System and process for producing oxygen-free copper from recycled copper

Abstract

The application provides a system and a process for preparing oxygen-free copper from recycled copper. The system comprises a smelting device for melting the pretreated recycled copper to obtain copper liquid; an oxidizing device having a first output end in communication with the interior of the smelting device for delivering oxygen to the interior of the smelting device through the first output end; a reducing device having a plurality of second output ends in communication with the interior of the smelting device through the bottom wall of the smelting device for delivering carbon monoxide to the interior of the smelting device through the second output ends; and a slag removal device for removing primary impurities and secondary impurities on the surface of the copper liquid. The application achieves efficient removal of impurities.

Description

Technical Field

[0001] This application relates to the field of oxygen-free copper preparation technology, specifically to a system and process for preparing oxygen-free copper from recycled copper. Background Technology

[0002] Copper is an important metallic material in the national economy, widely used in industries such as information technology, electronics, power, automobiles, refrigeration, and military. Industrial pure copper is generally classified into three categories: tough copper, phosphorus-deoxidized copper, and oxygen-free copper, with oxygen-free copper being the highest quality grade.

[0003] Oxygen-free copper is pure copper that contains no oxygen or has extremely low oxygen content. It contains neither cuprous oxide nor any residual deoxidizer. Compared with ordinary copper, its chemical composition contains more than 99.95% copper and less than 0.003% oxygen. It has the characteristics of high electrical and thermal conductivity, good elasticity, corrosion resistance, non-magnetic properties, low hydrogen permeability, easy machining, and low cost.

[0004] Currently, industrial processes for producing oxygen-free copper from recycled copper often use charcoal and natural gas as reducing agents, which have drawbacks such as easy introduction of impurities, long process steps, and high equipment investment. Furthermore, the adjustment of process parameters in the preparation of oxygen-free copper still relies heavily on manual experience, excessively depending on the operator's theoretical derivation and repeatable experimental verification. In addition, traditional control strategies use fixed parameter settings, which cannot achieve dynamic adaptation to different raw material characteristics, resulting in a narrow process window. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, this application provides a system and process for preparing oxygen-free copper from recycled copper.

[0006] The specific technical solution is as follows:

[0007] A system for preparing oxygen-free copper from recycled copper, comprising:

[0008] A smelting apparatus, configured to perform step S10: adding pretreated recycled copper into the smelting apparatus and melting the pretreated recycled copper at a temperature of 1300-1350°C to obtain molten copper;

[0009] An oxidation device having a first output end connected to the interior of the smelting device, the oxidation device being configured to perform step S20: increasing the flow rate to 300-500 m³ / h. 3 / h, oxygen with a purity ≥99.99% is delivered to the inside of the smelting device through the first output end;

[0010] The reduction device has multiple second output terminals, which are connected to the interior of the smelting device through the bottom wall of the smelting device. The reduction device is configured to perform step S50: to increase the flow rate to 400-600 m³ / s. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the inside of the smelting device through the second output end;

[0011] The slag removal device is configured to perform step S30: after the smelting device has been left to stand for a first preset time, perform initial impurity removal on the surface of the molten copper; and is also configured to perform step S60: after the smelting device has been left to stand for a second preset time, perform secondary impurity removal on the surface of the molten copper to form oxygen-free copper.

[0012] In one embodiment, the bottom wall of the smelting apparatus is provided with a plurality of first air inlets corresponding to a plurality of second output ends, and the second output ends are connected to the interior of the smelting apparatus through the first air inlets;

[0013] The first air inlet is inclined at 15°-30° relative to the horizontal direction, and multiple first air inlets are arranged circumferentially along the bottom wall of the melting device, and the inclination direction of the multiple first air inlets is consistent.

[0014] In one embodiment, the reduction device has multiple third output terminals, which are disposed on the side wall of the smelting device and communicate with the interior of the smelting device. Step S50 includes: adjusting the flow rate to 400-600 m³ / s. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the interior of the smelting device through the second output end and the third output end;

[0015] The side wall of the smelting device is provided with a plurality of second air inlets corresponding to the plurality of third output ends, and the third output ends are connected to the interior of the smelting device through the second air inlets;

[0016] The second air inlet is inclined at 15°-30° relative to the horizontal direction, and multiple second air inlets are arranged circumferentially along the side wall of the melting device, and the inclination direction of the multiple second air inlets is consistent.

[0017] In one embodiment, the system for preparing oxygen-free copper from recycled copper further includes a detection device, which includes an oxygen content detection device and an oxide volume detection device. The bottom wall of the smelting device is provided with a sampling output port. The oxygen content detection device and the oxide volume detection device are used to detect the sample output from the sampling output port.

[0018] Step S50 includes: inputting the initial oxygen content data obtained by the oxygen content detection device and the initial furnace bottom oxide volume data output by the oxide volume detection device into a trained machine learning model, and outputting a first flow rate prediction value and a first flow velocity prediction value corresponding to each of the second output terminals, as well as a second flow rate prediction value and a second flow velocity prediction value corresponding to each of the third output terminals. Each of the second output terminals delivers carbon monoxide with a purity ≥99.9% to the smelting device with the corresponding first flow rate prediction value and first flow velocity prediction value, and each of the third output terminals delivers carbon monoxide with a purity ≥99.9% to the smelting device with the corresponding second flow rate prediction value and second flow velocity prediction value.

[0019] In one embodiment, the machine learning model is constructed in the following manner:

[0020] Collect multiple sets of historical processing data, including initial oxygen content, initial furnace bottom oxide volume, preset oxygen content, preset furnace bottom oxide volume, process parameters, and actual processing time. The process parameters include the first flow rate value and the first flow velocity value of each of the second output terminals, and the second flow rate value and the second flow velocity value of each of the third output terminals.

[0021] The oxygen content difference is calculated based on the initial oxygen content data and the preset oxygen content data, and the furnace bottom oxide volume difference is calculated based on the initial furnace bottom oxide volume data and the preset furnace bottom oxide volume data.

[0022] A sample database was constructed based on the differences in oxygen content, the difference in oxide volume at the bottom of the furnace, process parameters, and actual time consumption for each group.

[0023] The oxygen content difference and the furnace bottom oxide volume difference are used as input features, and the process parameters and actual time consumption are used as target outputs. The preset machine learning algorithm is input for iterative training, and the model parameters are adjusted until the convergence condition is met to form a machine learning model.

[0024] In one embodiment, the machine learning model is configured to perform the following steps:

[0025] Receive the initial oxygen content data, the initial furnace bottom oxide volume data, the preset oxygen content data, and the preset furnace bottom oxide volume data;

[0026] The oxygen content difference is calculated based on the initial oxygen content data and the preset oxygen content data, and the furnace bottom oxide volume difference is calculated based on the initial furnace bottom oxide volume data and the preset furnace bottom oxide volume data.

[0027] Based on the oxygen content difference and the furnace bottom oxide volume difference, output each predicted process parameter and predicted time.

[0028] All predicted time durations are sorted in ascending order, and the predicted process parameters corresponding to the first predicted time duration are taken as the final output.

[0029] In one embodiment, a three-way valve is provided at the first air inlet, and the three-way valve is connected to the first air inlet, the first output terminal and the second output terminal respectively;

[0030] Step S20 includes: adjusting the valve of the three-way valve to connect the first air inlet to the first output end, and increasing the flow rate to 300-500m³ / h. 3 / h, oxygen with a purity ≥99.99% is delivered to the inside of the smelting device through the first output end and the first air inlet;

[0031] Step S50 includes: adjusting the valve of the three-way valve to connect the first air inlet to the second output end, and increasing the flow rate to 400-600 m³ / h. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the inside of the smelting device through the second output end and the first air inlet.

[0032] In one embodiment, the system for preparing oxygen-free copper from recycled copper further includes a deoxygenation device having a fourth output terminal connected to the interior of the smelting apparatus. The deoxygenation device is configured to perform step S40 before step S50: increasing the flow rate to 300-500 m³ / s. 3 Nitrogen gas with a purity of ≥99.99% is delivered to the smelting device through the fourth output terminal at a rate of / h.

[0033] In one embodiment, the system for preparing oxygen-free copper from recycled copper further includes a pretreatment device, which includes a magnetic separator and a vibrating screen;

[0034] The magnetic separator is configured to perform step S01: adding recycled copper to the magnetic separator and performing magnetic separation at a magnetic induction intensity > 8500 Gauss to remove ferromagnetic impurities from the recycled copper;

[0035] The vibrating screen is configured to perform step S02: adding the recycled copper after removing ferromagnetic impurities to the vibrating screen, screening and separating non-copper particles in the recycled copper, and obtaining pretreated recycled copper.

[0036] A process for preparing oxygen-free copper from recycled copper, using the system for preparing oxygen-free copper from recycled copper as described in any of the above-mentioned methods, the process includes the following steps:

[0037] S10: Add the pretreated recycled copper into the smelting device and melt the pretreated recycled copper at a temperature of 1300-1350℃ to obtain molten copper.

[0038] S20: Flow rate 300-500m 3 / h, oxygen with a purity ≥99.99% is supplied to the smelting device through the first output end of the oxidation device until the copper liquid meets the preset conditions;

[0039] S30: After the smelting device is left to stand for a first preset time, the surface of the molten copper is initially removed to remove impurities.

[0040] S50: Flow rate 400-600m 3 / h, carbon monoxide with a purity ≥99.9% is supplied to the smelting device through the second output end of the reduction device;

[0041] S60: After the smelting device is left to stand for a second preset time, the surface of the copper liquid is subjected to secondary impurity removal to form oxygen-free copper.

[0042] This application has at least the following beneficial effects:

[0043] This application provides a system for preparing oxygen-free copper from recycled copper, comprising: a smelting apparatus configured to perform step S10: adding pretreated recycled copper into the smelting apparatus and melting the pretreated recycled copper at a temperature of 1300-1350℃ to obtain molten copper; and an oxidation apparatus having a first output end connected to the interior of the smelting apparatus, configured to perform step S20: [The system then describes an oxidation process involving a flow rate of 300-500 m³ / h]. 3 Oxygen with a purity ≥ 99.99% is supplied to the smelting unit through the first output end at a rate of / h; the reduction unit has multiple second output ends, which are connected to the interior of the smelting unit through the bottom wall of the smelting unit, and is configured to execute step S50: supplying oxygen at a flow rate of 400-600 m³ / h. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the smelting device through the second output end until the copper liquid meets the preset conditions; the slag removal device is configured to perform step S30: after the smelting device has been settling for a first preset time, the surface of the copper liquid is initially removed; it is also configured to perform step S60: after the smelting device has been settling for a second preset time, the surface of the copper liquid is removed a second time to form oxygen-free copper.

[0044] This application also provides a process for preparing oxygen-free copper from recycled copper, using the system for preparing oxygen-free copper from recycled copper described above. The process includes the following steps: S10: adding the pretreated recycled copper into a smelting device and melting the pretreated recycled copper at a temperature of 1300-1350℃ to obtain molten copper.

[0045] S20: Flow rate 300-500m 3 / h, oxygen with a purity ≥99.99% is supplied to the smelting device through the first output end of the oxidation device; S30: after the smelting device is left to stand for a first preset time, the surface of the copper liquid is initially removed for impurities; S50: the flow rate is 400-600m³ / h. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the smelting device through the second output end of the reduction device; S60: after the smelting device is left to stand for a second preset time, the surface of the copper liquid is subjected to secondary impurity removal to form oxygen-free copper.

[0046] This application utilizes the high-temperature thermal energy of the smelting stage to drive the redox reaction, replacing the reduction step that requires additional heating in the traditional process. This achieves efficient reuse of thermal energy and reduces the overall energy consumption and processing cost of the system.

[0047] This application generates metal oxide impurities during the oxidation stage, achieves rapid flotation of the metal oxide impurities through density differences, and removes the metal oxide impurities through a slag removal device; and in the reduction stage, reduces copper oxide and cuprous oxide to copper through chemical reduction, forming a dual removal mechanism combining physicochemical processes, thereby improving the impurity removal rate.

[0048] The reduction device of this application uses carbon monoxide as a reducing agent to generate carbon dioxide in a gaseous state, which can directly escape from the copper liquid without leaving any solid substances. This avoids the carbon pollution problem that may be caused by traditional reducing agents (carbon powder). Furthermore, using carbon monoxide as a reducing agent eliminates the need for carbon monoxide pretreatment, reducing process steps and additional equipment investment.

[0049] The reduction apparatus of this application introduces carbon monoxide through the bottom wall of the smelting device, causing the carbon monoxide gas to rise from the bottom of the molten copper, forming an upward flow path. This prolongs the residence time of the gas in the molten copper, ensuring sufficient contact between the carbon monoxide and the target reactants such as cuprous oxide and copper oxide, thus improving the thoroughness of the reduction reaction. Simultaneously, the rising carbon monoxide gas forms microbubbles, which stir the molten copper, breaking up any possible temperature or compositional stratification within the copper and promoting contact between unreacted target reactants and carbon monoxide. Furthermore, it evenly distributes the carbon dioxide generated in the reaction, preventing localized reaction stagnation.

[0050] This application utilizes a slag removal device to perform initial slag removal before the reduction stage, which can quickly remove a large amount of oxide slag floating on the surface, reduce impurity interference in the subsequent reduction stage, and significantly improve the purity of the final product. Attached Figure Description

[0051] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0052] Figure 1 A schematic diagram of the overall structure of the system for preparing oxygen-free copper from recycled copper provided in this embodiment;

[0053] Figure 2 This is a cross-sectional view of the smelting apparatus provided in this embodiment;

[0054] Figure 3 This is a bottom view of the smelting apparatus provided in this embodiment;

[0055] Figure 4 This is a top view of the smelting apparatus provided in this embodiment;

[0056] Figure 5 This is a schematic diagram of the process for preparing oxygen-free copper from recycled copper provided in this embodiment;

[0057] Figure 6 This is a schematic diagram of the reduction stage of the process for preparing oxygen-free copper from recycled copper provided in this embodiment.

[0058] Figure label:

[0059] 1-Smelting device; 2-Oxidation device; 3-Reduction device; 4-Slag removal device; 5-Oxygen content detection device; 6-Oxide volume detection device; 7-Magnetic separator; 8-Vibrating screen; 9-Deoxygenation device; 11-First air inlet; 12-Second air inlet; 13-Third air inlet; 14-Sampling output port; 15-Three-way valve; 21-First output end; 31-Second output end; 32-Third output end; 91-Fourth output end. Detailed Implementation

[0060] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0061] In the description of this application, it should be noted that the terms "vertical", "up", "down", "horizontal", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0062] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0063] Currently, industrial processes for preparing oxygen-free copper from recycled copper often use charcoal and natural gas as reducing agents, which have drawbacks such as easy introduction of impurities, long process steps, and high equipment investment. Therefore, this embodiment provides a system for preparing oxygen-free copper from recycled copper, such as... Figures 1-4 As shown, it includes:

[0064] The smelting apparatus 1 is configured to perform step S10: adding the pretreated recycled copper into the smelting apparatus 1 and melting the pretreated recycled copper at a temperature of 1300-1350°C, so as to ensure that the recycled copper is completely melted to form copper liquid through high-temperature smelting.

[0065] Oxidation device 2 has a first output terminal 21, which is connected to the interior of smelting device 1. Oxidation device 2 is configured to perform step S20: increasing the flow rate to 300-500 m³ / h. 3 / h, oxygen with a purity ≥99.99% is delivered to the interior of the smelting device 1 through the first output end 21, so that impurity metals (such as Fe, Zn) are preferentially oxidized to form oxide slag (such as FeO, Fe2O3, ZnO);

[0066] The reduction device 3 has multiple second output terminals 31, which are connected to the interior of the smelting device 1 through the bottom wall of the smelting device 1. The reduction device 3 is configured to perform step S50: to increase the flow rate of 400-600 m³ / h. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the inside of the smelting device 1 through the second output end 31, so that the carbon monoxide reacts with cuprous oxide and copper oxide in the copper liquid to produce copper and carbon dioxide;

[0067] The slag removal device 4 is configured to perform step S40: after the smelting device 1 has been settling for a first preset time, the oxidized slag (such as FeO, Fe2O3, ZnO) on the surface of the copper liquid is initially removed to improve the initial purity of the copper liquid; and is also configured to perform step S60: after the smelting device 1 has been settling for a second preset time, the remaining slag on the surface of the copper liquid is removed a second time to form oxygen-free copper.

[0068] The first preset time is 10-15 minutes, and the second preset time is 10-30 minutes.

[0069] Specifically, the slag removal device is a slag removal rake, but it is not limited to this.

[0070] This embodiment utilizes the high-temperature thermal energy of the smelting stage to drive the oxidation-reduction reaction, replacing the reduction step that requires additional heating in the traditional process. This achieves efficient reuse of thermal energy and reduces the overall energy consumption of the system.

[0071] In this embodiment, metal oxide impurities are generated during the oxidation stage. The metal oxide impurities are rapidly floated up by the density difference and removed by the slag removal device 4. During the reduction stage, the reduction effect of carbon monoxide is used to reduce copper oxide and cuprous oxide, forming a dual removal mechanism that combines physicochemical processes, thereby improving the impurity removal rate.

[0072] In this embodiment, the carbon dioxide generated after the reduction device 3 is fed with carbon monoxide for reduction reaction is gaseous and can directly escape from the copper liquid without leaving any solid residue, thus avoiding the carbon pollution problem that may be caused by traditional reducing agents (carbon powder).

[0073] In this embodiment, the reduction apparatus 3 introduces carbon monoxide through the bottom wall of the melting apparatus 1, causing the carbon monoxide gas to rise from the bottom of the molten copper, forming an upward flow path. This prolongs the residence time of the gas in the molten copper, ensuring sufficient contact between the carbon monoxide and the target reactants such as cuprous oxide and copper oxide, thus improving the thoroughness of the reduction reaction. Simultaneously, the rising carbon monoxide gas forms microbubbles, stirring the molten copper and breaking up any potential temperature or compositional stratification within the copper. This promotes contact between unreacted target reactants and carbon monoxide, while also evenly distributing the generated carbon dioxide, preventing localized reaction stagnation.

[0074] In this embodiment, the slag removal device 4 performs initial slag removal before the reduction stage, which can quickly remove a large amount of oxide slag floating on the surface, reduce the interference of impurities in the subsequent reduction stage, and greatly improve the purity of the final product.

[0075] like Figures 1-2 As shown, in one embodiment, the system for preparing oxygen-free copper from recycled copper further includes a pretreatment device, which includes a magnetic separator 7 and a vibrating screen 8;

[0076] The magnetic separator 7 is configured to perform step S01: add recycled copper to the magnetic separator 7 and perform magnetic separation under a magnetic induction intensity > 8500 Gauss to remove ferromagnetic impurities from the recycled copper;

[0077] The vibrating screen 8 is configured to perform step S02: add the recycled copper after removing ferromagnetic impurities to the vibrating screen 8, screen and separate the non-copper particles in the recycled copper, and obtain the pretreated recycled copper.

[0078] Specifically, the pretreatment unit is equipped with a conveying device, which (not shown in the figure) transports the recycled copper from the outlet of the magnetic separator 7 to the inlet of the vibrating screen 8.

[0079] This embodiment pre-treats the recycled copper to remove ferromagnetic impurities (such as Fe and Ni), preventing iron impurities from dissolving and contaminating the molten copper during subsequent smelting, and reducing the amount of iron oxide slag generated during the smelting process. Furthermore, a vibrating screen 8 physically separates non-metallic inclusions, removing non-conductive impurities such as plastics, rubber, and sand, providing a more uniform copper material for subsequent smelting and reducing impurity interference during the smelting process.

[0080] like Figures 1-2 As shown, in one embodiment, the system for preparing oxygen-free copper from recycled copper further includes a deoxygenation device 9, which has a fourth output terminal 91 connected to the interior of the smelting apparatus 1. The deoxygenation device 9 is configured to perform step 30 before step S40: adjusting the flow rate to 300-500 m³ / s. 3 / h, nitrogen gas with a purity of ≥99.99% is delivered to the interior of the smelting device 1 through the fourth output terminal 91.

[0081] In this embodiment, an oxygen removal device 9 is set up to replace the residual oxygen in the smelting device 1 with nitrogen, forming an inert atmosphere protective layer to prevent secondary oxidation of the copper liquid and to create conditions for the subsequent reduction reaction.

[0082] Specifically, the bottom wall of the smelting device 1 is provided with a third air inlet 13, and the fourth output end 91 is connected to the third air inlet 13, and nitrogen is transported to the inside of the smelting device 1 through the third air inlet 13.

[0083] like Figure 1 and Figure 3 As shown, in one embodiment, the bottom wall of the smelting apparatus 1 is provided with a plurality of first air inlets 11 corresponding to a plurality of second output ends 31, and the second output ends 31 are connected to the interior of the smelting apparatus 1 through the first air inlets 11.

[0084] The first air inlet 11 is inclined at 15°-30° relative to the horizontal direction, and multiple first air inlets 11 are arranged circumferentially along the bottom wall of the melting device 1, and the inclination direction of the multiple first air inlets 11 is consistent.

[0085] Specifically, multiple first air inlets 11 are arranged around the outside of the third air inlet 13.

[0086] In this embodiment, by setting an inclined first air inlet 11, gas enters the melting device 1 at a tangential velocity, forming a spiral upward airflow. This allows the gas to fully contact the molten copper, significantly enhancing the contact efficiency between the gas and the molten copper, prolonging the reaction time between the gas and the molten copper, and improving the reaction effect.

[0087] Secondly, this embodiment ensures that the multiple first air inlets 11 are evenly distributed circumferentially to avoid excessively strong or weak local airflow. Furthermore, the multiple first air inlets 11 are inclined in the same direction to ensure that the gas diffuses symmetrically in the melting device 1, thereby eliminating the bottom dead zone and achieving uniform gas distribution in the inner cavity of the melting device 1.

[0088] Furthermore, in this embodiment, the first air inlet 11 has an inclination angle greater than 15° relative to the horizontal direction, which increases the tangential velocity component of the gas, helps to form a stronger spiral airflow, and enhances the contact frequency between the copper liquid surface and the gas. At the same time, the inclination angle of the first air inlet 11 relative to the horizontal direction is less than 30°, which prolongs the residence time of the gas in the melting device 1, avoids premature gas escape due to excessive swirling, and further prolongs the reaction time between the gas and the copper liquid.

[0089] like Figures 1-2 As shown, in one embodiment, a three-way valve 15 is provided at the first air inlet 11, and the three-way valve 15 is connected to the first air inlet 11, the first output terminal 21 and the second output terminal 31 respectively.

[0090] Step S20 includes: adjusting the valve of the three-way valve 15 to connect the first air inlet 11 with the first output end 21, thereby increasing the flow rate to 300-500 m³ / h. 3 / h, oxygen with a purity ≥99.99% is delivered to the interior of the smelting device 1 through the first output end 21 and the first air inlet 11;

[0091] Step S50 includes: adjusting the valve of the three-way valve 15 to connect the first air inlet 11 with the second output end 31, thereby increasing the flow rate to 400-600 m³ / h. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the inside of the smelting device 1 through the second output end 31 and the first air inlet 11.

[0092] In this embodiment, by having the first output terminal 21 and the second output terminal 31 share the first air inlet 11 for gas delivery, it ensures that the impurity metals in the copper liquid react fully with oxygen to generate oxide slag, while also ensuring that the copper oxide and cuprous oxide in the copper liquid react fully with carbon monoxide to generate copper and carbon dioxide, which helps to improve the impurity removal rate; at the same time, it simplifies the structure of the smelting device 1 and reduces the production and manufacturing cost.

[0093] like Figure 4 As shown, in one embodiment, the reduction device 3 has a plurality of third output terminals 32, which are disposed on the side wall of the melting device 1 and communicate with the interior of the melting device 1. Step S50 includes: increasing the flow rate to 400-600 m³ / s. 3 / h, carbon monoxide with a purity ≥99.9% is delivered to the interior of the smelting device 1 through the second output end 31 and the third output end 32;

[0094] The side wall of the smelting device 1 is provided with a plurality of second air inlets 12 corresponding to a plurality of third output ends 32, and the third output ends 32 are connected to the interior of the smelting device 1 through the second air inlets 12.

[0095] The second air inlet 12 is inclined at 15°-30° relative to the horizontal direction. Multiple second air inlets 12 are arranged circumferentially along the side wall of the smelting device 1, and the inclination direction of the multiple second air inlets 12 is consistent.

[0096] Specifically, the first air inlet 11 and the second air inlet 12 are tilted in the same direction, which ensures that the airflow input from the two air inlets rotates in the same direction, avoiding mutual cancellation of airflow; and the swirling flow in the same direction can superimpose momentum, reducing turbulent dissipation.

[0097] In this embodiment, gas is injected tangentially from the bottom wall through the first air inlet 11 to form a basic vortex, which drives the copper liquid to move upward in a spiral motion and establishes the main circulation flow field. At the same time, gas is supplemented from the side wall through the second air inlet 12 at the same tilt angle to form a secondary vortex layer. Through the cooperation of the first air inlet 11 set on the bottom wall and the second air inlet 12 set on the side wall, the uniformity of the copper liquid vortex intensity in the height direction is maintained, local dead zones are eliminated, and it is ensured that the gas is in uniform contact with the copper liquid in the height direction.

[0098] Furthermore, the beneficial effects of the second air inlet 12 being tilted 15°-30° relative to the horizontal direction in this embodiment are the same as those of the first air inlet 11, and will not be repeated here.

[0099] like Figures 1-2 As shown, in one embodiment, the system for preparing oxygen-free copper from recycled copper also includes a detection device, which includes an oxygen content detection device 5 and an oxide volume detection device 6. A sampling output port 14 is provided on the bottom wall of the smelting device 1. The oxygen content detection device 5 and the oxide volume detection device 6 are used to detect the sample output from the sampling output port 14.

[0100] Step S50 includes: inputting the initial oxygen content data obtained by the oxygen content detection device 5 and the initial furnace bottom oxide volume data output by the oxide volume detection device 6 into the trained machine learning model, and outputting the first flow rate prediction value and the first flow velocity prediction value corresponding to each second output terminal 31, and the second flow rate prediction value and the second flow velocity prediction value corresponding to each third output terminal 32 through the machine learning model. Each second output terminal 31 delivers carbon monoxide with a purity ≥99.9% to the inside of the smelting device 1 with the corresponding first flow rate prediction value and the first flow velocity prediction value, and each third output terminal 32 delivers carbon monoxide with a purity ≥99.9% to the inside of the smelting device 1 with the corresponding second flow rate prediction value and the second flow velocity prediction value.

[0101] For example, in the process of preparing oxygen-free copper from recycled copper, real-time initial oxygen content data and initial furnace bottom oxide volume data are input into a trained machine learning model, and the machine learning model outputs:

[0102] For the second output terminal 31 with odd-numbered serial numbers, both the first flow rate prediction value and the first flow velocity prediction value are 0; for the second output terminal 31 with even-numbered serial numbers, the first flow rate prediction value is 500 m³ / s. 3 / h, the first predicted velocity is 5m / s;

[0103] For the third output terminal 32 with odd-numbered serial numbers, both the second flow rate prediction value and the second flow velocity prediction value are 0; for the third output terminal 32 with even-numbered serial numbers, the second flow rate prediction value is 600m³. 3 / h, the second predicted velocity is 5m / s;

[0104] Each second output terminal 31 delivers carbon monoxide with a purity ≥ 99.9% to the smelting device 1 with a corresponding first flow rate prediction value and a first flow velocity prediction value, and each third output terminal 32 delivers carbon monoxide with a purity ≥ 99.9% to the smelting device 1 with a corresponding second flow rate prediction value and a second flow velocity prediction value.

[0105] Specifically, before step S50, the following steps are included: opening the sampling output port 14 to output a quantitative copper liquid sample, the oxygen content detection device 5 and the oxide volume detection device 6 respectively receiving the copper liquid sample, and the oxygen content detection device 5 detecting the copper oxide and cuprous oxide content based on the copper liquid sample, and the oxide volume detection device 6 detecting the copper oxide and cuprous oxide volume based on the copper liquid sample.

[0106] Specifically, the oxygen content detection device 5 is an X-ray fluorescence spectrometer (XRF).

[0107] Specifically, the oxide volume detection device 6 is a LIBS laser-induced breakdown spectrometer.

[0108] Currently, the adjustment of process parameters in the preparation of oxygen-free copper still relies heavily on manual experience, excessively depending on the operator's theoretical derivation and repeatable experimental verification. This embodiment introduces a machine learning model to establish a quantitative mapping relationship between process parameters and the retention of copper oxide and cuprous oxide, capturing the complex nonlinear correlations between multiple variables during the reduction process. This eliminates reliance on manual experience, achieving full automation of the reduction process, eliminating fluctuations caused by human operation, and improving process stability.

[0109] Furthermore, the compositional fluctuations of recycled copper raw materials (such as impurity element content and oxidation level) lead to significant nonlinear changes in the kinetic characteristics of the reduction process. Traditional control strategies, which use fixed parameter settings, cannot achieve dynamic adaptation to different raw material characteristics, resulting in a narrow process window. In this embodiment, oxygen content detection device 5 and oxide volume detection device 6 continuously feed back oxygen content and oxide volume data and input them into a machine learning model. This enables flow rate prediction based on real-time conditions, dynamically adjusting the process window, and achieving real-time operating condition response.

[0110] Furthermore, by using a machine learning model to predict the flow rate and velocity from each second output terminal 31 and each third output terminal 32, the second output terminal 31 and each third output terminal 32 can transport gas based on the predicted value, thereby achieving global optimization of multi-channel transport parameters, eliminating coupling interference between channels, and realizing spatiotemporal coordination of flow rate and velocity.

[0111] In one embodiment, the machine learning model is constructed in the following way:

[0112] Collect multiple sets of historical processing data, including initial oxygen content, initial furnace bottom oxide volume, preset oxygen content, preset furnace bottom oxide volume, process parameters, and actual processing time. The process parameters include the first flow rate and first velocity value of each second output terminal 31, and the second flow rate and second velocity value of each third output terminal 32.

[0113] The oxygen content difference is calculated based on the initial oxygen content data and the preset oxygen content data, and the furnace bottom oxide volume difference is calculated based on the initial furnace bottom oxide volume data and the preset furnace bottom oxide volume data.

[0114] A sample database was constructed based on the differences in oxygen content, the difference in oxide volume at the bottom of the furnace, process parameters, and actual time consumption for each group.

[0115] The oxygen content difference and the furnace bottom oxide volume difference are used as input features, and the process parameters and actual time consumption are used as target outputs. The preset machine learning algorithm is input for iterative training, and the model parameters are adjusted until the convergence condition is met to form a machine learning model.

[0116] Among the methods for constructing machine learning models, there are also methods such as using Isolation Forest or Z-Score to identify outlier data points in each group of historical processed data and removing those outlier data points, which helps to improve the prediction accuracy of machine learning models.

[0117] The construction of the machine learning model also includes: performing Z-Score standardization on the oxygen content difference and oxide volume difference, and performing Min-Max normalization on the first flow rate value, the first flow velocity value, the second flow rate value, and the second flow velocity value to eliminate dimensional differences.

[0118] The construction of machine learning models also includes: periodically collecting historical processing data of new production (such as processing data of the most recent week), incrementally training the machine learning model based on the historical processing data of new production to update the model parameters and form a new machine learning model.

[0119] This embodiment calculates the difference between initial and preset values ​​(such as oxygen content difference and oxide volume difference), allowing the machine learning model to focus on the necessary adjustment range of oxygen content and oxide volume at the furnace bottom in this process, avoiding the model's overemphasis on initial values ​​due to orders-of-magnitude differences. Simultaneously, the difference feature explicitly expresses the "gap between the current state and the target state," directly mapping the model output (flow rate / velocity) to the process adjustment target. Furthermore, the difference feature changes in real time as the process progresses, enabling the machine learning model to dynamically respond to changes in the process stage and dynamically adjust the flow rate / velocity.

[0120] like Figure 6 As shown, in one embodiment, the machine learning model is configured to perform the following steps:

[0121] Receive initial oxygen content data, initial furnace bottom oxide volume data, preset oxygen content data, and preset furnace bottom oxide volume data;

[0122] The oxygen content difference is calculated based on the initial oxygen content data and the preset oxygen content data, and the furnace bottom oxide volume difference is calculated based on the initial furnace bottom oxide volume data and the preset furnace bottom oxide volume data.

[0123] Based on the oxygen content difference and the furnace bottom oxide volume difference, the predicted process parameters and predicted time are output;

[0124] All predicted time durations are sorted in ascending order, and the predicted process parameters corresponding to the first predicted time duration are taken as the final output.

[0125] The machine learning model provided in this embodiment uses the predicted process parameters with the least prediction time as the final output, which not only achieves the spatiotemporal coordination of flow rate and velocity, but also reduces the production process time and improves production efficiency.

[0126] like Figure 5 As shown, this embodiment also provides a process for preparing oxygen-free copper from recycled copper. Using the system for preparing oxygen-free copper from recycled copper described in any of the above embodiments, the process includes the following steps:

[0127] S10: The pretreated recycled copper is added into the smelting device 1 and melted at a temperature of 1300-1350℃ to obtain molten copper; the high-temperature smelting ensures that the recycled copper is completely melted to form molten copper.

[0128] S20: Flow rate 300-500m 3 / h, oxygen with a purity ≥99.99% is delivered to the interior of the smelting device 1 through the first output end 21 of the oxidation device 2 until the copper liquid meets the preset conditions, so that impurity metals (such as Fe, Zn) are preferentially oxidized to form oxide slag (such as FeO, Fe2O3, ZnO).

[0129] S40: After the smelting device 1 has been left to stand for a first preset time, the oxide slag (such as FeO, Fe2O3, ZnO) on the surface of the copper liquid is initially removed to improve the initial purity of the copper liquid.

[0130] S50: Flow rate 400-600m 3 / h, carbon monoxide with a purity ≥99.9% is transported to the inside of the smelting device 1 through the second output end 31 of the reduction device 3, so that the carbon monoxide reacts with cuprous oxide and copper oxide in the copper liquid to produce copper and carbon dioxide;

[0131] S60: After the smelting device 1 has been left to stand for a second preset time, the remaining slag on the surface of the copper liquid is removed as a second impurity to form oxygen-free copper.

[0132] In one embodiment, S20 includes: converting the flow rate of 300-500m 3 / h, oxygen with a purity ≥99.99% is delivered to the interior of the smelting device 1 through the first output end 21 of the oxidation device 2;

[0133] Sample copper liquid is output through sampling output port 14 every 15 minutes, and the sample copper liquid is detected by atomic absorption spectrometry.

[0134] If the sample copper liquid meets the preset conditions, stop supplying oxygen into the smelting device 1;

[0135] If the sample copper liquid does not meet the preset conditions, oxygen is continuously supplied into the melting device 1 until the sample copper liquid meets the preset conditions.

[0136] The preset conditions are: iron content ≤ 0.004% and zinc content ≤ 0.003% in the copper liquid, to meet the requirements for No. 1 oxygen-free copper in Chinese National Standard GB / T 5231-2012(TU1); or the preset conditions are: iron content ≤ 0.004% and zinc content ≤ 0.005% in the copper liquid, to meet the requirements for No. 2 oxygen-free copper in Chinese National Standard GB / T5231-2012(TU2).

[0137] In one embodiment, the process for preparing oxygen-free copper from recycled copper further includes:

[0138] S01: Add recycled copper to magnetic separator 7 and perform magnetic separation at a magnetic induction intensity > 8500 Gauss to remove ferromagnetic impurities from the recycled copper;

[0139] S02: The recycled copper after removing ferromagnetic impurities is added to the vibrating screen 8 via a conveyor belt to separate non-copper particles from the recycled copper, thus obtaining pretreated recycled copper.

[0140] In one embodiment, the process for preparing oxygen-free copper from recycled copper further includes:

[0141] S30: Flow rate 300-500m 3 / h, nitrogen gas with a purity of ≥99.99% is delivered to the interior of the smelting device 1 through the fourth output end 91 of the deoxygenation device 9.

[0142] Note that the above description is merely a preferred embodiment and the technical principles employed in this application. Those skilled in the art will understand that this application is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of this application. Therefore, although this application has been described in detail through the above embodiments, this application is not limited to the above embodiments. Many other equivalent embodiments may be included without departing from the concept of this application, and the scope of this application is determined by the scope of the appended claims.

[0143] The above description is only a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A system for preparing oxygen-free copper from recycled copper, characterized in that, include: A smelting apparatus, configured to perform step S10: adding pretreated recycled copper into the smelting apparatus and melting the pretreated recycled copper at a temperature of 1300-1350°C to obtain molten copper; An oxidation device having a first output end connected to the interior of the smelting device, the oxidation device being configured to perform step S20: delivering oxygen with a flow rate of 300-500 m³ / h and a purity ≥99.99% to the interior of the smelting device through the first output end; A reduction device having multiple second output terminals, the multiple second output terminals being connected to the interior of the smelting device through the bottom wall of the smelting device, the reduction device being configured to perform step S50: delivering carbon monoxide with a flow rate of 400-600 m³ / h and a purity ≥99.9% to the interior of the smelting device through the second output terminals; The slag removal device is configured to perform step S40: after the smelting device has been left to stand for a first preset time, perform initial impurity removal on the surface of the molten copper; and is also configured to perform step S60: after the smelting device has been left to stand for a second preset time, perform secondary impurity removal on the surface of the molten copper to form oxygen-free copper. The bottom wall of the smelting device is provided with a plurality of first air inlets corresponding to a plurality of second output ends. The second output ends are connected to the interior of the smelting device through the first air inlets. The first air inlets are inclined at 15°-30° relative to the horizontal direction. The plurality of first air inlets are arranged circumferentially along the bottom wall of the smelting device, and the inclination direction of the plurality of first air inlets is consistent. It also includes a detection device, which includes an oxygen content detection device and an oxide volume detection device. The bottom wall of the smelting device is provided with a sampling output port. The oxygen content detection device and the oxide volume detection device are used to detect the sample output from the sampling output port. Step S50 includes: inputting the initial oxygen content data obtained by the oxygen content detection device and the initial furnace bottom oxide volume data output by the oxide volume detection device into the trained machine learning model, and outputting the first flow prediction value and the first flow velocity prediction value corresponding to each of the second output terminals through the machine learning model, and conveying carbon monoxide with a purity ≥99.9% to the inside of the smelting device with the corresponding first flow prediction value and the first flow velocity prediction value.

2. The system for producing oxygen-free copper from recycled copper according to claim 1, characterized in that, The reduction device has multiple third output terminals, which are disposed on the side wall of the smelting device and communicate with the interior of the smelting device. Step S50 includes: conveying carbon monoxide with a flow rate of 400-600 m³ / h and a purity of ≥99.9% to the interior of the smelting device through the second output terminal and the third output terminal. The side wall of the smelting device is provided with a plurality of second air inlets corresponding to the plurality of third output ends, and the third output ends are connected to the interior of the smelting device through the second air inlets; The second air inlet is inclined at 15°-30° relative to the horizontal direction, and multiple second air inlets are arranged circumferentially along the side wall of the melting device, and the inclination direction of the multiple second air inlets is consistent.

3. The system for producing oxygen-free copper from recycled copper according to claim 2, wherein Step S50 further includes: outputting a second flow prediction value and a second flow velocity prediction value corresponding to each of the third output terminals through the machine learning model, and each of the third output terminals conveying carbon monoxide with a purity ≥99.9% to the interior of the smelting device with the corresponding second flow prediction value and second flow velocity prediction value.

4. The system for producing oxygen-free copper from recycled copper according to claim 3, wherein The machine learning model is constructed in the following manner: Collect multiple sets of historical processing data, including initial oxygen content, initial furnace bottom oxide volume, preset oxygen content, preset furnace bottom oxide volume, process parameters, and actual processing time. The process parameters include the first flow rate value and the first flow velocity value of each of the second output terminals, and the second flow rate value and the second flow velocity value of each of the third output terminals. The oxygen content difference is calculated based on the initial oxygen content data and the preset oxygen content data, and the furnace bottom oxide volume difference is calculated based on the initial furnace bottom oxide volume data and the preset furnace bottom oxide volume data. A sample database was constructed based on the differences in oxygen content, the difference in oxide volume at the bottom of the furnace, process parameters, and actual time consumption for each group. The oxygen content difference and the furnace bottom oxide volume difference are used as input features, and the process parameters and actual time consumption are used as target outputs. The preset machine learning algorithm is input for iterative training, and the model parameters are adjusted until the convergence condition is met to form a machine learning model.

5. The system for producing oxygen-free copper from recycled copper according to claim 4, characterized in that, The machine learning model is configured to perform the following steps: Receive the initial oxygen content data, the initial furnace bottom oxide volume data, the preset oxygen content data, and the preset furnace bottom oxide volume data; The oxygen content difference is calculated based on the initial oxygen content data and the preset oxygen content data, and the furnace bottom oxide volume difference is calculated based on the initial furnace bottom oxide volume data and the preset furnace bottom oxide volume data. Based on the oxygen content difference and the furnace bottom oxide volume difference, output each predicted process parameter and predicted time. All predicted time durations are sorted in ascending order, and the predicted process parameters corresponding to the first predicted time duration are taken as the final output.

6. The system for producing oxygen-free copper from recycled copper according to claim 1, wherein A three-way valve is provided at the first air inlet, and the three-way valve is connected to the first air inlet, the first output terminal and the second output terminal respectively; Step S20 includes: adjusting the valve of the three-way valve to connect the first air inlet to the first output end, and delivering oxygen with a flow rate of 300-500 m³ / h and a purity of ≥99.99% to the inside of the smelting device through the first output end and the first air inlet; Step S50 includes: adjusting the valve of the three-way valve to connect the first air inlet to the second output end, and delivering carbon monoxide with a flow rate of 400-600 m³ / h and a purity of ≥99.9% to the inside of the smelting device through the second output end and the first air inlet.

7. The system for producing oxygen-free copper from recycled copper according to claim 1, wherein The system for preparing oxygen-free copper from recycled copper also includes an oxygen removal device. The oxygen removal device has a fourth output end, which is connected to the interior of the smelting device. The oxygen removal device is configured to perform step S30 before step S40: to deliver nitrogen gas with a flow rate of 300-500 m³ / h and a purity of ≥99.99% to the interior of the smelting device through the fourth output end.

8. The system for producing oxygen-free copper from recycled copper according to claim 1, wherein The system for preparing oxygen-free copper from recycled copper also includes a pretreatment device, which includes a magnetic separator and a vibrating screen. The magnetic separator is configured to perform step S01: adding recycled copper to the magnetic separator and performing magnetic separation at a magnetic induction intensity > 8500 Gauss to remove ferromagnetic impurities from the recycled copper; The vibrating screen is configured to perform step S02: adding the recycled copper after removing ferromagnetic impurities to the vibrating screen, screening and separating non-copper particles in the recycled copper, and obtaining pretreated recycled copper.

9. A process for the production of oxygen-free copper from recycled copper, characterized in that, The system for preparing oxygen-free copper using recycled copper according to any one of claims 1 to 8, the process comprising the following steps: S10: Add the pretreated recycled copper into the smelting device and melt the pretreated recycled copper at a temperature of 1300-1350℃ to obtain molten copper. S20: Oxygen with a flow rate of 300-500 m³ / h and a purity of ≥99.99% is supplied through the first output end of the oxidation device to the inside of the smelting device until the copper liquid meets the preset conditions. S40: After the smelting device is left to stand for a first preset time, the surface of the molten copper is initially removed to remove impurities. S50: Carbon monoxide with a flow rate of 400-600 m³ / h and a purity of ≥99.9% is transported to the inside of the smelting device through the second output end of the reduction device; S60: After the smelting device is left to stand for a second preset time, the surface of the copper liquid is subjected to secondary impurity removal to form oxygen-free copper.

Images