean of .

[0033] As a further improvement of the present invention, the energy-mass coupling metallurgical mathematical physics calculation energy flow network matrix model in the oxygen top blowing molten pool smelting process can collect various types of heat into q 1～6 And various types of heat expenditure q7～14 Through the mass g of each input and output material 1～9 The weighted form of is expressed as:

[0034]

[0035] Where: q m g represents values ​​ranging from 1 to 15, representing energy flows: free sulfur oxidation heat generated by FeS2 dissociation, slag-making heat, coal combustion heat, charge sensible heat, coal sensible heat, furnace air sensible heat, FeS2 dissociation endothermic heat, SnO2 and Fe3O4 reduction absorption heat, crude tin carry-away heat, slag carry-away heat, smoke carry-away heat, water evaporation endothermic heat, flue gas carry-away heat, water cooling jacket carry-away heat, and unmeasurable heat; g 1～n Indicates the input amount of tin concentrate, slag-making agent, coal and oxygen-enriched air, and the output amount of tin amine, tin ethylene, slag, smoke and flue gas, t / h; ξ m,1～m,n It represents the weighting coefficient for calculating the relevant energy flow balance;

[0036] The empirical equations for energy-mass coupling metallurgical mathematical physics calculation and the energy flow network matrix model in the oxygen-enriched top-blown molten pool smelting process are as follows:

[0037] Input energy flow, free sulfur oxidation heat generated by FeS2 dissociation, slag release, coal combustion heat, charge sensible heat, coal sensible heat and furnace air sensible heat:

[0038] Output energy flow, FeS2 dissociation absorbs heat, SnO2 and Fe3O4 reduction takes away heat, crude tin takes away heat, slag takes away heat, smoke takes away heat, water evaporation absorbs heat, flue gas takes away heat, water cooling jacket takes away heat, and there are unquantifiable heat losses.

[0039] As a further improvement of the present invention, the matter-energy coupling optimization configuration strategy is:

[0040] Optimization of thermal efficiency of smelting furnace:

[0041]

[0042] In order to achieve a higher effective energy utilization rate in the smelting process, the corresponding expression is:

[0043]

[0044] In order to achieve higher economic benefits for smelting and meet the maximum supply constraints of various mineral materials, the corresponding expression is:

[0045]

[0046] The amount of ingredients fed is subject to the tonnage of the furnace, the production cycle and the processing capacity:

[0047]

[0048] In the formula, Ton is the rated tonnage of the furnace design, T cycle It is a single furnace production smelting cycle;

[0049] Through the Lagrange multiplier method, the maximum value of the multivariate function equation of material and energy balance is solved under the constraints, and the values ​​of the decision variables for production optimization batching can be determined.

[0050] As a further improvement of the present invention, the OPC server is transmitted to the distributed control system DCS, including:

[0051] Real-time monitoring of data transmission between the OPC server and the distributed control system DCS, regular collection and recording of communication delay, error packet rate and connection status; when the delay of the communication link exceeds the preset threshold or data packet loss occurs, it is automatically marked as a risky communication state;

[0052] In the collected data, the characteristic values ​​of important operating parameters are defined; when the deviation between the actual parameters and the target parameters exceeds the set tolerance range, the system automatically determines it as an abnormal situation and triggers the safety mode; in the safety mode, the instruction to reduce the feed amount will be executed immediately and the operation of the feeding device will be suspended;

[0053] After entering the safety mode, an alarm is issued to notify the operator. At the same time, the feed rate is reduced to the lowest operating level according to the preset safety strategy, and the minimum risk feed rate strategy is implemented. After receiving the alarm, the operator obtains detailed warning information through the interface and understands the current operating status. The deviation between the actual feed rate and the historical record is regularly evaluated to form a feedback loop. When the communication returns to normal and the actual parameters are within the set range, the normal feed process is gradually restored and the target parameters are readjusted.

[0054] As a further improvement of the present invention, for each data transmission, the relevant transmission timestamp and status information are recorded. When a risk communication state occurs, the current feed amount, target parameters and actual operating status are automatically checked. Through the threshold judgment mechanism, the rationality of the feeding process is judged, and it is evaluated whether it is necessary to switch to the safe mode.

[0055] As a further improvement of the present invention, the corrected target parameters are obtained, including:

[0056] Compare the actual parameters with the target values ​​and calculate the deviation of each parameter; calculate the sum of the absolute values ​​of all deviations to obtain a comprehensive deviation index to evaluate the overall deviation degree; set the allowable deviation range for each parameter. If the deviation of a parameter exceeds the preset range, the parameter will be corrected in detail.

[0057] Analyze the correction coefficient of each parameter based on historical deviation data, calculate the amount to be corrected in the next control cycle, and convert the correction amount into a specific material or gas delivery adjustment value; analyze the trend of the actual impact of energy flow and material flow on the target parameters under the current state based on historical data; combine the predicted value with the actual deviation to generate a feedforward output value;

[0058] The correction amount is combined with the feedforward output value to generate the final corrected target parameter.

[0059] To achieve the above object, the present invention also provides the following technical solutions:

[0060] A tin smelting automatic batching system with bidirectional coupling of material flow and energy flow, which is applied to the tin smelting automatic batching method with bidirectional coupling of material flow and energy flow, and the tin smelting automatic batching system with bidirectional coupling of material flow and energy flow comprises:

[0061] The batching calculation module is used to input the information of ore and fuel composition, set the top blowing air volume, oxygen concentration and three target parameter values; based on the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting, it automatically calculates material balance, energy balance calculation and material-energy coupling optimization configuration, and determines the decision variable value of production optimization batching, that is, the batching scheme; among which, the three target parameter values ​​include crude tin grade, Fe / SiO2 ratio in slag and melt temperature; the batching scheme includes the proportion and feeding amount of imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag, and smoke dust into the furnace; granular coal, pulverized coal and top blowing air volume;

[0062] Distributed control module, used to display batching scheme and target parameters through window, and transmit them to distributed control system DCS through OPC server, and distributed control system DCS controls feeder discharge amount and hardware instrument equipment;

[0063] The parameter correction module is used to analyze the current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature, and compare them with the target value; if the deviation exceeds the allowable range, feedback is automatically triggered, and the correction amount and feedforward output value are calculated to obtain the corrected target parameters. After confirmation by the operator, the calculated target parameters are transmitted to the distributed control system DCS through the transmission subsystem of the OPC server for terminal control.

[0064] The present invention inputs information and automatically calculates, and realizes centralized management and processing of data by inputting composition information of ore and fuel, and setting top blowing air volume, oxygen concentration and three target parameter values; based on the mathematical model of oxygen-enriched top blowing tin smelting, it can automatically perform material balance and energy balance calculations, and optimize the configuration to realize efficient batching scheme generation. Significance achieved: Automatic calculation and optimization reduce the time and errors of manual operation, and improve overall production efficiency; through reasonable material-energy coupling configuration, the waste of raw materials is reduced, and the efficient use of resources is ensured; by setting specific target parameters (such as crude tin grade, Fe / SiO2 ratio in slag and melt temperature), the quality and stability of the final product are improved. The batching scheme and data transmission, the batching scheme and target parameters are displayed through the window, which is convenient for operators to monitor in real time; the data is transmitted to the DCS system through the OPC server, ensuring efficient communication and collaboration between different systems. Significance achieved: Clearly visible batching schemes and target parameters enable operators to respond and adjust more quickly, enhancing the flexibility of on-site management; the application of the DCS system ensures hardware implementation control (such as feeders and other equipment), reduces manual intervention, and improves the accuracy and consistency of operations. Real-time monitoring and feedback adjustment, by analyzing the current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature, can track the effect of the production process in real time; if the deviation exceeds the allowable range, the feedback mechanism is automatically triggered for correction and pre-adjustment. Significance achieved: The real-time monitoring and feedback mechanism ensures that the parameters in the production process are always kept within the set range, thereby ensuring production stability; through feedforward and feedback adjustment, dynamic control of the production process is achieved, and the intelligence level and automation capabilities of the system are improved; through real-time monitoring and feedback, when there are potential risks in material and process deviations, adjustments can be made in time to reduce the possibility of accidents. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] Figure 1 It is a schematic diagram of the steps of an embodiment of the method for automatic batching of tin smelting by bidirectionally coupling material flow and energy flow of the present invention;

[0066] Figure 2 It is a schematic diagram of an embodiment of the automatic batching method for tin smelting with bidirectional coupling of material flow and energy flow of the present invention;

[0067] Figure 3 It is a schematic flow chart of the steps of constructing a mathematical model of nonlinear energy flow-material flow coupling based on oxygen-enriched top-blown tin smelting in one embodiment of the method for automated batching of tin smelting with bidirectional coupling of material flow and energy flow of the present invention;

[0068] Figure 4 A schematic diagram of inputs and outputs of an embodiment of the method for automated batching of tin smelting in which material flow and energy flow are bidirectionally coupled according to the present invention;

[0069] Figure 5 It is a schematic flow chart of energy income and expenditure steps in the tin smelting process in one embodiment of the method for automatic batching of tin smelting in which material flow and energy flow are bidirectionally coupled;

[0070] Figure 6 It is a schematic flow chart of the steps of the tin smelting process model of an embodiment of the method for automatic batching of tin smelting in which material flow and energy flow are bidirectionally coupled;

[0071] Figure 7 It is a schematic flow chart of the steps of transmitting the material flow and energy flow bidirectionally coupled tin smelting automatic batching method to the distributed control system DCS through the OPC server in one embodiment of the present invention;

[0072] Figure 8 A schematic flow chart of steps for obtaining corrected target parameters in an embodiment of the method for automatic batching of tin smelting by bidirectional coupling of material flow and energy flow of the present invention;

[0073] Fig. 9 It is a functional module schematic diagram of an embodiment of the automatic batching system for tin smelting with bidirectional coupling of material flow and energy flow of the present invention;

[0074] Fig.10 It is a schematic diagram of an embodiment of the automatic batching system for tin smelting with bidirectional coupling of material flow and energy flow of the present invention;

[0075] Fig.11 It is a structural schematic diagram of an embodiment of an electronic device of the present invention;

[0076] Fig.12 It is a schematic structural diagram of an embodiment of the storage medium of the present invention. DETAILED DESCRIPTION

[0077] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the 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.

[0078] The term "process, method, system, product or device comprising a series of steps or units in the present invention is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products or devices. Reference to "embodiment" herein means that the specific features, structures or characteristics described in conjunction with the embodiment may be included in at least one embodiment of the present invention. The appearance of the phrase at various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0079] like Figure 1 As shown, this embodiment provides an embodiment of a method for automatic batching of tin smelting by bidirectionally coupling material flow and energy flow. In this embodiment, the method for automatic batching of tin smelting by bidirectionally coupling material flow and energy flow specifically includes the following steps:

[0080] Step S1: Input the composition information of ore and fuel, set the top blowing air volume, oxygen concentration and three target parameter values; based on the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting, automatically calculate the material balance, energy balance calculation and material-energy coupling optimization configuration, and determine the decision variable value of production optimization batching, that is, the batching plan;

[0081] Among them, the three major target parameter values ​​include crude tin grade, Fe / SiO2 ratio in slag and melt temperature; the batching plan includes the proportion and amount of imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag, smoke dust and other ore materials into the furnace; the amount of granular coal, pulverized coal and top blowing gas;

[0082] Step S2: the batching scheme and target parameters are displayed in a window and transmitted to the distributed control system DCS through the OPC server, and the distributed control system DCS controls the feeder discharge amount and hardware instrument equipment;

[0083] Step S3: Analyze the current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature, and compare them with the target value; if the deviation exceeds the allowable range, the feedback is automatically triggered, and the correction amount and the feedforward output value are calculated to obtain the corrected target parameters. After confirmation by the operator, the calculated target parameters are transmitted to the distributed control system DCS through the transmission subsystem of the OPC server for terminal control.

[0084] Preferably, in step S1 of this embodiment, input information and automatic calculation are performed, and by inputting the composition information of ore and fuel, and setting the top blowing air volume, oxygen concentration and three target parameter values, centralized management and processing of data are realized; based on the mathematical model of oxygen-enriched top-blown tin smelting, material balance and energy balance calculation can be automatically performed, and the configuration can be optimized to realize efficient batching scheme generation. Significance achieved: Automatic calculation and optimization reduce the time and errors of manual operation, and improve overall production efficiency; through reasonable material-energy coupling configuration, the waste of raw materials is reduced, and the efficient use of resources is ensured; by setting specific target parameters (such as crude tin grade, Fe / SiO2 ratio in slag and melt temperature), the quality and stability of the final product are improved. Step S2 batching scheme and data transmission, the batching scheme and target parameters are displayed through the window, which is convenient for operators to monitor in real time; the data is transmitted to the DCS system through the OPC server, ensuring efficient communication and collaboration between different systems. Significance achieved: Clearly visible batching schemes and target parameters enable operators to react and adjust more quickly, enhancing the flexibility of on-site management; the application of the DCS system ensures hardware implementation control (such as feeders and other equipment), reduces manual intervention, and improves the accuracy and consistency of operations. Step S3 real-time monitoring and feedback adjustment, by analyzing the current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature, can track the effect of the production process in real time; if the deviation exceeds the allowable range, the feedback mechanism is automatically triggered for correction and pre-adjustment. Significance achieved: The real-time monitoring and feedback mechanism ensures that the parameters in the production process always remain within the set range, thereby ensuring production stability; through feedforward and feedback adjustment, dynamic control of the production process is achieved, and the intelligence level and automation capabilities of the system are improved; through real-time monitoring and feedback, when there are potential risks in material and process deviations, adjustments can be made in time to reduce the possibility of accidents (for specific principles, please refer to the attached Figure 2 ).

[0085] This embodiment achieves precise control and optimal configuration of materials and energy in the tin smelting process by establishing a material flow-energy flow coupling calculation method. The system can automatically calculate the optimal batching scheme, including the ratio of furnace ore, slag-making agent, fuel and oxygen-enriched air, so as to achieve optimal utilization of resources and reduce production costs. At the same time, the system can also monitor the production process in real time and dynamically adjust the batching scheme according to actual conditions to ensure the stability of the production process and product quality. In addition, by optimizing the batching scheme and energy utilization, the invention can also effectively reduce energy consumption and emissions and achieve green production.

[0086] This embodiment realizes the automatic control of the feeding and batching process of tin smelting based on advanced metallurgical mathematical models and intelligent control technology. The system can automatically perform material balance, energy balance calculation and material-energy coupling optimization configuration, without the need for manual extensive regulation based on experience, thereby improving the scientific nature of batching, tin smelting production efficiency and automation level. In addition, the system also analyzes and makes decisions based on historical data and real-time data to further improve the scientific nature and accuracy of decision-making, and ensures the stability of the production process and product quality through a closed-loop control mechanism. This embodiment improves the energy efficiency and automation level of the tin smelting process, and realizes precise regulation of the batching of ore entering the furnace during the production process. It solves the current production problems such as extensive regulation of batching based on manual experience, large fluctuations in the grade of smelted tin matte, and low energy efficiency. This embodiment establishes a metallurgical mathematical model that is strongly related to actual production. Based on the metallurgical thermodynamics database, process operation parameters and instrument detection data, it automatically calculates the composition and operation mode of the energy flow and material flow between different equipment under various smelting conditions, and adjusts the mixing ratio of the ore entering the furnace, the amount of coal input into the molten pool and the amount of oxygen-enriched supply during the smelting process in real time, so as to ultimately achieve the purpose of continuous, low-carbon, high-energy-efficiency and stable production of the smelting process.

[0087] In summary, each step of the tin smelting automated batching method of this embodiment effectively integrates modern intelligent control and automation technology. It not only improves production efficiency and product quality, but also optimizes economy and safety. The integrated automatic control system ensures the stability and safety of the tin smelting process through accurate data transmission and real-time feedback, making the entire smelting process more intelligent and in line with the needs of modern industry.

[0088] Furthermore, if Figure 3 As shown, the method for constructing a nonlinear energy flow-material flow coupling mathematical model based on oxygen-enriched top-blown tin smelting in step S1 specifically includes the following steps:

[0089] Step S11: establishing a material balance model based on the input materials in the tin smelting process of the oxygen-enriched top-blown smelting system; and calculating the data that cannot be directly measured based on the input and output data in the tin smelting process, and the data that can be directly measured include flue gas composition and flow rate, etc.;

[0090] Step S12: Calculate the material balance result according to the energy balance equation, analyze the flow of various substances and energy in the tin smelting process, and the energy flow includes heat income and heat expenditure; through the material balance model and the energy balance equation, perform mathematical calculations to obtain the flow direction, quantity, utilization efficiency, theoretical smelting end point temperature and material composition of various substances and energy parameters, and realize the mathematical modeling of multi-energy loads and dynamic prediction of related energy quality networks for large-scale oxygen-enriched top-blown smelting process;

[0091] Step S13: The heat income and heat expenditure are expressed in a weighted form of the mass of each input and output material, and a nonlinear energy flow-material flow coupling mathematical model is obtained.

[0092] Preferably, in step S11 of this embodiment, a material balance model is established. According to various raw materials (such as ore, fuel, etc.) input during the oxygen-enriched top-blown smelting process, a material balance model is established to realize the dynamic balance calculation of various substances in the smelting process, and ensure that the relationship between input substances and output substances is accurately identified; by analyzing the input and output data, key data that cannot be directly measured, such as flue gas composition and flow rate, are calculated, and necessary process parameters are provided. The significance achieved: the data that cannot be directly measured are extrapolated, the integrity and accuracy of the model are enhanced, and a reliable data basis is provided for subsequent calculations and model analysis; the establishment of a material balance model helps to discover potential problems in material utilization, provide a scientific basis for process optimization, and thus improve the efficiency and output of the smelting process. Step S12 energy balance analysis, calculate the flow of various substances and energy through the energy balance equation, including heat income (such as heat released by chemical reactions) and heat expenditure (such as heat loss, melting energy consumption, etc.); using the material balance model and the energy balance equation, important parameters such as energy flow direction, quantity, utilization efficiency, theoretical smelting end temperature, and material composition in the smelting process are obtained. Significance achieved: By systematically analyzing the energy flow, the thermodynamic characteristics and energy utilization efficiency of the smelting process can be more comprehensively understood, thereby providing a basis for subsequent process improvements; by analyzing the energy balance, the main sources of heat loss can be identified, and targeted measures can be taken to reduce energy consumption and improve overall energy efficiency. Step S13 constructs a nonlinear energy flow-material flow coupling mathematical model, and by weighting the heat income and heat expenditure with the quality of each input and output material, a more complex nonlinear energy flow-material flow coupling mathematical model is constructed, which reflects the coupling relationship between matter and energy; the model can dynamically predict the mutual influence of matter and energy, and provides strong mathematical support for the simulation and optimization of the smelting process. Significance achieved: Through the coupling mathematical model, the material and energy conversion in the smelting process can be simulated more accurately, which is helpful to find the optimization path and improve the overall process efficiency; the constructed coupling model provides a basis for the intelligent control system, which can realize real-time monitoring, prediction and optimization of the smelting process, improve the level of automation, and enhance the stability and safety of the production process.

[0093] In summary, the construction of the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting in this embodiment provides a systematic method for understanding the material and energy changes in the tin smelting process. Each step not only realizes the calculation and analysis of key parameters technically, but also helps to optimize the smelting process, improve overall production efficiency, and lay the foundation for achieving a more efficient and environmentally friendly smelting process. The promotion and application of this methodology can play an important role in a wider range of metallurgical and material engineering fields.

[0094] Furthermore, if Figure 4 As shown, the material balance model in step S11 specifically includes:

[0095] The input materials involved in the tin smelting process of the entire oxygen-enriched top-blown smelting system can be mainly divided into tin concentrate, slag-making agent, fuel and oxygen-enriched air;

[0096] ∑G 投入 =g1+g2+g3+g4 (1)

[0097] Where: g 1、2、3、4 They represent the materials fed into the furnace: the amount of ore, slag-making agent, coal and oxygen-enriched air fed into the furnace, t / h;

[0098] The specific input materials include imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag and fume dust (also known as smoke dust and vacuum particles). The material composition and mass flow rate of the ore entering the submerged top-blown smelting furnace are monitored in real time by online component detectors and electronic belt scales.

[0099] According to the measurement results, it can be calculated that the feeding amount of the ore and the proportion of each element are:

[0100]

[0101] Where: η 1,j The content ratio of element and component j in the ore feed for tin smelting;

[0102] g 1,1、1,2、1,3、1,4、1,5、1,6 It indicates the input amount of imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag and smoke dust in tin concentrate, t / h;

[0103] η 1,j,1、1,j,2、1,j,3、1,j,4、1,j,5、1,j,6 It represents the content proportion of element and component j in imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag and smoke dust.

[0104] Generally speaking, tin in tin concentrate with industrial value usually exists in the form of cassiterite (SnO2), while iron mainly exists in the form of magnetite (Fe3O4), and a small amount exists in the form of pyrite (FeS2). Cassiterite is the main mineral for tin smelting. Since the content of metals such as Pb, As, and Al in the ore is relatively small (accounting for only 3.64%), the impact on the smelting process is relatively low. Therefore, the relevant material flow analysis considers that in addition to limestone, quartz, water (W) and other substances, the tin concentrate mixed ore mainly contains SnO2, Fe3O4, and FeS2. Therefore, the main elements and components in the ore entering the furnace are mainly Sn, Fe, S, Si, Ca, Al, and H2O.

[0105] According to the proportion of each element and chemical composition in the tin concentrate entering the furnace, the reasonable composition of the tin concentrate compound entering the furnace can be calculated:

[0106]

[0107] In the formula, Mr j Indicates the relative molecular mass of element / substance j.

[0108] Slag-forming agent, mainly composed of limestone (CaCO3) and quartz (SiO2); the mass flow rate of slag-forming agent entering the submerged top-blown smelting furnace can be monitored in real time by online component detector and electronic belt scale:

[0109]

[0110] Where: g 2,1、2,2 Indicates the amount of limestone (CaCO3) and quartz stone (SiO2) added, t / h;

[0111] As the fuel entering the furnace, anthracite needs to be introduced because CO is needed to reduce Fe and Sn oxides in the tin-containing iron ore pellets. At the same time, since the reduction of tin oxide is an endothermic reaction, the furnace temperature is maintained by top-blowing pulverized coal injection. Therefore, the main fuel entering the furnace is pulverized coal and anthracite. The mass flow rate and composition of anthracite and pulverized coal can be monitored in real time through online component detectors and electronic belt scales.

[0112] According to the measurement results, it can be calculated that the amount of fuel entering the furnace and the proportion of each element are:

[0113]

[0114] Where: η 3,j It indicates the content ratio of the combustible (C, H, O, S, N) and inert (A (ash) and W (water)) component j in the fuel for tin smelting.

[0115] g 3,1、3,2 Indicates the amount of anthracite and pulverized coal fed into the furnace, t / h;

[0116] η 3,j,1、3,j,2 It represents the content ratio of combustible matter (C, H, O, S, N) and inert matter (A (ash) and W (water)) component j in anthracite and pulverized coal.

[0117] Oxygen-enriched air, the submerged top-blowing lance for tin smelting usually consists of four layers, the innermost layer (pulverized coal pipe), lance air duct (inner pipe), lance air duct (outer pipe), and sleeve air duct, and the gas components inside are compressed air, air, oxygen-enriched air, and air respectively; the gas composition and flow rate of the oxygen-enriched air of the submerged top-blown smelting furnace can be monitored online and in real time through the wind speed detector.

[0118] According to the measurement results, it can be calculated that the volume flow rate and gas composition of the oxygen-enriched air entering the furnace are:

[0119]

[0120] Where: η 4,j It indicates the content ratio of component j (air and oxygen) in the oxygen-enriched air entering the furnace for tin smelting;

[0121] V 4,1、4,2、4,3、4,4 Indicates the oxygen-enriched air volume entering the furnace at each level (pulverized coal pipe, inner pipe, outer pipe, sleeve air duct), Nm 3 / h;

[0122] η 4,j,1 , 4,j,2 It represents the proportion of gas component j (air and oxygen) in the pulverized coal pipe, inner pipe, outer pipe and sleeve air duct;

[0123] The output materials involved in the tin smelting process of the entire oxygen-enriched top-blown smelting system can be mainly divided into tin amine, tin ethylene, slag, smoke and flue gas;

[0124] ∑G 产出 =g5+g6+g7+g8+g9 (15)

[0125] Where: g 5、6、7、8、9 Respectively represent the output materials: tin A, tin B, slag, smoke and flue gas output, t / h;

[0126] Among the outputs, the output and composition of tin amine, tin ethylene, slag and smoke dust in each furnace period can be monitored online and in real time. l,j is the content ratio of element and component j in product l.

[0127] Since flue gas composition and flow rate are difficult to measure, they need to be analyzed through material flow balance;

[0128] In addition, during the feeding process, some air will be brought into the furnace; there is also air leakage in the flue, which can also oxidize the charge when it enters the smelting furnace, so it is necessary to consider the part of oxygen brought in by the charge and the oxygen utilization in the leaked air. This part of gas is also unmeasurable.

[0129] Calculation of the theoretical oxygen requirement of an oxygen-enriched top-blown molten pool smelting furnace per hour. The theoretical oxygen requirement of an oxygen-enriched top-blown molten pool smelting furnace per hour can be mainly divided into the oxygen required for fuel combustion and the oxygen required for charge smelting;

[0130] For the fuel entering the furnace, C in the fuel reacts according to formula (16):

[0131] C+O2=CO2(16)

[0132] For 1000η 3,C g3kg C (Formula 12), the theoretical amount of oxygen required for combustion is:

[0133] 1000η 3,C g3·32 / 12=2666.67η 3,C g3 (kg)

[0134] The H in the fuel reacts according to equation (17):

[0135] 2H2+O2=2H2O(17)

[0136] For 1000η 3,H g3kg H (Formula 12), the theoretical amount of oxygen required for combustion is:

[0137] 1000η 3,H g3·32 / 4.04=7920.79η 3,H g3 (kg)

[0138] The sulfur in the fuel reacts according to formula (18):

[0139] S+O2=SO2(18)

[0140] For 1000η 3,S g3kg S (Formula 12), the theoretical amount of oxygen required for combustion is:

[0141] 1000η 3,Sg3 ·32 / 32.06=998.13η 3,Sg3 (kg)

[0142] In addition, the coal fuel entering the furnace contains 1000η oxygen. 3,Og3 kg (Formula 12), the presence of oxygen should be considered when calculating fuel combustion.

[0143] For charge smelting, if excess oxygen is not considered, oxygen will finally exist mainly in the form of SO2 and FeO in the flue gas, slag and crude tin respectively. Therefore, by calculating the amount of SO2 in the flue gas, the amount of FeO in the slag and crude tin, the amount of oxygen required for charge smelting can be obtained.

[0144] For substance S, the content of S in the mixed ore is calculated to be 1000η through the conservation of substance S. 1,sg1 kg (Formula 3). The oxygen consumption of sulfur combustion in the charge can be calculated by chemical reaction, that is, the oxygen consumption of sulfur generated by the decomposition of pyrite and sulfur in FeS is calculated. The content of sulfur in the smelting output (tin methyl tin, tin ethyl tin, vacuum particles and slag) is Therefore, the total amount of the charge The S element participates in the oxidation reaction. If we consider that the content of monomer S in the flue gas is very small and assume that all S in the flue gas exists in the form of SO2, the amount of oxygen required for the combustion of S in the charge is calculated as follows:

[0145]

[0146] The release and oxygen consumption of Fe element before and after top-blowing smelting are completed by the reduction of Fe3O4 to FeO and CO2 through CO. The consumed oxygen enters FeO through the combustion of FeS2 in the charge, and FeO enters the slag and other products through the slag-making reaction. At the same time, the Fe element in the output material mainly exists in the form of FeO and FeS. S, it can be seen that the Fe element accounts for 2.5% of the smelting product FeS. The total content of Fe in the output material is Therefore, the content of Fe in the FeO contained therein is: Therefore, the oxygen content in the output material is The oxygen content of Fe3O4 in the input material is 572.96 (η 1,Fe -0.87η 1,S )g1kg (Formula 6). Therefore, the amount of oxygen released and consumed by Fe element before and after the top-blowing smelting reaction is:

[0147]

[0148] From the above calculation, the theoretical oxygen requirement of the oxygen-enriched top-blown molten pool smelting furnace per hour is:

[0149]

[0150] Converted into standard volume:

[0151]

[0152] From equations (13) and (14), we know that the total amount of oxygen actually fed into the smelting furnace through the top-blowing lance is: η 4,氧 V4+0.21η 4,空 V4Nm 3 / h.

[0153] Since a certain amount of air is introduced when charging, and there is also air leakage in the flue, the air leakage into the smelting furnace can also oxidize the charge. Therefore, by comparing the theoretical oxygen requirement and the actual oxygen input, the oxygen gap can be calculated as (Nm 3 / h):

[0154]

[0155] Consider the amount of oxygen brought in by the feed and utilized in the air leakage.

[0156] Theoretical flue gas composition and flue gas volume analysis of oxygen-enriched top-blown smelting furnace. The main components of flue gas of oxygen-enriched top-blown smelting furnace are CO2, H2O, SO2, N2 and O2. The sources of CO2 are the combustion of carbon in the fuel and the decomposition of CaCO3 in the concentrate; the sources of H2O are the combustion of hydrogen in the fuel, the water content in the tin concentrate, the water content in the fuel and the water content in the air; the sources of SO2 are the desulfurization of the concentrate; the sources of N2 are the air and the air leakage; the source of O2 is the excess in the air. The following calculations are all for the component content in the flue gas generated in 1 hour.

[0157] Calculation of CO2 content in flue gas

[0158] The C in the fuel reacts according to equation (16). For 1000η 3,C g3kg C, the amount of CO2 produced during combustion is: (1000η 3,C g3)*44 / 12=3666.67η 3,C g3kg;

[0159] The CaCO3 in the concentrate and slag-making agent reacts according to formula (22):

[0160] CaCO3=CaO+CO2 (22)

[0161] For 2274.55η 1,Ca g1+1000g 2,1 kg of CaCO3 (Equation 7 and Equation 10), the amount of CO2 produced by decomposition is: (2274.55η 1,Ca g1+1000g 2,1 )*44 / 100.08=1000η 1,Ca g1+439.65g 2,1 kg;

[0162] Therefore, the total amount of CO2 in the flue gas is: 1000η 1,Cag1+439.65g 2,1 +3666.67η 3,C g3kg;

[0163] Converted to standard volume (Nm 3 / h) is:

[0164] (1000η 1,Ca g1+439.65g 2,1 +3666.67η 3,c g3)*22.4 / 44=509.09η 1,Ca g1+223.82g 2,1 +1866.67η 3,C g3

[0165] Calculation of H2O content in flue gas. H in fuel reacts according to formula (17). For 1000η 3,H g3kg H, the amount of H2O produced during combustion is: (1000η 3,H g3)*36.04 / 4.04=8920.79η 3,H g3kg;

[0166] The water content of the ore entering the furnace is 1000η 1,W g1kg; 5% water is added to the mixing and granulation, slagging agent, which is 50g2kg; fuel water content 1000η 3,w g3kg;

[0167] Find meteorological statistics, import the local temperature T (T is the absolute temperature, for example, the absolute temperature corresponding to 25°C is 273.15+25=298.15K) and relative humidity (RH), and the water content per kilogram of dry air (W) can be calculated using the following mathematical formula:

[0168] W=(RH·e s ) / (R·T·(1-RH·e s / (Pe s )))

[0169] Where R is the gas constant, which is 461.5 J / (kg·K) for water vapor, P is the atmospheric pressure, 101325 Pa, e s is the saturated water vapor pressure at temperature T, which can be obtained by looking up the data table and then performing interpolation calculation.

[0170] From equations (13) and (14), we can know that the amount of air injected into the top-blown smelting furnace by the oxygen lance is η 4,空 V4Nm 3 / h, also known as η 4,空 V4*29 / 22.4=12.9η 4,空 V4kg;

[0171] The total water content in the air is: 12.9η 4,空 V4W kg;

[0172] The total amount of H2O in the flue gas is: 8920.79η 3,H g3+1000η 1,W g1+50g2+1000η 3,w g3+12.9η 4,空 V4Wkg;

[0173] Converted into the volume under standard conditions: (8920.79η 3,H g3+1000η 1,W g1+50g2+1000η 3,w g3+

[0174] 12.9η 4,空 V4W)*22.4 / 18=11101.43η 3,H g3+1244.44η 1,W g1+62.22g2+1244.44η 3,w g3+16.05η 4,空 V4W Nm 3 .

[0175] The SO2 content in flue gas is calculated by the reaction of S in fuel and concentrate according to formula (18). For 1000η 3,S g3kg S, the generated SO2 is: (1000η 3,S g3)*64.06 / 32.06=1998.13η 3,S g3kg;

[0176] Converted into the volume under standard conditions: (1998.13η 3,S g3)*22.4 / 64.06=698.69η3,Sg3Nm 3 .

[0177] Calculation of N2 content in flue gas: the amount of air injected into the top-blown smelting furnace by the oxygen lance is η 4,空 V4Nm 3 / h, where the content of N2 is: 0.79η 4,空 V4Nm 3 / h;

[0178] Since a certain amount of air is brought in when feeding, and there is also air leakage in the flue, the total amount of air leaking into the smelting furnace is assumed to be u.

[0179] According to actual production experience, the concentration of O2 in the flue gas is taken as 4% (in order to ensure sufficient smelting, excess oxygen must be ensured). From formula (21), the amount of oxygen used in the leakage air is:

[0180] Then we have:

[0181]

[0182] (The left side of the equation is the O2 content in the flue gas, and the right side is the oxygen content in the leaked air and the oxygen used in the leaked air)

[0183] The air leakage volume u is solved as:

[0184]

[0185] Therefore, N2 in the air leakage is: 0.79u Nm 3 ;

[0186] N2 content in flue gas: 0.79η 4,空 V4+0.79u Nm 3 .

[0187] Calculation of O2 content in flue gas: O2 content in flue gas is:

[0188]

[0189] Therefore, the total amount of flue gas is:

[0190]

[0191] Preferably, this embodiment can accurately grasp the input amount of each material by real-time monitoring of the composition and mass flow of the ore entering the furnace. Accurate control helps to optimize the smelting process and ensure the stability of the reaction conditions to improve the smelting efficiency of tin; the online composition detector and the electronic belt scale provide real-time data, so that the operator can adjust the addition amount of various materials in real time according to the actual situation to avoid the problem of excessive or insufficient amount, thereby improving the safety and reliability of production; through scientific data balancing, human errors can be reduced and the reliability of data can be improved, which is particularly important for subsequent production analysis and optimization; automated real-time monitoring and data processing can reduce human intervention, improve the automation level of the overall smelting process, and improve production efficiency. Significance achieved: Through precise material input, we can effectively avoid waste of resources, improve the efficiency of raw material use, and thus reduce production costs; precise control of the input amount of each substance can improve the purity and quality of the final tin product to meet market demand; by controlling the generation and emission of by-products such as smoke dust, we can reduce the impact of the smelting process on the environment, in line with the requirements of sustainable development of modern industry; resource optimization and cost reduction directly help to improve the economic benefits of the enterprise, so that it can maintain its advantage in the fierce market competition; the establishment of a real-time monitoring system can timely discover potential safety hazards, reduce the risk of safety accidents, and ensure the safety of operators.

[0192] The material balance model of this embodiment not only improves the efficiency and product quality of the tin smelting process, but also promotes the improvement of related production processes and management levels.

[0193] Furthermore, if Figure 5 As shown, the energy balance equation in step S12 specifically includes:

[0194] The heat input involved in the tin smelting process of the entire oxygen-enriched top-blown smelting system can be mainly divided into 6 categories: heat released by oxidation of free sulfur generated by FeS2 dissociation, heat released by slag making, heat released by coal combustion, sensible heat of charge, sensible heat of coal and sensible heat of air entering the furnace:

[0195] ∑Q 收入 =q1+q2+q3+q4+q5+q6 (24)

[0196] Where: q 1、2、3、4、5、6 It represents the heat released by oxidation of free sulfur generated by the dissociation of FeS2, heat released by slagging, heat released by coal combustion, sensible heat of charge, sensible heat of coal and sensible heat of air entering the furnace, MJ / h;

[0197] The free sulfur generated by the dissociation of sulfides is oxidized and released heat:

[0198] There is S1000η in the tin concentrate entering the furnace 1,s g1kg (Formula 3), the product contains S Therefore, the mass of sulfur released from FeS2 is

[0199] The decomposition reaction of FeS2 is shown in formula (25):

[0200]

[0201] From formula (25), it can be seen that 0.5 kg S is released from 1 kg S in FeS2, and the S generated by the decomposition of FeS2 is Therefore, there is FeS2 participates in the sulfide dissociation reaction.

[0202] S is burned according to formula (26):

[0203]

[0204] Therefore, the oxidation heat of free sulfur is:

[0205]

[0206] FeO and SiO2 release heat in slag formation. According to the chemical reaction manual, the heat released by slag formation reaction is 0.418MJ for 1kg Fe. From the above material balance results, it can be seen that the Fe involved in slag formation is The slag-making heat q2 of FeO and SiO2 is:

[0207]

[0208] Coal combustion releases heat. Through sampling and testing, it can be found that the heat released by anthracite and pulverized coal is Q1 and Q2 MJ / kg respectively. The heat released by coal combustion is:

[0209] q3=1000Q1g 3,1 +1000Q2g 3,2 MJ / h

[0210] The sensible heat of the charge can be calculated based on the chemical composition of the charge using the standard enthalpy value of each component and its molar ratio in the reaction process, c1 kJ / (kg·℃). The sensible heat of the charge is:

[0211] q4=1000g1kg*c1kJ / (kg·℃)*t1℃=g1c1t1 MJ / h

[0212] Where: t1℃ is measured by an anti-interference infrared temperature measuring instrument;

[0213] The sensible heat of coal is:

[0214] q5=1000g 3,1 kg*c 3,1kJ / (kg·℃)*t1℃+1000g 3,2 kg*c 3,2 kJ / (kg·℃)*t2℃=g 3, 1c 3,1 t1+g 3,2 c 3,2 t2 MJ / h

[0215] Where: c 3,1 kJ / (kg·℃) is the specific heat capacity of anthracite; c 3,2 kJ / (kg·℃) is the specific heat capacity of pulverized coal; t1 is the temperature of anthracite when it enters the furnace, which is consistent with the temperature of the charge when it enters the furnace; t2 is the temperature of pulverized coal when it enters the furnace.

[0216] Sensible heat of air entering the furnace, including oxygen-enriched air and leakage air; the amount of oxygen-enriched air is V4Nm 3 , where the amount of air is η 4,空 V4Nm 3 , the amount of pure oxygen is η 4,氧 V4Nm 3 , so the total oxygen content is: η 4,氧 V4+0.21η 4,空 V4Nm 3 ; N2: 0.79η 4,空 V4Nm 3 The temperature of oxygen-enriched air is consistent with the temperature of pulverized coal when it enters the furnace (both are sent into the furnace through oxygen lances), which is t2°C.

[0217] The amount of nitrogen in the air leakage is 0.79u Nm 3 ; Oxygen content: 0.21u Nm 3 The air leakage temperature is consistent with the furnace charge inlet temperature, which is t1℃.

[0218] The sensible heat of the air entering the furnace is:

[0219] q6=7.9*10 -4 c N2 η 4,空 V4+10 -3 c O2 η 4,氧 V4+2.1*10 -4 c O2 η 4,空 V4+7.9*10 -4 c N2 u+2.1*10 -4 c O2 uMJ / h

[0220] Among them, c N2 Represents the average specific heat capacity of nitrogen, which is usually 1.5 kJ / (m 3℃); c O2 Represents the average specific heat capacity of oxygen, which is usually 1.36 kJ / (Nm 3 ·℃).

[0221] Bring in:

[0222]

[0223] Heat expenditure calculation:

[0224] Sulfide dissociation endothermic:

[0225] From formula (25), we know that the heat absorbed by FeS2 decomposition is:

[0226]

[0227] SnO2 and Fe3O4 reduction absorb heat

[0228] The reduction reaction of SnO2 and Fe3O4 by coal is shown in equations (27) and (28):

[0229]

[0230] 1000(g 2,2 +2.14η 1,Si g1) The heat absorbed by SnO2 reduction is:

[0231] [1000(g 2,2 +2.14η 1,Si g1)*41.9] / 150.7MJ / h;

[0232] 1.57(η 1,Fe -0.87η 1,S )g1kg Fe3O4 reduction heat absorption is:

[0233] 1000[1.57(η 1,Fe -0.87η 1,S )g1*355.98] / (231.55*2)MJ / h.

[0234] The total heat absorption of the reduction reaction is:

[0235] q8=1206.84η 1,Fe g1+595η 1,su g1-1049.95η 1,s g1+278.04g 2,2 MJ / h

[0236] The heat taken away by crude tin is obtained through sampling and analysis. The specific heat capacity of crude tin is c5 kJ / (kg·℃). The release temperature of crude tin is measured by armored thermocouple as ℃. The heat taken away by crude tin is:

[0237] q9=t3c5(g5+g6)MJ / h

[0238] The slag takes away the heat. Through sampling and analysis, the specific heat capacity of the slag is c7 kJ / (kg·℃). The armored thermocouple measures its release temperature as t4℃. The heat taken away by the slag is:

[0239] q 10 =t4c7g7MJ / h

[0240] The heat taken away by the smoke is: the specific heat capacity of the smoke is c8kJ / (kg·℃), the exhaust temperature is t5℃, and the heat taken away by the smoke is:

[0241] q 11 =t5c8g8MJ / h

[0242] The evaporation of water in the ore and fuel absorbs heat. The heat consumed by the evaporation of water in the ore entering the furnace, the water added during mixing and granulation, and the water in the fuel can be calculated by formula (29):

[0243] q 12 =M w [(t 沸 -t 始 )×C 水 +q 潜 ]+[t 烟 ×C3-t 沸 ×C2]V (29)

[0244] Where: q 12 It represents the heat consumed by evaporation of water in mineral materials and fuels, MJ;

[0245] M w Indicates the mass of water in the ore and fuel. According to the previous analysis, the value is 1000η 1,W g1+50g2+1000η 3,w g3kg;

[0246] t 沸 Indicates the boiling temperature of water, usually 100°C; t 始 Indicates the starting temperature of water, which is the same as the temperature of concentrate and fuel entering the furnace, which is t1℃; C 水 Represents the specific heat capacity of water, usually 4.18 kJ / (kg·℃); q 潜 Indicates the latent heat of evaporation of water, usually taken as 2256 kJ / kg; t 烟Indicates the flue gas temperature, which is the same as the smoke temperature, t5°C; C3 indicates the average specific heat capacity of water vapor under high-temperature flue gas t5°C environment, usually 1.77 kJ / (Nm 3 ·℃); C2 represents the average specific heat capacity of water vapor at the phase transition critical temperature of 100℃, usually 1.5kJ / (Nm 3 ℃); V represents the volume of water contained in concentrate, slag-making agent and fuel converted into water vapor, W*22.4 / 18Nm 3 .

[0247] Substituting the data, the heat absorbed by evaporation of water in the ore and fuel is:

[0248] q 12 =(η 1,W g1+0.05g2+η 3,w g3)*(1244.44t5-4.18t1+2487.33)MJ / h

[0249] Flue gas takes away heat:

[0250] The calculation formula for the heat carried away by each component of flue gas is shown in formula (30):

[0251] q i =V i C pi t 烟 (30)

[0252] Where: q i Indicates the heat carried away by a certain component in the flue gas, kJ; V i Indicates the volume of a certain component in the flue gas, m 3 ; C pi It indicates the average specific heat capacity of a component in flue gas under high temperature flue gas t5℃ environment. Among them, the average specific heat capacity of carbon dioxide is usually 2.27kJ / (Nm·℃); the average specific heat capacity of water is usually 1.77kJ / (Nm·℃); the average specific heat capacity of sulfur dioxide is usually 2.28kJ / (Nm·℃); the average specific heat capacity of nitrogen is usually 1.36kJ / (Nm·℃); the average specific heat capacity of oxygen is usually 1.5kJ / (Nm·℃); t 烟 Indicates the flue gas temperature, which is the same as the smoke dust temperature, which is t5℃.

[0253] From this, the heat value taken away by each component of the flue gas can be calculated as:

[0254] q CO2 =1155.63η 1,Ca g1+508.07g 2,1 +4237.34η 3,C g3MJ / h

[0255] q H2O =19649.53η 3,H g3+28.41η 4,空 V4W MJ / h

[0256] q SO2 =1593.01η 3,s g3MJ / h

[0257]

[0258] Therefore, the heat carried away by the flue gas is:

[0259] q 13 =q CO2 +q H2O +q SO2 +q N2 +q O2 MJ / h

[0260]

[0261] The water cooling jacket removes heat:

[0262] The heat removed by cooling water can be calculated by formula (31):

[0263] q 14 =V W [(t 进 -t 出 )×C 水 ] (31)

[0264] Where: q 13 Indicates the heat consumed by evaporation of water in concentrate and fuel, kJ; V W Indicates cooling water flow rate, m 3 / h;t 进 Indicates the cooling water inlet temperature, °C; t 出 Indicates the cooling water outlet temperature, ℃; C 水 Represents the specific heat capacity of water, usually taken as 4.18 kJ / (kg·℃);

[0265] Substituting the data, the heat absorbed by the water cooling jacket is:

[0266] q 14 =4.18(t 进 -t 出 )V W MJ / h

[0267] Unquantifiable heat loss

[0268] Other heat losses mainly include heat loss from the furnace body and heat loss from measurement errors. Among them, heat dissipation from the furnace body mainly includes heat dissipation from the furnace body and the top wall of the furnace. In addition, there is radiation heat from the feed port and the flue gas outlet. All of these are included in the difference in heat balance calculation, calculated as q 15 ,but:

[0269] q 15 =q1+q2+q3+q4+q5+q6-q7-q8-q9-q 10 -q 11 -q 12 -q 13 -q 14 MJ / h

[0270] Table 1 Heat balance table of oxygen-enriched top-blown smelting furnace

[0271]

[0272]

[0273] Preferably, the energy balance equation of this embodiment comprehensively considers multiple sources of heat income, such as the dissociation of FeS2, slag making, and combustion of coal; this comprehensive evaluation helps to analyze the energy conversion efficiency of each link, thereby optimizing the smelting process; clarify the specific sources and values ​​of various types of heat income, so that heat can be used more effectively in the smelting process; for example, making full use of the heat energy generated by coal combustion can reduce the demand for other energy sources and improve overall energy efficiency; the energy balance model provides data support for improving the smelting process, for example, by analyzing the relationship between heat loss and heat input, it is possible to identify links with large heat energy losses and make improvements, thereby enhancing the sustainability and economy of the process. By specifically analyzing the decomposition of FeS2 and its energy relationship with the reactants, the heat and heat release required in the smelting process can be more accurately calculated, providing a reference for the setting of process parameters. Significance achieved: By understanding and controlling the source of heat income, smelting conditions can be adjusted more accurately, smelting processes can be optimized, and the output and quality of tin metal can be improved; the improvement of energy efficiency directly leads to a reduction in energy consumption, reducing the dependence on external energy in the production process, thereby reducing production costs and improving economic benefits; better energy balance can help enterprises conduct environmental impact assessments, such as reducing the emission of carbon dioxide and other harmful gases, making enterprises more environmentally friendly in resource use and meeting the requirements of sustainable development; accurate calculation and control of heat can reduce safety hazards caused by overheating or insufficient reaction. For example, proper management of sulfides can avoid the leakage of toxic gases and ensure production safety; in-depth research on energy balance can promote the development of related technologies, such as the design of new heating and reactors, making the smelting process more efficient and modern; by establishing and applying this energy balance equation, the tin smelting process of the oxygen-enriched top-blown smelting system will be able to more effectively achieve efficient resource utilization and efficient production management, thereby enhancing the core competitiveness of enterprises in an increasingly competitive market environment.

[0274] Furthermore, if Figure 6 As shown, step S13 also includes an energy flow network matrix model;

[0275] The heat input involved in the tin smelting process of the entire oxygen-enriched top-blown smelting system can be mainly divided into 6 categories: free sulfur oxidation heat generated by FeS2 dissociation, slag exotherm, coal combustion exotherm, charge sensible heat, coal sensible heat and air sensible heat entering the furnace. At the same time, the smelting heat expenditure can be mainly divided into 9 categories: FeS2 dissociation endotherm, SnO2 and Fe3O4 reduction heat, crude tin heat, slag heat, smoke heat, water evaporation endotherm, flue gas heat, water cooling jacket heat and unquantifiable heat loss.

[0276] According to the law of conservation of energy:

[0277] ∑Q 收入 =∑Q支出 (32)

[0278] ∑Q 收入 =q1+q2+q3+q4+q5+q6 (33)

[0279] ∑Q 支出 =q7+q8+q9+q 10 +q 11 +q 12 +q 13 +q 14 +q 15 (34)

[0280] Where: ∑Q 收入 , 支出 Indicates the heat entering the top-blown smelting reaction zone;

[0281] ∑Q 收入 , 支出 Indicates the heat expended from the top-blowing smelting reaction zone;

[0282] q 1、2、3、4、5、6 It represents the heat released by oxidation of free sulfur generated by the dissociation of FeS2, heat released by slagging, heat released by coal combustion, sensible heat of charge, sensible heat of coal and sensible heat of air entering the furnace, MJ / h;

[0283] q 7、8、9、10、11、12、13、14、15 It represents the heat taken away by FeS2 dissociation, the heat taken away by SnO2 and Fe3O4 reduction, the heat taken away by crude tin, the heat taken away by slag, the heat taken away by smoke, the heat taken away by water evaporation, the heat taken away by flue gas, the heat taken away by water cooling jacket and the unquantifiable heat expenditure, MJ / h.

[0284] The heat flow balance results of the relevant oxygen-enriched top-blown smelting furnace are shown in Table 1. Through the above-mentioned material and energy balance equations, mathematical calculations using the relevant parameters involved can obtain important parameters such as the flow direction, quantity, utilization efficiency, theoretical smelting end temperature and material composition of various substances and energy, and realize the mathematical modeling of multi-energy loads and dynamic prediction of related energy-quality networks for large-scale oxygen-enriched top-blown smelting processes.

[0285] In the process of oxygen-enriched top-blown molten pool smelting, heat income and heat expenditure run through the entire production process and are closely related to the input and output materials. In order to string together the various tin smelting production processes and material flow networks in the process with the energy flow in the tin smelting process, various types of heat income q 1～6 And various types of heat expenditure q 7～14 Through the mass of each input and output material (g 1～9 ) is expressed in weighted form as follows:

[0286]

[0287] Where: q m It takes values ​​from 1 to 15, representing energy flows: free sulfur oxidation heat generated by FeS2 dissociation, slag-making heat, coal combustion heat, charge sensible heat, coal sensible heat, furnace air sensible heat, FeS2 dissociation endothermic heat, SnO2 and Fe3O4 reduction absorption heat, crude tin carry-away heat, slag carry-away heat, smoke carry-away heat, water evaporation endothermic heat, flue gas carry-away heat, water cooling jacket carry-away heat, and unquantifiable heat;

[0288] g 1～n Indicates the input amount of tin concentrate, slag-making agent, coal, oxygen-enriched air, etc., and the output amount of tin amine, tin ethylene, slag, smoke and flue gas, etc., t / h;

[0289] ξ m,1～m,n Represents the weighted coefficient for calculating relevant energy flow balance.

[0290] Therefore, it can be concluded that the empirical equations for energy-mass coupling metallurgical mathematical physics calculation and the energy flow network matrix model in the oxygen-enriched top-blown molten pool smelting process are:

[0291] Input energy flow (free sulfur oxidation heat generated by FeS2 dissociation, slag release, coal combustion heat, charge sensible heat, coal sensible heat and furnace air sensible heat):

[0292]

[0293] Output energy flow (heat absorption by dissociation of FeS2, heat taken away by reduction of SnO2 and Fe3O4, heat taken away by crude tin, heat taken away by slag, heat taken away by smoke, heat absorption by evaporation of water, heat taken away by flue gas, heat taken away by water cooling jacket and unquantifiable heat loss):

[0294]

[0295] Preferably, the establishment of the nonlinear energy flow-material flow coupling mathematical model of the oxygen-enriched top-blown tin smelting system under the above-mentioned multivariable constraints of this embodiment is helpful to deeply understand the conversion and coordination relationship between different energy sources in each smelting link. It can conveniently calculate the composition and operation mode of energy flow and material flow under various smelting conditions, which can help to achieve the continuous, low-carbon, high-energy-efficiency and stable production goals of the smelting process, and is an indispensable and important link in the transformation of traditional smelting plants to non-ferrous smart factories. Specifically, it can sort out the material flow and energy flow of the whole process of tin smelting for enterprises, and realize the dynamic statistics and evaluation of material flow and energy flow; it can reveal the synergistic effect of energy utilization and smelting process under the fluctuation of production capacity of the whole process of non-ferrous tin metal smelting process for the group, and then overcome the problems of large volatility of material flow distribution and poor coupling of operation mode and energy utilization in the smelting production process; it can help enterprises obtain the flow direction, quantity, utilization efficiency, development trend, reasonable degree of use and other related contents of various materials and energy, and improve the energy efficiency utilization level of tin smelting process.

[0296] Furthermore, step S1 also includes:

[0297] Material balance equation: Combined with the analysis of material flow in oxygen-enriched top-blown tin molten pool smelting, it can be seen that the input materials involved in the tin smelting process of the entire oxygen-enriched top-blown smelting system can be mainly divided into tin concentrate, slag-making agent, fuel and oxygen-enriched air. At the same time, the smelting output materials can be mainly divided into tin methyl tin, tin ethyl tin, slag, vacuum particles (smoke dust) and flue gas;

[0298] According to the material balance:

[0299] ∑G 投入 =∑G 产出 (36)

[0300] ∑G 投入 =g1+g2+g3+g4 (37)

[0301] ∑G 产出 =g5+g6+g7+g8+g9 (38)

[0302] Where: ∑G 投入、产出 Indicates the total mass of input and output materials of top-blown smelting furnace, t / h; g 1、2、3、4 Indicates the feeding amount of tin concentrate, slag-making agent, coal and oxygen-enriched air, t / h; g 5、6、7、8、9 Indicates the output of tin A, tin B, slag, smoke and flue gas, t / h;

[0303] Among them, in the oxygen-enriched top-blown molten pool smelting process, tin, iron, silicon, sulfur and other elements are the main substances in the tin smelting process and are also the main processed objects and products, running through the entire production process. Therefore, the balance equation of the flow of j elements before and after smelting is:

[0304] G j,投入 =G j,产出 (39)

[0305]

[0306] Where: G j,投入、产出 It represents the total input and output of element j in the tin smelting process, t / h; η 1,j、2,j、3,j , 4,j represents the proportion of element j in the tin concentrate, slag-making agent, coal and oxygen-enriched air entering the furnace; η 5,j、6,j、7,j、8,j、9,j It indicates the proportion of element j in tin A, tin B, slag, smoke and flue gas in the smelting products;

[0307] The calculation of the material balance equation will be disturbed by the air brought in during the feeding and the air leakage in the flue. In order to improve the precision and accuracy of the batching optimization decision, it is necessary to make an estimate based on the data in the historical smelting database system. According to the material flow-energy flow metallurgical physics mathematical model mentioned above, the theoretical air leakage / gas volume of the smelting system is:

[0308] in is the historical statistical data of furnace air leakage u * The mean of .

[0309] Energy balance equation: Combined with the above analysis of the material flow of oxygen-enriched top-blown tin molten pool smelting, it can be seen that, except for the unquantifiable heat loss, in the process of determining the initial decision-making process of production optimization, the heat income involved can be mainly divided into the free sulfur oxidation heat generated by FeS2 dissociation, slag release, coal combustion release, charge sensible heat, coal sensible heat and air entering the furnace sensible heat, a total of 6 categories. At the same time, the smelting heat expenditure involved can be mainly divided into FeS2 dissociation endothermic, SnO2 and Fe3O4 reduction away heat, crude tin away heat, slag away heat, smoke away heat, water evaporation endothermic, flue gas away heat, water cooling jacket away heat, and unquantifiable heat loss, a total of 9 categories. It is worth noting that there are certain unquantifiable furnace heat dissipation losses in the energy balance calculation process. The unquantifiable heat loss of smelting is taken from the historical smelting data. The mean Calculate. According to the law of conservation of energy:

[0310] ∑Q 收入 =∑Q 支出 (42)

[0311] ∑Q 收入 =q1+q2+q3+q4+q5+q6 (43)

[0312]

[0313] Where: ∑Q 收入、支出 Indicates the heat entering the top-blowing smelting reaction zone; ∑Q 收入、支出 Indicates the heat expenditure from the top-blowing smelting reaction zone; q 1、2、3、4、5、6 It represents the heat released by oxidation of free sulfur generated by FeS2 dissociation, heat released by slag making, heat released by coal combustion, sensible heat of charge, sensible heat of coal and sensible heat of air entering the furnace, MJ / h; q 7、8、9、10、11、12、13、14 It means that FeS2 dissociation absorbs heat, SnO2 and Fe3O4 reduction takes away heat, crude tin takes away heat, slag takes away heat, smoke takes away heat, water evaporation absorbs heat, flue gas takes away heat, and water cooling jacket takes away heat, MJ / h.

[0314] Matter-energy coupling optimization configuration strategy:

[0315] ① Considering the effective energy utilization rate of smelting, the thermal efficiency evaluation of the smelting furnace (positive balance thermal efficiency):

[0316]

[0317] In order to achieve a higher effective energy utilization rate in the smelting process:

[0318] Therefore, the corresponding expression is:

[0319]

[0320] ② Consider the economic benefits of ore matching:

[0321] In the process of ore blending, the cost of each ore material (imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag, and smoke dust) is P 1,i , i is 1 to 6. In addition, due to the limitation of raw material sources (for example, the fume dust is a large amount of dust generated during the tin smelting process and the slag fume dust is returned as raw material, and the supply is limited), the maximum supply of each mineral material is g max1,i , i is 1 to 6; the cost of slag-making agent (limestone, quartz stone) is P 2,i , i is 1 to 2; the cost of the fuel (pulverized coal, granular coal) entering the furnace is P 3,i ,i takes 1~2;

[0322] In order to achieve higher economic benefits for smelting and meet the maximum supply constraints of various mineral materials, the corresponding expression is:

[0323]

[0324]

[0325] ③ Consider the single furnace tonnage and production cycle:

[0326] Affected by the tonnage of a single furnace and the production cycle, the amount of ingredients fed is constrained by the tonnage of the furnace, the production cycle and the processing capacity:

[0327]

[0328] In the formula, Ton is the rated tonnage of the furnace design, T cycle It is the smelting cycle of single furnace production.

[0329] Through the Lagrange multiplier method, the multivariate function equations of material and energy balance are solved under the above three constraints to determine the values ​​of the decision variables for production optimization batching.

[0330] Preferably, this embodiment, by establishing a material balance equation and an energy balance equation, conducts detailed statistics and analysis of inputs and outputs to ensure that both material flow and energy flow are balanced during the smelting process. Such a model helps to accurately grasp the resource usage during the smelting process and identify possible sources of loss or waste; incorporating historical smelting data into the analysis can assist in generating more scientific batching and feeding strategies, reducing the impact of uncontrollable factors (such as air leakage, furnace heat dissipation, etc.) on production efficiency; by evaluating the thermal efficiency of the smelting furnace, the main source of energy loss is identified, and then the batching, operating parameters, etc. are optimized to improve the overall thermal efficiency and reduce energy consumption; systematically considering various inputs and outputs can not only balance the flow of materials and energy, but also suppress product quality fluctuations caused by changes in operating conditions, thereby improving product consistency and controllability; by considering the constraints of raw material costs and maximum supply, optimizing the mixed configuration to minimize costs in the production process, helping enterprises maintain competitive advantages in the fierce market competition; considering the treatment and conversion of smoke, flue gas, etc., to ensure that the smelting process is carried out under the premise of complying with regulations and environmental protection requirements, and reducing the impact on the environment. Significance achieved: By optimizing the ingredients and production process, unnecessary waste of resources is reduced, the overall economic benefits are maximized, and the company obtains higher profits; the calculation and modeling methods of material flow and energy flow are applied to the smelting process, which promotes the advancement of metallurgical technology and provides data support for future new equipment and new processes; through the effective use of energy and the recycling of materials, the smelting industry is promoted to transform to sustainable development, reducing dependence on natural resources and ecological damage; the established models and algorithms can provide a scientific basis for management, promote the scientific and digital production and operation decisions, and improve the management level of the company; through flexible ingredient configuration strategies, enterprises can quickly adapt to market changes, especially in the case of raw material price fluctuations and changes in supply and demand, to enhance market retention and adaptability; through effective management and control of furnace heat dissipation and gas leakage, the safety of the smelting process is improved and the risk of accidents is reduced.

[0331] In summary, this embodiment not only provides a systematic analysis of material and energy flow in theory, but also promotes higher economic, environmental and social benefits for the tin smelting industry in practical applications, and promotes the development of the entire industry towards high efficiency, environmental protection and intelligence.

[0332] Furthermore, if Figure 7 As shown, the process of transmitting to the distributed control system DCS through the OPC server in step S2 specifically includes the following steps:

[0333] Step S21 monitors the data transmission status between the OPC server and the distributed control system DCS in real time, and regularly collects and records the communication delay, error packet rate and connection status; when it is detected that the delay of the communication link exceeds the preset threshold or data packet loss occurs, it is automatically marked as a risky communication state;

[0334] For each data transmission, the relevant transmission timestamp and status information are recorded. When a risk communication state occurs, the current feeding amount, target parameters and actual operation status are automatically checked. The rationality of the feeding process is judged through the threshold judgment mechanism, and whether it is necessary to switch to the safe mode is evaluated;

[0335] Step S22: defining characteristic values ​​of important operating parameters (such as feed amount, melt temperature, etc.) in the collected data; when the deviation between the actual parameter and the target parameter exceeds the set tolerance range, the system automatically determines it as an abnormal situation and triggers the safety mode; in the safety mode, the instruction to reduce the feed amount will be executed immediately, and the operation of the feeding device will be suspended;

[0336] Step S23: After entering the safety mode, an alarm is issued to notify the operator; at the same time, the feed amount is reduced to the lowest operating level according to the preset safety strategy, and the minimum risk feed strategy is implemented; after the operator receives the alarm, he can obtain detailed warning information through the interface and understand the current operating status; regularly evaluate the deviation between the actual feed amount and the historical record to form a feedback loop; when the communication returns to normal and the actual parameters are within the set range, gradually resume the normal feed process and readjust the target parameters.

[0337] Preferably, step S21 of this embodiment monitors the data transmission status between the OPC server and the DCS in real time, automatically identifies and records the delay, error packet rate and connection status of the communication link, and marks it as a risk communication status so as to deal with the problem in time. Significance: Ensure the stability and reliability of the system during operation, discover communication failures in time, and prevent the transmission of erroneous data; provide an accurate data basis for subsequent decision-making, ensure that feeding and other control operations are carried out under reliable communication conditions, and reduce production risks caused by communication failures. Step S22 defines the characteristic values ​​of important operating parameters, which can quantify key indicators in the production process (such as feed amount, melt temperature, etc.); automatically judge the deviation between actual parameters and target parameters, and identify abnormal situations. Significance: Through the set tolerance range and characteristic values, possible problems in the production process can be discovered at the first time, so that countermeasures can be taken in time to reduce the risk of abnormal operation; once it is determined to be abnormal, the safety mode will be automatically triggered to maintain equipment safety and production stability. Step S23 After entering the safety mode, the system immediately issues an alarm to notify the operator to intervene; reduce the feed amount to the lowest operating level, suspend the equipment operation, and execute the minimum risk feeding strategy. Significance: It realizes automated risk prevention and control. By issuing alarms in time, operators can understand the equipment operation status at critical moments, so as to make reasonable decisions and ensure safe production. It reduces losses caused by abnormalities, protects equipment from overload or other serious consequences, and creates conditions for the resumption of normal production, ensuring the safety of the system at multiple levels.

[0338] In summary, this embodiment builds a timely monitoring and response mechanism to enhance the stability and reliability of the entire system in the face of emergencies; utilizes real-time data inspection and anomaly identification mechanisms to establish preventive safety management of the system and reduce the necessity of human intervention; through automated feedback and adjustment, ensures the continuity of the production process, reduces downtime, and improves overall production efficiency; allows the system to dynamically adjust according to actual conditions during operation, thereby improving adaptability to changes in the production environment; ensures compliance with safety policies and standards in smelting production, thereby achieving compliance and sustainable development goals.

[0339] Furthermore, the process of evaluating whether to switch to the safe mode in step S21 specifically includes the following steps:

[0340] Step S211: define the normal range of key operating parameters, including feed amount, melt temperature, pressure and flow rate, etc. Each parameter is set with an ideal value and a tolerable deviation range, and the operation within the deviation range is considered normal;

[0341] Step S212: collecting the current feed amount, actual melt temperature and other key parameters in real time, and comparing them with the preset target parameters;

[0342] Step S213: Analyze using the threshold judgment mechanism and compare the current parameter with the historical data based on the set slice deviation range; if the real-time value of a parameter exceeds the set tolerable deviation range, the parameter will be marked as abnormal.

[0343] Preferably, step S211 of this embodiment defines the normal range of key operating parameters, establishes a clear normal range for each key operating parameter (such as feed amount, melt temperature, pressure and flow rate), including ideal values ​​and tolerable deviation ranges; ensures that these parameters are measurable for subsequent data collection and analysis. Significance: Provides a baseline for the system to facilitate subsequent real-time monitoring and evaluation, and defines data that can help operators quickly identify which data is considered normal, thereby improving overall safety; establishes standardized references for parameters, helps to unify operating specifications and training, improves operators' operating skills and awareness, and reduces operating risks. Step S212 collects the current feed amount and other key parameters in real time, monitors and collects relevant key parameter data (such as feed amount, melt temperature and pressure) in the production process in real time, ensures the timeliness and accuracy of the data; enables the system to obtain real-time dynamic data for comparison with target parameters. Significance: Improves the accuracy and effectiveness of data analysis, ensures that the system handles potential abnormal situations in a timely manner through rapid data collection; enables operators to obtain information on the current production status in a timely manner, make rapid responses and adjustments, and avoid potential safety hazards. Step S213 uses the threshold judgment mechanism to analyze and compare the real-time data with the set tolerable deviation range to identify whether the parameter exceeds the normal range; if the parameter exceeds the tolerance range, the parameter will be immediately marked as abnormal and the relevant information will be recorded. Significance: Through the threshold judgment mechanism, abnormal conditions in the feeding process can be captured at the first time to ensure timely processing and prevent greater losses caused by equipment failure or operational errors; provide clear warnings and guidance to operators, prompting them to take necessary safety measures, such as switching to safety mode, to ensure the safety and reliability of production; improve the intelligence of the production process, reduce the pressure of manual monitoring, and improve overall production efficiency.

[0344] In summary, through the above steps, this embodiment aims to establish an efficient and reliable monitoring and response mechanism to enhance the safety and stability of the production process, which can not only ensure equipment safety, but also maintain product quality, reduce resource waste, and ultimately achieve the goal of reducing production costs and improving economic benefits.

[0345] Furthermore, the process of analyzing by using the threshold judgment mechanism in step S213 specifically includes the following steps:

[0346] Step S2131: collect real-time parameter data, including solid parameters such as feed amount, melt temperature, pressure and flow rate; center on the real-time value of each parameter at the current moment, and extract historical data within a certain time range before and after (such as the last 30 seconds or 1 minute);

[0347] Step S2132: For each historical value in the current data and the local data set, the difference between the historical values ​​is calculated one by one to form a difference set, and a distance index is calculated to reflect the distance between the current real-time parameter and the historical value; after each difference calculation, a score is generated to evaluate the abnormality of the current real-time value relative to the historical value;

[0348] Step S2133: Weight the differences within the local data set to highlight the historical values ​​that have the greatest impact on the threshold judgment; integrate the differences in real-time parameters at the current moment, weight factors, and other contextual information (such as temperature, equipment status, etc.) to generate a comprehensive decision-making indicator to reflect whether the current parameters are within the normal range and whether further safety measures need to be taken.

[0349] Preferably, step S2131 of this embodiment collects real-time parameter data. The key parameters (such as feed amount, melt temperature, pressure and flow rate) collected in real time provide the necessary data basis for subsequent analysis; extract the historical data of 30 seconds or 1 minute before and after to form a local data set to provide context for real-time judgment. Significance: It ensures accurate reflection of the current production status, so that the system can monitor and analyze in real time. By focusing on short-term historical data, short-term trends and fluctuation characteristics can be better identified, and the sensitivity to abnormalities in future steps can be enhanced; timely data collection and analysis improves the response speed, ensuring that measures can be taken quickly when abnormalities occur, reducing potential safety risks. Step S2132 calculates the difference of historical values ​​and generates a distance index, compares the current real-time value with each historical value in the local data set one by one, calculates the difference set, and generates a score for each difference, reflecting the similarity or distance between the real-time parameter and the historical value; the distance index formed can quantify the relationship between the current value and the historical value, providing a specific numerical basis for subsequent analysis. Significance: The implementation of this step enables the system to quantify the degree of anomaly and provide a basis for determining whether action is needed; through clear scores, operators or automatic monitoring systems can quickly identify abnormal situations that are worthy of attention and possible; this calculation process helps to establish a dynamic fault indication mechanism, making the monitoring system more responsive and reliable, and ensuring the safety of real-time operations. Step S2133 weights the differences and generates a comprehensive decision index, weighting according to the differences to highlight the historical values ​​that have a greater impact on the threshold judgment. This weighting mechanism can combine real-time parameters, historical data and contextual information (such as current ambient temperature, equipment status, etc.) to comprehensively generate a decision index; the decision index can intuitively reflect whether the current parameters are within the normal range, and decide whether further safety measures need to be taken based on this assessment. Significance: The weighting mechanism ensures the accuracy of anomaly detection. By emphasizing key historical values, the system can better reflect the actual situation related to the field; the comprehensive decision index makes the monitoring system not limited to simple threshold comparison, but incorporates dynamic adjustment capabilities to meet the needs of specific application scenarios; this method can significantly improve the intelligence and automation level of the production system, reduce the necessity of human intervention, and improve overall production efficiency and safety.

[0350] In summary, through the implementation of these three steps, the overall monitoring system of this embodiment builds an efficient, accurate and dynamic threshold judgment mechanism. It not only enhances the real-time monitoring capability of the operating status, but also lays a solid foundation for abnormal detection, equipment management and safety control. This systematic approach improves the level of intelligent production, helps reduce potential risks, and improves resource utilization efficiency. It is an important part of the transformation of modern manufacturing industry to intelligence and automation.

[0351] Furthermore, if Figure 8As shown, the process of obtaining the corrected target parameters in step S3 specifically includes the following steps:

[0352] Step S31: Compare the actual parameter with the target value and calculate the deviation of each parameter; calculate the sum of the absolute values ​​of all deviations to obtain a comprehensive deviation index for evaluating the overall deviation degree; set the allowable deviation range of each parameter. If the deviation of a parameter exceeds the preset range, the parameter is corrected in a focused manner;

[0353] Step S32: Analyze the correction coefficient of each parameter based on the historical deviation data, calculate the amount to be corrected in the next control cycle, and convert the correction amount into a specific material or gas delivery adjustment value; analyze the trend of the actual impact of energy flow and material flow on the target parameter under the current state based on historical data; combine the predicted value with the actual deviation to generate a feedforward output value;

[0354] Step S33: Combine the correction amount and the feedforward output value to generate the final corrected target parameter.

[0355] Preferably, step S31 of this embodiment is deviation comparison and evaluation, which determines the deviation of each key parameter (such as crude tin grade, Fe / SiO2 ratio in slag, melt temperature) by comparing the actual parameter with the target value. This step provides quantitative data about the current operating status of the system; by calculating the sum of the absolute values ​​of all deviations, a comprehensive deviation index can be obtained, which intuitively reflects the degree of deviation of the overall production process; the allowable deviation range of each parameter is preset so that the system has the ability to accept normal fluctuations. Significance: Ensure that the system can grasp its operating status in real time, provide instant feedback information, and help operators make fast-paced decisions; by identifying out-of-range parameters, the system can make key corrections at key locations and give priority to parameters that may cause greater impacts, thereby reducing production risks; the comprehensive deviation index provides a basis for further decision-making, making the adjustment process more targeted and effective. Step S32: Calculation of correction amount and feedforward output. The correction coefficient obtained based on historical deviation data ensures that the system can make dynamic adjustments based on past experience and improve the accuracy of correction. Combined with the correction coefficient, the correction amount required for the next control cycle is calculated to adjust the delivery of mineral materials or gas in a timely manner. The actual impact trend is analyzed through historical data, and the predicted value is combined with the current deviation to generate a feedforward output value to provide foresight for future adjustments. Significance: This process enables the system to intelligently evaluate and correct the current operation based on historical data without relying on manual intervention, making the control process more automated and intelligent. Through the prediction of feedforward output, the system can identify future deviations earlier, so as to take remedial measures more quickly and increase the flexibility of overall operation. Accurate calculation of correction amount ensures efficient use of materials and energy and reduces the risk of over- or under-delivery. Step S33: Generate the final corrected target parameter. By combining the correction amount and the feedforward output, the final corrected target parameter is generated. This parameter is the comprehensive adjustment result for the current deviation and reflects the responsiveness of the system. The generated corrected target parameter can be directly applied by the control system, which is convenient for the adjustment of actual equipment and the precise control of feeding. Significance: The corrected target parameters provide a clear direction of action for the control system, enabling it to perform precise operations and effectively achieve the goals; this process forms a closed-loop feedback control mechanism that can continuously optimize the production process and ensure that the system always approaches the set target parameters to improve production efficiency and quality; through this systematic correction process, the stability of the production process can be significantly improved, abnormal situations can be reduced, and overall safety can be enhanced.

[0356] In summary, this embodiment can realize the efficient operation of the method for automatic batching of tin smelting through the implementation of these three steps. This systematic correction process not only improves the processing accuracy, but also enhances the intelligence of the overall production process and improves the efficiency of resource utilization, thus laying a solid foundation for the modernization and transformation of the tin smelting industry.

[0357] like Fig. 9 As shown, this embodiment also provides an embodiment of a tin smelting automatic batching system for bidirectional coupling of material flow and energy flow. In this embodiment, the tin smelting automatic batching system for bidirectional coupling of material flow and energy flow is applied to the tin smelting automatic batching method for bidirectional coupling of material flow and energy flow in the above embodiment. The tin smelting automatic batching system for bidirectional coupling of material flow and energy flow includes a batching calculation module 1, a distribution control module 2, and a parameter correction module 3 which are electrically connected in sequence;

[0358] Among them, the batching calculation module 1 is used to input the composition information of ore and fuel, set the top blowing air volume, oxygen concentration and three target parameter values; based on the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting, automatically calculate the material balance, energy balance calculation and material-energy coupling optimization configuration, and determine the decision variable value of production optimization batching, that is, the batching plan; among them, the three major target parameter values ​​include crude tin grade, Fe / SiO2 ratio in slag and melt temperature; the batching plan includes the proportion and feeding amount of imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag, smoke dust and other ore materials; granular coal, pulverized coal and top blowing volume; separation The batching control module 2 is used to display the batching scheme and target parameters through the window, and transmit them to the distributed control system DCS through the OPC server. The distributed control system DCS controls the feeder discharge amount and hardware instrument equipment; the parameter correction module 3 is used to analyze the current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature, and compare them with the target value; if the deviation exceeds the allowable range, the feedback is automatically triggered, the correction amount and the feedforward output value are calculated to obtain the corrected target parameters, and after confirmation by the operator, the calculated target parameters are transmitted to the distributed control system DCS through the transmission subsystem of the OPC server for terminal control.

[0359] Preferably, the batching calculation module 1 of this embodiment allows the user to input composition information such as ore and fuel, and set key parameters such as top blowing air volume, oxygen concentration and target parameter values ​​(coarse tin grade, Fe / SiO2 ratio in slag, melt temperature); based on the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting, automatically calculate the material balance and energy balance to ensure the scientificity and rationality of the batching scheme; use the calculation results to optimize the material flow and energy flow, and output a specific batching scheme, including the proportion of various types of ore entering the furnace, the feed amount, and different types of coal and top blowing gas. Significance: This module provides scientific data support and decision-making basis for the entire smelting process, ensures the accuracy of the batching scheme, thereby improving the economic benefits and product quality of the entire process; through automatic calculation and optimization, it reduces the need for manual intervention, improves the degree of automation of the smelting process, and reduces human errors. The distributed control module 2 receives and displays the batching scheme and target parameters from the batching calculation module through the window display, and transmits this information to the distributed control system (DCS) through the OPC server; controls various devices in the distributed computing system, such as feeders and instrumentation equipment, to ensure that the implementation of the batching scheme can be accurately implemented. Significance: It makes the information flow between the modules unimpeded, ensures that the various parts of the system can coordinate operations, and thus achieve overall regulation; ensures that the batching scheme can be executed in real time, which is of great value for process adjustment and adaptation to production changes, improves the response speed and adjustment ability, and ultimately achieves efficient production. The parameter correction module 3 performs real-time analysis on the current crude tin grade, Fe / SiO2 ratio in slag and melt temperature, and compares them with the set target value; when the deviation exceeds the allowable range, the feedback mechanism is automatically triggered to calculate the correction amount and feedforward output value to generate the corrected target parameters; after confirmation by the operator, the calculated corrected target parameters are transmitted to the DCS through the OPC server for terminal control. Significance: This module provides the system with dynamic adjustment capabilities, ensuring that even if deviations occur during the production process, the system can still automatically respond and adjust to maintain the stability of the production process; through real-time monitoring and correction, it effectively reduces product consistency issues, improves brand and quality stability, and enhances production safety (for specific principles, refer to the attached Fig.10 ).

[0360] In summary, through the effective collaboration of these three modules, the tin smelting automated batching system in this embodiment realizes a complete closed loop from data input to production control, improves the degree of automation, optimizes resource utilization, ensures product quality and consistency, and improves overall production efficiency, providing strong technical support for modern smelting processes. The mutual cooperation of various modules forms an efficient, controllable and stable production system, which helps to achieve continuous improvement and optimization.

[0361] like Fig.11 As shown, this embodiment provides an embodiment of an electronic device. In this embodiment, the electronic device 4 includes a processor 41 and a memory 42 coupled to the processor 41.

[0362] The memory 42 stores program instructions for implementing the automatic batching method for tin smelting with bidirectional coupling of material flow and energy flow in any of the above embodiments.

[0363] The processor 41 is used to execute the program instructions stored in the memory 42 to perform automatic batching of tin smelting by bidirectional coupling of material flow and energy flow.

[0364] The processor 41 may also be referred to as a CPU (Central Processing Unit). The processor 41 may be an integrated circuit chip having signal processing capabilities. The processor 41 may also be a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components. The general-purpose processor may be a microprocessor or the processor may also be any conventional processor, etc.

[0365] Further, Fig.12 The schematic diagram of the structure of the storage medium of an embodiment of the present application is that the storage medium 5 of the embodiment of the present application stores program instructions 51 that can implement all the above methods, wherein the program instructions 51 can be stored in the above storage medium in the form of a software product, including several instructions for enabling a computer device (which can be a personal computer, server, or network device, etc.) or a processor to execute all or part of the steps of the methods described in each embodiment of the present application. The aforementioned storage medium includes: various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, or terminal devices such as a computer, a server, a mobile phone, and a tablet.

[0366] In the several embodiments provided by the present invention, it should be understood that the disclosed systems, devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of units is only a logical function division, and there may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0367] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above integrated unit may be implemented in the form of hardware or in the form of software functional units. The above is only an implementation mode of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly used in other related technical fields, is also included in the patent protection scope of the present invention.

[0368] The specific implementation methods of the invention are described in detail above, but they are only examples, and the invention is not limited to the specific implementation methods described above. For those skilled in the art, any equivalent modification or substitution of the invention is also within the scope of the invention, therefore, the equalization, modification, improvement, etc. made without departing from the spirit and principle of the invention should be included in the scope of the invention.

Claims

1. An automated batching method for tin smelting with bidirectional coupling of material flow and energy flow, characterized in that: The method for automatic batching of tin smelting by bidirectionally coupling material flow and energy flow comprises: Input the information of ore and fuel composition, set the top blowing air volume, oxygen concentration and three target parameter values; based on the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting, automatically calculate the material balance, energy balance calculation and material-energy coupling optimization configuration, and determine the decision variable value of production optimization batching, that is, the precise batching plan; The batching plan and target parameters are displayed in the window and transmitted to the distributed control system DCS through the OPC server. The distributed control system DCS controls the feeder discharge amount and hardware instrument equipment; The current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature are analyzed and compared with the target values. If the deviation exceeds the allowable range, feedback is automatically triggered, and the correction amount and feedforward output value are calculated to obtain the corrected target parameters. After confirmation by the operator, the calculated target parameters are transmitted to the distributed control system DCS through the transmission subsystem of the OPC server for terminal control.

2. The method for automatic batching of tin smelting by bidirectional coupling of material flow and energy flow according to claim 1 is characterized in that: The construction of a nonlinear energy flow-material flow coupling mathematical model based on oxygen-enriched top-blown tin smelting includes: A material balance model is established based on the input materials in the tin smelting process of the oxygen-enriched top-blown smelting system; at the same time, based on the input and output data in the tin smelting process, the data that cannot be directly measured are calculated, and the data that can be directly measured include flue gas composition and flow rate; Calculate the material balance results according to the energy balance equation, analyze the flow of various substances and energy in the tin smelting process, and the energy flow includes heat income and heat expenditure; through the material balance model and energy balance equation, perform mathematical calculations to obtain the flow direction, quantity, utilization efficiency, theoretical smelting end point temperature and material component parameters of various substances and energy, and realize the mathematical modeling of multi-energy loads and dynamic prediction of related energy-quality networks for large-scale oxygen-enriched top-blown smelting processes; The heat income and heat expenditure are expressed in a weighted form by the mass of each input and output material, and a nonlinear energy flow-material flow coupling mathematical model is obtained.

3. The automatic batching method for tin smelting with bidirectional coupling of material flow and energy flow according to claim 1 is characterized in that: Material balance equation: ∑G 投入 =∑G 产出 ∑G 投入 =g1+g2+g3+g4 ∑G 产出 =g5+g6+g7+g8+g9 Where: ∑G 投入、产出 Indicates the total mass of input and output materials of top-blown smelting furnace, t / h; g 1、2、3、4 Indicates the feeding amount of tin concentrate, slag-making agent, coal and oxygen-enriched air, t / h; g 5、6、7、8、9 Indicates the output of tin A, tin B, slag, smoke and flue gas, t / h; Among them, in the oxygen-enriched top-blown molten pool smelting process, the J element flow balance equation before and after smelting is: G j,投入 =G j,产出 Where: G j,投入、产出 It represents the total input and output of element j in the tin smelting process, t / h; η 1,j 、2,j、3,j、 4,j represents the proportion of element j in the tin concentrate, slag-making agent, coal and oxygen-enriched air entering the furnace; η 5,j 、6,j、7,j、8,j、 9,j It indicates the proportion of element j in tin A, tin B, slag, smoke and flue gas in the smelting products; Energy balance equation takes historical smelting data to calculate the unquantifiable heat loss The mean Calculate and according to the law of conservation of energy: ∑Q 收入 =∑Q 支出 ∑Q 收入 =q1+q2+q3+q4+q5+q6 Where: ∑Q 收入 , 支出 Indicates the heat entering the top-blown smelting reaction zone; ∑Q 收入 , 支出 Indicates the heat expenditure from the top-blowing smelting reaction zone; q 1、2、3、4、5、6 It represents the heat released by oxidation of free sulfur generated by FeS2 dissociation, heat released by slag making, heat released by coal combustion, sensible heat of charge, sensible heat of coal and sensible heat of air entering the furnace, MJ / h; q 7、8、9、10、11、12、13、14 It means that FeS2 dissociation absorbs heat, SnO2 and Fe3O4 reduction takes away heat, crude tin takes away heat, slag takes away heat, smoke takes away heat, water evaporation absorbs heat, flue gas takes away heat, and water cooling jacket takes away heat, MJ / h.

4. The method for automatic batching of tin smelting by bidirectional coupling of material flow and energy flow according to claim 3 is characterized in that: Theoretical air leakage / gas volume of material balance equation: in is the historical statistical data of furnace air leakage u * The mean of .

5. The method for automatic batching of tin smelting by bidirectional coupling of material flow and energy flow according to claim 1 is characterized in that: Energy-mass coupling metallurgical mathematical physics calculation energy flow network matrix model in oxygen-enriched top-blown molten pool smelting process, various types of heat are input into q 1～6 And various types of heat expenditure q 7～14 Through the mass g of each input and output material 1～9 The weighted form of is expressed as: Where: q m It takes values ​​from 1 to 15, representing energy flows: free sulfur oxidation heat generated by FeS2 dissociation, slag-making heat, coal combustion heat, charge sensible heat, coal sensible heat, furnace air sensible heat, FeS2 dissociation endothermic heat, SnO2 and Fe3O4 reduction absorption heat, crude tin carry-away heat, slag carry-away heat, smoke carry-away heat, water evaporation endothermic heat, flue gas carry-away heat, water cooling jacket carry-away heat, and unquantifiable heat; g 1～n Indicates the input amount of tin concentrate, slag-making agent, coal and oxygen-enriched air, and the output amount of tin amine, tin ethylene, slag, smoke and flue gas, t / h; ξ m,1～m,n It represents the weighting coefficient for calculating the relevant energy flow balance; The empirical equations for energy-mass coupling metallurgical mathematical physics calculation and the energy flow network matrix model in the oxygen-enriched top-blown molten pool smelting process are as follows: Input energy flow, free sulfur oxidation heat generated by FeS2 dissociation, slag release, coal combustion heat, charge sensible heat, coal sensible heat and furnace air sensible heat: Output energy flow, FeS2 dissociation heat absorption, SnO2 and Fe3O4 reduction heat, crude tin heat, slag heat, smoke heat, water evaporation heat absorption, flue gas heat, water cooling jacket heat and unquantifiable heat loss:

6. The automatic batching method for tin smelting with bidirectional coupling of material flow and energy flow according to claim 1 is characterized in that: Matter-energy coupling optimization configuration strategy: In order to achieve a higher effective energy utilization rate in the smelting process, the corresponding expression is: In order to achieve higher economic benefits for smelting and meet the maximum supply constraints of various mineral materials, the corresponding expression is: The amount of ingredients fed is subject to the tonnage of the furnace, the production cycle and the processing capacity: In the formula, Ton is the rated tonnage of the furnace design, t cycle It is a single furnace production smelting cycle; Through the Lagrange multiplier method, the maximum value of the multivariate function equation of material and energy balance is solved under the constraints, and the values ​​of the decision variables for production optimization batching can be determined.

7. The automatic batching method for tin smelting with bidirectional coupling of material flow and energy flow according to claim 1 is characterized in that: Passed to the distributed control system DCS through the OPC server, including: Real-time monitoring of data transmission between the OPC server and the distributed control system DCS, regular collection and recording of communication delay, error packet rate and connection status; when the delay of the communication link exceeds the preset threshold or data packet loss occurs, it is automatically marked as a risky communication state; In the collected data, the characteristic values ​​of important operating parameters are defined; when the deviation between the actual parameters and the target parameters exceeds the set tolerance range, the system automatically determines it as an abnormal situation and triggers the safety mode; in the safety mode, the instruction to reduce the feed amount will be executed immediately and the operation of the feeding device will be suspended; After entering the safety mode, an alarm is issued to notify the operator. At the same time, the feed rate is reduced to the lowest operating level according to the preset safety strategy, and the minimum risk feed rate strategy is implemented. After receiving the alarm, the operator obtains detailed warning information through the interface and understands the current operating status. The deviation between the actual feed rate and the historical record is regularly evaluated to form a feedback loop. When the communication returns to normal and the actual parameters are within the set range, the normal feed process is gradually restored and the target parameters are readjusted.

8. The automatic batching method for tin smelting with bidirectional coupling of material flow and energy flow according to claim 7 is characterized in that: For each data transmission, the relevant transmission timestamp and status information are recorded. When a risky communication state occurs, the current feed amount, target parameters and actual operating status are automatically checked. The rationality of the feed process is judged through the threshold judgment mechanism, and it is evaluated whether it is necessary to switch to safe mode.

9. The automatic batching method for tin smelting with bidirectional coupling of material flow and energy flow according to claim 1 is characterized in that: The corrected target parameters are obtained, including: Compare the actual parameters with the target values ​​and calculate the deviation of each parameter; calculate the sum of the absolute values ​​of all deviations to obtain a comprehensive deviation index to evaluate the overall deviation degree; set the allowable deviation range for each parameter. If the deviation of a parameter exceeds the preset range, the parameter will be corrected in detail. Analyze the correction coefficient of each parameter based on historical deviation data, calculate the amount to be corrected in the next control cycle, and convert the correction amount into a specific material or gas delivery adjustment value; analyze the trend of the actual impact of energy flow and material flow on the target parameters under the current state based on historical data; combine the predicted value with the actual deviation to generate a feedforward output value; The correction amount is combined with the feedforward output value to generate the final corrected target parameter.

10. An automated batching system for tin smelting with bidirectional coupling of material flow and energy flow, which is applied to the automated batching method for tin smelting with bidirectional coupling of material flow and energy flow as claimed in any one of claims 1 to 9, characterized in that: The material flow and energy flow bidirectional coupling tin smelting automatic batching system comprises: The batching calculation module is used to input the information of ore and fuel composition, set the top blowing air volume, oxygen concentration and three target parameter values; based on the nonlinear energy flow-material flow coupling mathematical model of oxygen-enriched top-blown tin smelting, it automatically calculates material balance, energy balance calculation and material-energy coupling optimization configuration, and determines the decision variable value of production optimization batching, that is, the batching scheme; among which, the three target parameter values ​​include crude tin grade, Fe / SiO2 ratio in slag and melt temperature; the batching scheme includes the proportion and feeding amount of imported ore, high-concentrate ore, purchased tin slag, roasted concentrate, roasted slag, and smoke dust into the furnace; granular coal, pulverized coal and top blowing air volume; Distributed control module, used to display batching scheme and target parameters through window, and transmit them to distributed control system DCS through OPC server, and distributed control system DCS controls feeder discharge amount and hardware instrument equipment; The parameter correction module is used to analyze the current crude tin grade, Fe / SiO2 ratio in the slag and melt temperature, and compare them with the target value; if the deviation exceeds the allowable range, feedback is automatically triggered, and the correction amount and feedforward output value are calculated to obtain the corrected target parameters. After confirmation by the operator, the calculated target parameters are transmitted to the distributed control system DCS through the transmission subsystem of the OPC server for terminal control.

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