Double-reaction-zone copper smelting furnace and method for controlling grade of matte by using same

Abstract

The invention discloses a double-reaction-zone copper smelting furnace and a method for controlling the grade of matte through the double-reaction-zone copper smelting furnace, and belongs to the technical field of heavy metal smelting. Copper concentrate, flux, fuel, auxiliary materials and smoke dust are added into a smelting furnace through a material conveying system via a furnace top feeding port; blowing oxygen-enriched air into the smelting furnace through primary air holes in the two sides of the furnace body for smelting in a molten pool; after smelting is completed, slag and matte are separated, the slag overflows and is discharged, and the matte is discharged through a siphon channel. According to the method, the reaction degree of the copper concentrate in the smelting furnace is controlled by controlling the ratio of oxygen to the copper concentrate in the oxygen-enriched air and adjusting the ratio of oxygen to the copper concentrate, and the needed copper matte products of different grades are produced to be further treated by the converting furnace. And moreover, the double reaction zones are independently controlled to cope with various production working conditions, and finally, the double-side-blown smelting furnace guarantees stable control of the grade of matte produced by the two reaction zones.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of heavy metal smelting, and particularly relates to a double-reaction-zone copper smelting furnace and a method for controlling the matte grade by using the same. BACKGROUND

[0002] At present, the copper pyrometallurgical process mainly includes flash smelting and bath smelting. The traditional bath smelting technology (such as reverberatory furnace and Noranda furnace) has been gradually eliminated due to high energy consumption and poor environmental performance. Although the flash smelting has high efficiency, the process has high requirements for the quality of copper concentrate and high investment cost. In order to adapt to the characteristics of complex and low-grade copper resources in China and meet the requirements of energy saving and emission reduction policies, the double-side blown bath smelting process is independently developed in China. The technology absorbs the advantages of Vanyukov method and Mitsubish method, and has outstanding performance in reaction efficiency, raw material adaptability and environmental performance. It has become one of the important choices for the new smelting plant in the Chinese copper smelting industry.

[0003] As the mainstream process, the double-side blown bath smelting process still has large-scale limitations, and the single furnace capacity is usually ≤300,000 tons / year. Large-scale projects still tend to use flash smelting. In order to overcome the large-scale limitation of the double-side blown bath smelting process, Yunnan Copper adopts the design of “two zones and one chamber” (two smelting reaction zones and one middle slag chamber), which effectively solves the problem of long-distance overflow of smelting slag in the large-scale double-side blown bath smelting process and realizes the breakthrough of 350,000 tons / year in the production capacity of the double-side bath smelting process. However, the design of “two zones and one chamber” has the problem that the process control of the two smelting reaction zones is different, and the grade of the intermediate product white matte fluctuates greatly. Therefore, the existing technology still needs to be improved and developed. SUMMARY

[0004] In order to solve or partially solve the problems in the related art, the present application provides a double-reaction-zone copper smelting furnace and a method for controlling the matte grade by using the same. The problems of the existing new double-side blown smelting furnace, such as the difference between the process controls of the two smelting reaction zones and the great fluctuation of the grade of the intermediate product white matte, are solved.

[0005] The present application provides a method for controlling the matte grade by using a double-reaction-zone copper smelting furnace, which includes the following steps: (1) The copper concentrate, flux, fuel, auxiliary material and flue dust are mixed uniformly in the intermediate bin to obtain a mixture, and then the mixture is added into the reaction zone 1 and the reaction zone 2 of the smelting furnace through the material conveying system from the intermediate bin; (2) Then the oxygen-enriched air is introduced into the smelting furnace through the primary air eye on both sides of the furnace body of the reaction zone 1 and the reaction zone 2, and continuous bath smelting is carried out in the reaction zone 1 and the reaction zone 2; (3) smelting is completed, the slag and the copper matte are separated, the slag is discharged from the slag chamber arranged between the reaction zone 1 and the reaction zone 2, the copper matte is discharged through the siphon arranged on one side of the reaction zone 1 and the reaction zone 2, and the high-temperature SO2 gas generated in the smelting process flows to the waste heat boiler through the flue arranged above the slag chamber.

[0006] Preferably, the flux is quartz sand, quartz stone containing SiO2 or limestone containing CaO; the fuel is coke or lump coal; the auxiliary material is converting slag, anode slag or cold copper matte; and the dust is waste heat boiler dust or electric dust.

[0007] Preferably, the oxygen volume concentration in the oxygen-enriched air is 65%-92%.

[0008] Preferably, the primary air eyes on both sides of the furnace body of the reaction zone 1 and the reaction zone 2 adopt a separate air supply mode.

[0009] Preferably, the relationship between the total material mass of the copper concentrate, the flux, the fuel, the auxiliary material and the dust and the oxygen-enriched air flow is as follows: (1); wherein M is a given amount of the mixed material in the reaction zone 1 or the reaction zone 2, in ton / hour; Q is the oxygen-enriched air flow in the reaction zone 1 or the reaction zone 2, in Nm 3 / hour; is the oxygen concentration of the oxygen-enriched air in the reaction zone 1 or the reaction zone 2; Y is a given value of the oxygen-material ratio in the reaction zone 1 or the reaction zone 2, in Nm 3 / ton; x is the mass ratio of the fuel dry basis to the copper concentrate in the mixed material in the reaction zone 1 or the reaction zone 2; a is the oxygen consumption per ton of fuel dry basis, in Nm 3 / ton; H is the water content of the fuel; y is the mass content of the flux SiO2 or CaO to the mass of the copper concentrate in the mixed material in the reaction zone 1 or the reaction zone 2; N is the mass fraction of SiO2 or CaO in the flux; and b is the mass ratio of the dust to the mass of the copper concentrate in the mixed material in the reaction zone 1 or the reaction zone 2.

[0010] The oxygen-material ratio is the ratio of oxygen to the copper concentrate.

[0011] A double-reaction-zone copper smelting furnace comprises a copper concentrate batching bin, a flux batching bin, a fuel batching bin, an auxiliary material batching bin, a dust batching bin, a 1# intermediate bin, a 2# intermediate bin, a reaction zone 1, a reaction zone 2 and a slag chamber. The copper concentrate batching bin, the flux batching bin, the fuel batching bin, the auxiliary material batching bin and the smoke dust batching bin are connected with the 1# intermediate bunker and the 2# intermediate bunker; the 1# intermediate bunker is connected with the reaction zone 1, and the 2# intermediate bunker is connected with the reaction zone 2; the slag chamber is located in the middle of the reaction zone 1 and the reaction zone 2 and is communicated with the reaction zone 1 and the reaction zone 2; one side of the furnace body of the reaction zone 1 and the reaction zone 2 is respectively provided with a primary air eye; two overflow ports are arranged on one side of the furnace body of the slag chamber, and a flue gas port is arranged on the upper portion of the furnace body of the slag chamber; one side of the reaction zone 1 and the reaction zone 2 is respectively provided with a siphon port.

[0012] Preferably, the primary air eye air supply system is arranged on both sides of the furnace body of the reaction zone 1 and the reaction zone 2, the primary air eye air supply system arranged on both sides of the furnace body of the reaction zone 1 and the reaction zone 2 adopts a separate air supply mode, and the two sets of air supply systems are respectively provided with a valve group and a flow meter to control the air inlet amount of the primary air eye.

[0013] Preferably, the copper concentrate batching bin, the flux batching bin, the fuel batching bin, the auxiliary material batching bin and the smoke dust batching bin are mixed by a belt conveyor and then transferred to the 1# intermediate bunker and the 2# intermediate bunker, and then the 1# intermediate bunker and the 2# intermediate bunker are respectively conveyed to the reaction zone 1 and the reaction zone 2 through the belt conveyor and then discharged into the furnace through the furnace top discharge port.

[0014] The belt conveyor for conveying the 1# intermediate bunker and the 2# intermediate bunker to the reaction zone 1 and the reaction zone 2 is respectively provided with an electronic belt scale or a distributed control system to control the material amount through formula (1).

[0015] The technical scheme provided by the application has the following beneficial effects: (1) The separate air supply mode of the double reaction zones can determine the actual air supply condition of the reaction zone 1 and the reaction zone 2, and meanwhile, in the implementation process, if a device fault (such as a feeding system fault) or a production condition fluctuation occurs in a reaction zone, the single control of the reaction zone 1 and the reaction zone 2 can be realized, so as to guarantee the stability and the controllability of the production process of the double-side blown smelting furnace.

[0016] (2) The double reaction zone feeding mode can realize the stability and the controllability of the raw material composition of the double reaction zones under the condition that one set of batching system is shared, can significantly reduce the investment cost and the production site, and meanwhile, the setting of the intermediate bunker can provide a certain redundancy for the fault of the batching system, for example, if a small fault occurs in the batching bin, the equipment fault can be eliminated under the condition that the position of the intermediate bunker is controlled, without affecting the production of the side blown smelting furnace, so as to guarantee the production stability of the side blown smelting furnace.

[0017] (3) The synergistic control model of the double reaction zone production can realize the individual control of the double reaction zone to cope with various production conditions. Due to the large-scale of the furnace of the double reaction zone, the actual amount of oxygen-enriched air entering the reaction zone may be reduced or fluctuated due to the sticking of the primary air eye in the production process. The double-zone control model can adjust the feed amount according to the real-time air volume to ensure the appropriate proportion of oxygen-enriched air and material, so as to control the oxidation-reduction reaction intensity and degree of copper concentrate, fuel, and oxygen-enriched air, and finally realize the stable control of the matte grade of the two reaction zones of the double-side blown smelting furnace. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 is a production schematic diagram of a double reaction zone copper smelting furnace.

[0019] Figure 2 is a schematic diagram of a double-zone individual air supply mode of a double reaction zone copper smelting furnace.

[0020] Figure 3 is a schematic diagram of a feed mode of a double reaction zone copper smelting furnace. DETAILED DESCRIPTION

[0021] Example 1 A double reaction zone copper smelting furnace, comprising a copper concentrate batching bin, a flux batching bin, a fuel batching bin, an auxiliary material batching bin, a smoke dust batching bin, a 1# intermediate bin, a 2# intermediate bin, a reaction zone 1, a reaction zone 2, and a slag chamber. The copper concentrate batching bin, the flux batching bin, the fuel batching bin, the auxiliary material batching bin, and the smoke dust batching bin are connected with the 1# intermediate bin and the 2# intermediate bin through belt conveyors.

[0022] The 1# intermediate bin is connected with the reaction zone 1 through a belt conveyor, and the 2# intermediate bin is connected with the reaction zone 2 through a belt conveyor. The belt conveyors from the 1# intermediate bin and the 2# intermediate bin to the reaction zone 1 and the reaction zone 2 are respectively provided with an electronic belt scale or a distributed control system to control the amount of material.

[0023] The slag chamber is located in the middle of the reaction zone 1 and the reaction zone 2, and is in communication with the reaction zone 1 and the reaction zone 2. A hollow partition wall is arranged between the slag chamber and the reaction zone 1 and the reaction zone 2, and only smelting slag and matte can pass through. One primary air eye is arranged on each side of the furnace body of the reaction zone 1 and the reaction zone 2; overflow ports are arranged on both sides of the furnace body of the slag chamber, and a flue gas port is arranged on the upper part of the furnace body of the slag chamber; one siphon port is arranged on one side of the reaction zone 1 and the reaction zone 2. The primary air eye is immersed in the melt in the reaction zone 1 and the reaction zone 2.

[0024] Preferably, the reaction zone 1 and the reaction zone 2 furnace body are provided with a primary air eye air supply system, and the primary air eye air supply system provided on the two sides of the reaction zone 1 and the reaction zone 2 furnace body adopts a separate air supply mode, and the two sets of air supply systems are respectively provided with a valve group and a flow meter to control the air inlet amount of the primary air eye.

[0025] Preferably, the copper concentrate batching bin, the flux batching bin, the fuel batching bin, the auxiliary material batching bin and the smoke dust batching bin are transported to the 1# intermediate bin and the 2# intermediate bin after compounding by the belt conveyor, and then the 1# intermediate bin and the 2# intermediate bin are respectively conveyed to the reaction zone 1 and the reaction zone 2 by the belt conveyor respectively and then enter the furnace through the furnace top discharge port.

[0026] Example 2 The matte grade is cooperatively controlled by using the double-reaction-zone copper smelting furnace of Example 1, including the following steps: (1) In the present application, the oxygen coke ratio, the fuel rate, the flux rate, the auxiliary material rate and the smoke dust rate are empirical constants; under the given oxygen material ratio, the primary air eye air supply system obtains the pure oxygen amount in the oxygen-rich air through the flow meter and the oxygen concentration, and then the relationship between the amounts of the copper concentrate, the flux, the fuel, the auxiliary material and the smoke dust is known, and then the calculated amounts of the copper concentrate, the flux, the fuel, the auxiliary material and the smoke dust are put into the 1# intermediate bin and the 2# intermediate bin to mix uniformly to obtain the mixed material.

[0027] Reaction zone 1: oxygen-rich air flow 20000 Nm 3 / h, oxygen concentration of oxygen-rich air is 80%, given oxygen material ratio is 180 Nm 3 / t, oxygen coke ratio is 900 Nm 3 / t, fuel (coke) rate is 2.5%, fuel water content is 10%, flux (quartzite) rate is 3.1%, flux SiO2 content is 70%, auxiliary material (blowing slag) rate is 4%, smoke dust (boiler dust) rate is 2%. The target output white matte grade is 75%.

[0028] Reaction zone 2: oxygen-rich air flow 18000 Nm 3 / h, oxygen concentration of oxygen-rich air is 80%, given oxygen material ratio is 180 Nm 3 / t, oxygen coke ratio is 900 Nm 3 / t, fuel (coke) rate is 2.5%, fuel water content is 10%, flux (quartzite) rate is 3.1%, flux SiO2 content is 70%, auxiliary material (blowing slag) rate is 4%, smoke dust (boiler dust) rate is 2%.

[0029] (2) But in the smelting process, the flow and concentration of oxygen-enriched air are dynamically changing, therefore, the primary air supply system obtains the pure oxygen amount in the oxygen-enriched air through the flow meter and oxygen concentration, and obtains the matched material amount under the specific oxygen amount through the following mathematical control model under the given oxygen-to-material ratio, and gives the matched material amount to the feeding system, then the feeding system puts the total amount of the mixed material calculated by the mathematical model in the 1# and 2# intermediate bins into the reaction zone 1 and the reaction zone 2. The mathematical control model is as follows: ; M is the given amount of mixed material in the reaction zone 1 or the reaction zone 2 (unit: ton / hour); Q is the flow of oxygen-enriched air in the reaction zone 1 or the reaction zone 2 (unit: Nm 3 / hour); is the oxygen concentration of oxygen-enriched air in the reaction zone 1 or the reaction zone 2; Y is the given value of oxygen-to-material ratio (oxygen to copper concentrate ratio) in the reaction zone 1 or the reaction zone 2 (unit: Nm 3 / ton); x is the ratio of fuel (dry basis) to copper concentrate (fuel rate) in the mixed material in the reaction zone 1 or the reaction zone 2; a is the oxygen consumption per ton of fuel (dry basis) (oxygen coke ratio, unit: Nm 3 / ton); H is the water content of fuel; y is the ratio of the content of flux (SiO2 or CaO) to the mass of copper concentrate (flux rate) in the mixed material in the reaction zone 1 or the reaction zone 2; N is the mass fraction of SiO2 or CaO in the flux; z is the ratio of the mass of auxiliary material to the mass of copper concentrate (auxiliary material rate) in the mixed material in the reaction zone 1 or the reaction zone 2; b is the ratio of the mass of flue dust to the mass of copper concentrate (flue dust rate) in the mixed material in the reaction zone 1 or the reaction zone 2.

[0030] ​(3) The above material parameters are given to the feedback control algorithm of the industrial control system of the feeding system, and the total material amount of reaction zone 1 is 88.4 t / h and the total material amount of reaction zone 2 is 79.5 t / h through the PID control adjustment system output obtained by the mathematical model in step (2); then the amounts of each material in reaction zone 1 and reaction zone 2 are calculated according to the amounts of copper concentrate, flux, fuel, auxiliary material and smoke dust in 1# intermediate bin and 2# intermediate bin in step (1), wherein, reaction zone 1: the amount of copper concentrate is 78.0 t / h, the amount of fuel is 2.2 t / h, the amount of flux is 3.5 t / h, the amount of cold material is 3.1 t / h, the amount of smoke dust is 1.6 t / h, and the total material amount is 88.4 t / h. Reaction zone 2: the amount of copper concentrate is 70.2 t / h, the amount of fuel is 2.0 t / h, the amount of flux is 3.1 t / h, the amount of cold material is 2.8 t / h, the amount of smoke dust is 1.4 t / h, and the total material amount is 79.5 t / h. The above copper concentrate, flux, fuel, auxiliary material and smoke dust are added into reaction zone 1 and reaction zone 2 of the smelting furnace through the material conveying system and the furnace top feeding port, so that the feeding amount of reaction zone 1 reaches the set value 88.4 t / h quickly and stably, and the feeding amount of reaction zone 2 reaches the set value 79.5 t / h quickly and stably.

[0031] (4) While the material enters the furnace, the oxygen-enriched air is introduced into the smelting furnace through the primary air eye on both sides of the furnace body of reaction zone 1 and reaction zone 2, and the melt smelting is carried out in reaction zone 1 and reaction zone 2.

[0032] (5) After smelting, the slag and the copper matte are separated, the slag is discharged from the slag chamber arranged in the middle of reaction zone 1 and reaction zone 2, the copper matte is discharged through the siphon arranged on one side of reaction zone 1 and reaction zone 2, and the gas generated in the smelting process is discharged through the flue gas port arranged above the slag chamber after being cooled and dedusted.

[0033] When the actual wind amount entering reaction zone 1 of the side-blown smelting furnace is reduced to 19000 Nm 3 / h due to the coking of the primary air eye, if the control model provided by the present application is not adopted, the total material amount of reaction zone 1 is still 88.4 t / h, and the grade of the produced copper matte is reduced to 71.4±1%. According to steps (1) and (2), the material parameters given to the industrial control system of the feeding system are adjusted by the cooperative control model, so that the feeding amount of reaction zone 1 is quickly adjusted: reaction zone 1: the amount of copper concentrate is 74.1 t / h, the amount of fuel is 2.1 t / h, the amount of flux is 3.3 t / h, the amount of cold material is 3.0 t / h, the amount of smoke dust is 1.5 t / h, and the total material amount is stably controlled to 83.9 t / h, which guarantees the oxygen and copper concentrate ratio and controls the oxidation and reduction degree of the mixed material and oxygen, and the grade of the produced copper matte product is still controlled at the target grade of 75±1%.

[0034] Example 3 The copper smelting furnace of the double reaction zones of Example 1 is used to cooperatively control the matte grade, including the following steps: (1) In the present application, the oxygen coke ratio, fuel rate, flux rate, auxiliary material rate, and dust rate are empirical constants; under the given oxygen material ratio, the pure oxygen amount in the oxygen-rich air is obtained by the flow meter and oxygen concentration of the primary air eye air supply system, and then the amount relationship between the copper concentrate, flux, fuel, auxiliary material, and dust is known, and then the calculated amounts of the copper concentrate, flux, fuel, auxiliary material, and dust are mixed evenly into the 1# intermediate bin and the 2# intermediate bin to obtain the mixed material.

[0035] Reaction zone 1: oxygen-rich air flow 20000 Nm 3 / h, oxygen concentration of oxygen-rich air 80%, given oxygen material ratio 180 Nm 3 / t, oxygen coke ratio 900 Nm 3 / t, fuel (coke) rate 2.5%, fuel water content 10%, flux (quartzite) rate 3.1%, flux SiO2 content 70%, cold material (converting slag) rate 4%, dust (boiler dust) rate 2%. The target output white matte grade is 75%.

[0036] Reaction zone 2: oxygen-rich air flow 18000 Nm 3 / h, oxygen concentration of oxygen-rich air 80%, given oxygen material ratio 180 Nm 3 / t, oxygen coke ratio 900 Nm 3 / t, fuel rate 2.5%, fuel water content 10%, flux rate 3.1%, flux SiO2 content 70%, cold material rate 4%, dust rate 2%.

[0037] (2) However, during the smelting process, the oxygen-rich air flow and concentration are dynamically changing, therefore, the pure oxygen amount in the oxygen-rich air is obtained by the flow meter and oxygen concentration of the primary air eye air supply system, and under the given oxygen material ratio, the matching material amount under the specific oxygen amount is obtained by the following mathematical control model, and the matching material amount is given to the material supply system, and then the total amount of the mixed material calculated by the mathematical model in the 1# intermediate bin and the 2# intermediate bin is entered into the reaction zone 1 and the reaction zone 2 by the material supply system. The mathematical control model is as follows: ; M is the given amount of the mixed material in the reaction zone 1 or the reaction zone 2 (unit: ton / hour); Q is the oxygen-rich air flow in the reaction zone 1 or the reaction zone 2 (unit: Nm 3 / hour); is the oxygen concentration of the oxygen-rich air in the reaction zone 1 or the reaction zone 2; Y is the given value of the oxygen material ratio (oxygen to copper concentrate ratio) in the reaction zone 1 or the reaction zone 2 (unit: Nm 3 ​(ton); x is the ratio of fuel (dry basis) to copper concentrate (fuel rate) in the mixture of reaction zone 1 or reaction zone 2; a is the oxygen consumption per ton of fuel (dry basis) (oxygen coke ratio, unit: Nm 3 (ton); H is the water content of the fuel; y is the ratio of flux (SiO2 or CaO) content to copper concentrate mass (flux rate) in the mixture of reaction zone 1 or reaction zone 2; N is the mass fraction of SiO2 or CaO in the flux; z is the ratio of auxiliary material mass to copper concentrate mass (auxiliary material rate) in the mixture of reaction zone 1 or reaction zone 2; b is the ratio of dust mass to copper concentrate mass (dust rate) in the mixture of reaction zone 1 or reaction zone 2.

[0038] (3) The above material parameters are given to the feedback control algorithm of the industrial control system of the feeding system, and the total material amount of reaction zone 1 is 88.4 t / h and the total material amount of reaction zone 2 is 79.5 t / h through PID control adjustment system output, which is obtained by mathematical model in step (2); then according to the amount of copper concentrate, flux, fuel, auxiliary material and dust in 1# intermediate bin and 2# intermediate bin in step (1), the amount of each material in reaction zone 1 and reaction zone 2 is calculated, wherein, reaction zone 1: copper concentrate amount is 78.0 t / h, fuel amount is 2.2 t / h, flux amount is 3.5 t / h, cold material amount is 3.1 t / h, dust amount is 1.6 t / h, total material amount is 88.4 t / h. Reaction zone 2: copper concentrate amount is 70.2 t / h, fuel amount is 2.0 t / h, flux amount is 3.1 t / h, cold material amount is 2.8 t / h, dust amount is 1.4 t / h, total material amount is 79.5 t / h. The above copper concentrate, flux, fuel, auxiliary material and dust are respectively added into reaction zone 1 and reaction zone 2 of the smelting furnace through the material conveying system and the furnace top charging port, so that the feeding amount of reaction zone 1 reaches the set value 88.4 t / h quickly and stably, and the feeding amount of reaction zone 2 reaches the set value 79.5 t / h quickly and stably.

[0039] (4) At the same time when the material enters the furnace, the oxygen-enriched air is respectively introduced into the smelting furnace through the primary air eye drums on both sides of the furnace body of reaction zone 1 and reaction zone 2, and the smelting of the melt is carried out in reaction zone 1 and reaction zone 2.

[0040] (5) After the smelting is completed, the slag and the copper matte are separated, the slag is discharged from the slag chamber overflow arranged in the middle of reaction zone 1 and reaction zone 2, the copper matte is discharged through the siphon arranged at the side of reaction zone 1 and reaction zone 2, and the gas generated in the smelting process is discharged through the flue gas port arranged above the slag chamber after being cooled and dedusted.

[0041] When the side-blown smelting furnace reaction zone 1 is caused to be blocked by the primary air eye, the actual air volume entering the reaction zone 1 is reduced to 18830 Nm 3 / h, if the control model provided by the present application is not adopted, the total material volume of the reaction zone 1 is still 88.4 t / h, and because the actual proportion of oxygen and copper concentrate changes, the produced matte grade is reduced to 70.9±1%. According to steps (1) and (2), the present application cooperates with the control model to monitor the material parameters adjusted to the industrial control system of the feeding system, so that the feeding volume of the reaction zone 1 is quickly adjusted: the copper concentrate volume of the reaction zone 1 is 73.5 t / h, the fuel volume is 2.0 t / h, the flux volume is 3.3 t / h, the cold material volume is 2.9 t / h, the dust volume is 1.5 t / h, and the total material volume is stably controlled to 83.2 t / h, which guarantees the oxygen and copper concentrate proportion and controls the oxidation and reduction degree of the mixed material and oxygen, and the produced matte product grade is still controlled at the target grade of 75±1%.

[0042] Example 4 The matte grade cooperation control of the double-reaction-zone copper smelting furnace in example 1 is adopted, including the following steps: In the present application, the oxygen coke ratio, fuel rate, flux rate, auxiliary material rate, and dust rate are empirical constants; under the given oxygen material ratio, the primary air eye air supply system obtains the pure oxygen volume in the oxygen-enriched air through the flow meter and oxygen concentration, and then the relationship between the volumes of the copper concentrate, flux, fuel, auxiliary material, and dust is known, and then the calculated volumes of the copper concentrate, flux, fuel, auxiliary material, and dust are mixed uniformly in the 1# and 2# intermediate bins to obtain the mixed material.

[0043] Reaction zone 1: oxygen-enriched air flow 20000 Nm 3 / h, oxygen-enriched air oxygen concentration is 80%, and the given oxygen material ratio is 180 Nm 3 / t, oxygen coke ratio is 900 Nm 3 / t, fuel (coke) rate is 2.5%, fuel water content is 10%, flux (quartzite) rate is 3.1%, flux SiO2 content is 70%, cold material (converting slag) rate is 4%, and dust (boiler dust) rate is 2%. The target output white matte grade is 75%.

[0044] Reaction zone 2: oxygen-enriched air flow 18000 Nm 3 / h, oxygen-enriched air oxygen concentration is 80%, and the given oxygen material ratio is 180 Nm 3 / t, oxygen coke ratio is 900 Nm 3 / t, fuel rate is 2.5%, fuel water content is 10%, flux rate is 3.1%, flux SiO2 content is 70%, cold material rate is 4%, and dust rate is 2%.

[0045] (2) But in the smelting process, the flow and concentration of oxygen-enriched air are dynamically changing, therefore, the primary air supply system obtains the pure oxygen amount in the oxygen-enriched air through the flow meter and oxygen concentration, and obtains the matched material amount under the specific oxygen amount through the following mathematical control model under the given oxygen-to-material ratio, and gives the matched material amount to the feeding system, then the feeding system puts the total amount of the mixed material calculated by the mathematical model in the 1# and 2# intermediate bins into the reaction zone 1 and the reaction zone 2. The mathematical control model is as follows: ; M is the given amount of mixed material in the reaction zone 1 or the reaction zone 2 (unit: ton / hour); Q is the flow of oxygen-enriched air in the reaction zone 1 or the reaction zone 2 (unit: Nm 3 / hour); is the oxygen concentration of oxygen-enriched air in the reaction zone 1 or the reaction zone 2; Y is the given value of oxygen-to-material ratio (oxygen to copper concentrate ratio) in the reaction zone 1 or the reaction zone 2 (unit: Nm 3 / ton); x is the ratio of fuel (dry basis) to copper concentrate (fuel rate) in the mixed material in the reaction zone 1 or the reaction zone 2; a is the oxygen consumption per ton of fuel (dry basis) (oxygen to coke ratio, unit: Nm 3 / ton); H is the water content of fuel; y is the ratio of the content of flux (SiO2 or CaO) to the mass of copper concentrate (flux rate) in the mixed material in the reaction zone 1 or the reaction zone 2; z is the ratio of the mass of auxiliary material to the mass of copper concentrate (auxiliary material rate) in the mixed material in the reaction zone 1 or the reaction zone 2; N is the mass fraction of SiO2 or CaO in the flux; b is the ratio of the mass of flue dust to the mass of copper concentrate (flue dust rate) in the mixed material in the reaction zone 1 or the reaction zone 2.

[0046] ​(3) The above material parameters are given to the feedback control algorithm of the industrial control system of the feeding system, and the total material amount of reaction zone 1 is 88.4 t / h and the total material amount of reaction zone 2 is 79.5 t / h through the PID control adjustment system output in step (2); then the amounts of each material in reaction zone 1 and reaction zone 2 are calculated according to the amounts of copper concentrate, flux, fuel, auxiliary material and dust in 1# intermediate bin and 2# intermediate bin in step (1), wherein, reaction zone 1: the amount of copper concentrate is 78.0 t / h, the amount of fuel is 2.2 t / h, the amount of flux is 3.5 t / h, the amount of cold material is 3.1 t / h, the amount of dust is 1.6 t / h, and the total material amount is 88.4 t / h. Reaction zone 2: the amount of copper concentrate is 70.2 t / h, the amount of fuel is 2.0 t / h, the amount of flux is 3.1 t / h, the amount of cold material is 2.8 t / h, the amount of dust is 1.4 t / h, and the total material amount is 79.5 t / h. The above copper concentrate, flux, fuel, auxiliary material and dust are added into reaction zone 1 and reaction zone 2 of the smelting furnace through the material conveying system and the furnace top charging port respectively, so that the feeding amount of reaction zone 1 reaches the set value 88.4 t / h quickly and stably, and the feeding amount of reaction zone 2 reaches the set value 79.5 t / h quickly and stably.

[0047] (4) While the material is entering the furnace, the oxygen-enriched air is blown into the smelting furnace through the primary air eyes on both sides of the furnace body of reaction zone 1 and reaction zone 2, and the smelting of the melt is carried out in reaction zone 1 and reaction zone 2.

[0048] (5) After the smelting is completed, the slag and the copper matte are separated, the slag is discharged from the slag chamber arranged in the middle of reaction zone 1 and reaction zone 2, the copper matte is discharged through the siphon arranged on one side of reaction zone 1 and reaction zone 2, and the gas generated in the smelting process is discharged through the flue gas port arranged above the slag chamber after being cooled and dedusted.

[0049] The oxygen-to-material ratio of reaction zone 2 of the side-blown smelting furnace needs to be reduced from 180 Nm 3 / t to 175 Nm 3 / t, according to steps (1) and (2), the material parameters given to the industrial control system of the feeding system are adjusted by the cooperative control model, so that the feeding amount of reaction zone 2 is quickly adjusted: the amount of copper concentrate in reaction zone 2 is 72 t / h, the amount of fuel is 2.0 t / h, the amount of flux is 3.2 t / h, the amount of cold material is 2.9 t / h, the amount of dust is 1.4 t / h, and the total material amount is quickly adjusted and stably controlled from 79.5 t / h to 81.5 t / h, the oxygen-to-material ratio is quickly adjusted, the oxidation and reduction degree of the mixed material and oxygen is controlled, and the grade of the produced copper matte product quickly returns to the control requirement of 75±1%.

[0050] Having described various embodiments of the application, it is to be understood that the above description is meant to be illustrative only and not exhaustive, and is not limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art, without departing from the scope and spirit of the described embodiments. The choice of words in this document is intended to best explain the principles of the embodiments, the practical application, or improvement over the technology in the art, or to enable other ordinary skilled in the art to understand the embodiments disclosed herein.

Claims

1. A method of controlling matte grade using a dual reaction zone copper smelting furnace, characterized by: It comprises the following steps: (1) the copper concentrate, flux, fuel, auxiliary materials and dust are mixed evenly in the intermediate bin through the material conveying system to obtain the mixed material, and then the mixed material is added into the reaction zone 1 and the reaction zone 2 of the smelting furnace through the material conveying system; (2) then the oxygen-enriched air is introduced into the smelting furnace through the primary air eye on both sides of the furnace body of the reaction zone 1 and the reaction zone 2, and continuous smelting is carried out in the reaction zone 1 and the reaction zone 2; (3) after the smelting is completed, the slag and the copper matte are separated, the slag is discharged from the slag chamber arranged in the middle of the reaction zone 1 and the reaction zone 2, the copper matte is discharged through the siphon arranged at the side of the smelting furnace, and the high-temperature gas generated in the smelting process is discharged through the flue gas port arranged above the slag chamber.

2. The method of controlling matte grade using a dual reaction zone copper smelting furnace according to claim 1, characterized in that: The flux is quartz sand, quartz stone or limestone; the fuel is coke or lump coal; the auxiliary material is blowing slag, anode slag or cold copper matte; and the dust is waste heat boiler dust or electric dust.

3. The method of controlling matte grade using a dual reaction zone copper smelting furnace as recited in claim 1, wherein: The oxygen volume fraction in the oxygen-enriched air is 65%-92%.

4. The method of controlling matte grade using a dual reaction zone copper smelting furnace of claim 1, wherein: The primary air eye on both sides of the furnace body of the reaction zone 1 and the reaction zone 2 adopts a separate air supply mode.

5. The method of controlling matte grade using a dual reaction zone copper smelting furnace of claim 1, wherein: The relationship between the mass of the mixed material added into the reaction zone 1 or the reaction zone 2 in step (1) and the flow of the oxygen-enriched air in step (2) is: ； Wherein, M is the given amount of mixture in reaction zone 1 or reaction zone 2, unit: ton / hour; Q is the oxygen-enriched air flow rate in reaction zone 1 or reaction zone 2, unit: Nm 3 / hour; is the oxygen concentration of oxygen-enriched air in reaction zone 1 or reaction zone 2; Y is the given value of oxygen-material ratio in reaction zone 1 or reaction zone 2, unit: Nm 3 / ton; x is the mass ratio of dry fuel to copper concentrate in the mixture in reaction zone 1 or reaction zone 2; a is the oxygen consumption per ton of dry fuel, unit: Nm 3 / ton; H is the water content of fuel; y is the mass content ratio of flux SiO2 or CaO to copper concentrate in the mixture in reaction zone 1 or reaction zone 2; N is the mass fraction of SiO2 or CaO in the flux; z is the mass ratio of auxiliary materials to copper concentrate in the mixture in reaction zone 1 or reaction zone 2; b is the mass ratio of flue dust to copper concentrate in the mixture in reaction zone 1 or reaction zone 2.

6. A dual reaction zone copper smelting furnace characterized by: It comprises a copper concentrate batching bin, a flux batching bin, a fuel batching bin, an auxiliary material batching bin, a dust batching bin, a 1# intermediate bin, a 2# intermediate bin, a reaction zone 1, a reaction zone 2 and a slag chamber. The copper concentrate batching bin, the flux batching bin, the fuel batching bin, the auxiliary material batching bin and the dust batching bin are connected with the 1# intermediate bin and the 2# intermediate bin; the 1# intermediate bin is connected with the reaction zone 1, and the 2# intermediate bin is connected with the reaction zone 2; the slag chamber is arranged in the middle of the reaction zone 1 and the reaction zone 2 and is communicated with the reaction zone 1 and the reaction zone 2; a primary air eye is arranged on each side of the furnace body of the reaction zone 1 and the reaction zone 2; two overflow ports are arranged on one side of the furnace body of the slag chamber, a flue gas port is arranged on the upper part of the furnace body of the slag chamber, and a siphon port is arranged at the side of the reaction zone 1 and the reaction zone 2.

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