Method for improving physical specification of positive plate in copper pyrometallurgy

Abstract

The invention relates to a method for improving the physical specification of a positive plate in copper pyrometallurgy. The method for improving the physical specification of the positive plate in copper pyrometallurgy comprises the following cooperatively executed steps: a tundish pouring step: controlling a tundish to pour copper liquid according to a preset rotation angle and rotation speed, and setting clockwise pouring parameters and anticlockwise pouring parameters in a differentiated manner; a casting ladle pouring step: controlling the casting ladle to rotate according to a preset time track, wherein the track comprises rotating the casting ladle to a critical position in a first time length, rotating the casting ladle to a limit position in a second time length and returning the casting ladle to a starting position in a third time length; a disc operation step: controlling the disc casting machine to operate according to a preset symmetric uniform angular acceleration curve, including accelerating to a maximum angular velocity at a first angular acceleration and then decelerating to stop at a second angular acceleration; according to the method for improving the physical specification of the positive plate in copper pyrometallurgy, generation of flashes and burrs can be reduced, waste plates are reduced, and the physical specification of the positive plate is improved.

Description

Technical Field

[0001] This invention belongs to the field of non-ferrous metal metallurgy technology, specifically relating to a method for improving the physical specifications of anode plates in copper pyrometallurgical processes. Background Technology

[0002] Pyrometallurgical copper smelting is an important copper smelting process used to extract pure copper from copper-containing raw materials. In this process, the disc casting system plays a crucial role, casting molten copper into copper plates or other shapes. The operational status of the disc casting system directly affects the efficiency of the entire smelting process and the quality of the finished product.

[0003] Currently, with the increasing market demand for high-quality copper products, copper pyrometallurgical enterprises are also facing higher requirements for production efficiency and energy consumption. Traditional disc casting systems have a relatively simple structural design, but limited load-bearing capacity and stability. Because disc casting systems need to bear the weight of a large amount of molten copper during operation, traditional designs often cannot meet the requirements of high-load operation, leading to problems such as low acceleration and unstable operation.

[0004] CN105499549A discloses an automatic quantitative casting control system and method for copper anode plates. This patent proposes an automatic quantitative casting control system that uses a PLC controller to collect casting ladle weight information and generate control signals to ensure that the casting speed follows a set trajectory. The invention analyzes the control process of the disc casting machine control system from a hardware development perspective through qualitative analysis of each movement stage of the casting curve. However, this invention does not deeply analyze the internal mechanism of the casting curve formation, and it essentially falls under the problem of setting a quantitative casting curve, failing to form a closed-loop circuit.

[0005] Because molten copper requires a certain speed and force to flow out, traditional drive systems often cannot meet the requirements for rapid response and increased acceleration. This means that the molten copper flows out of the disc slowly, affecting casting efficiency and prolonging the production cycle. Some disc casting systems may become unstable due to unreasonable structural design or external factors. This can lead to uneven flow of molten copper during the casting process, or even fluctuations or shaking, affecting the forming quality of the copper plate.

[0006] Therefore, there is an urgent need to propose a new method to improve the optimal rotation angle, acceleration, and casting time of the disc casting system in copper pyrometallurgical processes, thereby increasing production efficiency, reducing energy consumption, minimizing equipment wear, and promoting the sustainable development of the copper smelting industry. Summary of the Invention

[0007] The purpose of this invention is to solve the problem of unstable copper flow and high burr generation rate caused by mismatched action parameters of multiple motion units such as tundish, casting ladle, and disc casting machine in the existing copper anode plate casting process.

[0008] This invention provides a casting control method to improve the physical specifications of anode plates in copper pyrometallurgical processes. Its core lies in the coordinated optimization of parameters for three key actions: tundish tilting, ladle pouring, and disc rotation, forming a matched dynamic control window.

[0009] The method includes the following steps: controlling the intermediate ladle to pour molten copper according to differentiated preset parameters; controlling the casting ladle to rotate according to a preset time trajectory including critical positions, limit positions, and return times; and controlling the disc casting machine to run according to a preset symmetrical uniform angular acceleration curve. Through the coordinated setting of these parameters, the sloshing of molten copper throughout the casting process is effectively reduced.

[0010] Preferably, the tundish tilts clockwise at an angle of 25.0°–28.0°, at a speed of 12.0°–14.0° / s, with a period of 5.5–6.5s; and counterclockwise at an angle of 28.0°–31.0°, at a speed of 14.0°–16.0° / s, with a period of 5.5–6.5s. Preferably, the casting ladle takes 3.0–4.0s to rotate to the 6.0° critical position, 5.5–6.5s to reach the 14.0°–15.0° limit position, and 12.0–13.0s to return to the starting position. Preferably, the disk's uniform angular acceleration is 0.3–0.6° / s², the acceleration / deceleration phase lasts 6.0–7.0s, the maximum speed is 3.0–3.5° / s, and the period is 12.0–14.0s.

[0011] Furthermore, to adapt to changes in operating conditions, the method of the present invention may also include an adaptive optimization step: dynamically fine-tuning the above-mentioned action parameters based on real-time sensor data and machine learning models.

[0012] Furthermore, in pursuit of ultimate flatness, a non-uniform angular velocity curve based on the derivative of trigonometric functions can be used in the main casting stage of the casting ladle.

[0013] The beneficial effects of this invention are as follows: By controlling the clockwise and counterclockwise rotation angles, rotation speeds, and casting time of the tundish, as well as the time it takes for the casting ladle to reach the critical and limit angles for pouring molten copper, the invention improves the stability of the molten copper after pouring. Furthermore, by adjusting the angular velocity of the disc casting machine during startup acceleration, deceleration to stop, and cycle time, the invention reduces the generation of flash and burrs on the positive plates. Adopting these preferred solutions can reduce the generation of flash and burrs, reduce scrap, and improve the physical specifications of the positive plates. Attached Figure Description

[0014] Figure 1This is a schematic diagram of the copper liquid level during the rotation of the disc casting machine of the present invention; Figure 2 This is a schematic diagram of the angular velocity model of the disc casting machine of the present invention; Figure 3 This is a schematic diagram of the intermediate tundish rotation according to the present invention; Figure 4 This is a schematic diagram of the casting ladle rotating according to the present invention. Detailed Implementation

[0015] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0016] Comprehensive reference Figures 1 to 4 The diagram shows the structure. Specifically, the purpose of this invention is to provide a method for optimizing the rotation angle, acceleration, and casting time of the casting system and disc casting system in copper pyrometallurgical processes, thereby improving production efficiency and saving energy.

[0017] During the rotation of the disc casting machine, due to the acceleration and deceleration phases, the original horizontal copper molten surface in the mold will become an inclined surface. The maximum height difference Δh formed by the copper molten surface during this process determines the maximum height of the flash, burrs, and local ripples on the formed anode plate. The running acceleration corresponding to the mold is denoted as 'a'. Taking the center of the copper molten surface as the origin of the coordinate system, the positive x-axis is the same as the direction of motion, the y-axis is the corresponding parallel and perpendicular direction, the z-axis is positive upwards, and g is the acceleration due to gravity. 't' is the working cycle time of the copper disc casting machine. With a production capacity of 80 t / h, t ≤ 17 s can be calculated.

[0018] The angular velocity model of the disc casting machine is as follows: Figure 2 As shown, the acceleration phase lasts for t1 seconds, the constant speed phase lasts for t2 seconds, and the deceleration phase lasts for t3 seconds. During the operation of the disc casting machine, the magnitudes of the acceleration and deceleration phases are the same, but the directions are opposite. The copper disc casting machine starts with an angular acceleration of 0.49 / s², and after an acceleration phase of 6.78 seconds, it reaches a maximum speed of 3.32 / s. Then, it decelerates with an angular acceleration of 0.49 / s², and the disc stops after another 6.78 seconds. The entire operation takes 13.56 seconds.

[0019] It should be noted that the burr rate of anode plates = number of anode plates with burrs / total number of anode plates.

[0020] Example 1 A method for improving the physical properties of anode plates in copper pyrometallurgical processes. 1) A total of 416 tons of crude copper was produced in the converter. After oxidation-reduction refining in the anode furnace, the molten copper was injected into the tundish. 2) The tundish rotates 25.2° clockwise at a speed of 12.6° / s, maintains the tilt angle for casting, and then quickly returns to the initial position after 3.0s. The entire clockwise rotation casting time is 6.7s. 3) The tundish rotates 28.0° counterclockwise at a speed of 14.0° / s, maintains the tilt angle for casting, and then quickly returns to the initial position after 3.0s. The entire counterclockwise rotation casting time is 6.5s. 4) The casting ladle rotates 6.0° in 3.2s to reach the critical position for pouring molten copper. At 6.0s, the casting ladle reaches the limit position of 14.0°, and at 12.0s, the casting ladle reaches the starting position. 5) The disc casting machine starts and accelerates with an angular acceleration of 0.3 / s². After an acceleration phase of 7.0s, it reaches a maximum speed of 3.0° / s. Then it decelerates with an angular acceleration of 0.3 / s². The disc stops after 7.0s. The entire process takes 14.0s. 6) The burr rate of the anode plates in this furnace is 12.4%, which is 22.6% lower than before optimization.

[0021] Example 2 1) A total of 446 tons of crude copper was produced in the converter. After oxidation-reduction refining in the anode furnace, the molten copper was injected into the tundish. 2) The tundish rotates 26° clockwise at a speed of 13° / s, maintains the tilt angle for casting, and then quickly returns to the initial position after 2.6s. The entire clockwise rotation casting time is 6.3s. 3) The tundish rotates 28.5° counterclockwise at a speed of 14.5° / s, maintains the tilt angle for 2.6s for casting, and then quickly returns to the initial position. The entire counterclockwise rotation casting time is 6.3s. 4) The casting ladle rotates 6.0° in 3.4s to reach the critical position for pouring molten copper. At 6.2s, the casting ladle reaches the limit position of 14.0°, and at 12.2s, the casting ladle reaches the starting position. 5) The disc casting machine starts and accelerates with an angular acceleration of 0.4 / s². After an acceleration phase of 6.7s, it reaches a maximum speed of 3.2° / s. Then it decelerates with an angular acceleration of 0.4 / s². The disc stops after 6.7s. The entire process takes 13.4s. 6) The burr rate of the anode plates in this furnace is 10.7%, which is 24.3% lower than before optimization.

[0022] Example 3 1) A total of 402 tons of crude copper was produced in the converter. After oxidation-reduction refining in the anode furnace, the molten copper was injected into the tundish. 2) The tundish rotates 26.8° clockwise at a speed of 13.4° / s, maintains the tilt angle for casting, and then quickly returns to the initial position after 3.0s. The entire clockwise rotation casting time is 6.0s. 3) The tundish rotates 29.6° counterclockwise at a speed of 14.8° / s, maintains the tilt angle for casting, and then quickly returns to the initial position after 2.4s. The entire counterclockwise rotation casting time is 6.0s. 4) The casting ladle rotates 6.0° in 3.6 seconds to reach the critical position for pouring molten copper. At 6.6 seconds, the casting ladle reaches the limit position of 14.0°, and at 12.6 seconds, the casting ladle reaches the starting position. 5) The disc casting machine starts and accelerates with an angular acceleration of 0.5 / s². After an acceleration phase of 6.4s, it reaches a maximum speed of 3.4° / s. Then it decelerates with an angular acceleration of 0.5 / s². The disc stops after 6.4s. The entire process takes 12.8s. 6) The burr rate of the anode plates in this furnace is 13.8%, which is 21.2% lower than before optimization.

[0023] Example 4 1) A total of 427 tons of crude copper was produced in the converter. After oxidation-reduction refining in the anode furnace, the molten copper was injected into the tundish. 2) The tundish rotates 27.6° clockwise at a speed of 13.8° / s, maintains the tilt angle for casting, and then quickly returns to the initial position after 2.5s. The entire clockwise rotation casting time is 5.5s. 3) The tundish rotates counterclockwise by 30.2° at a speed of 15.1° / s, maintains the tilt angle for casting, and then quickly returns to the initial position after 2.2s. The entire counterclockwise rotation casting time is 5.5s. 4) The casting ladle rotates 6.0° in 3.8s to reach the critical position for pouring molten copper. At 6.6s, the casting ladle reaches the limit position of 14.0°, and at 13.0s, the casting ladle reaches the starting position. 5) The disc casting machine starts and accelerates with an angular acceleration of 0.6 / s2. After an acceleration phase of 6.0s, it reaches a maximum speed of 3.5° / s. Then it decelerates with an angular acceleration of 0.6 / s2. The disc stops after 6.0s. The entire process takes 12s. 6) The burr rate of the anode plates in this furnace is 8.7%, which is 26.3% lower than before optimization.

[0024] Example 5 In summary, embodiments 1-4 above provide the most basic implementation of the present invention, namely, controlling the casting process through a set of static, collaboratively optimized parameters that have been verified through extensive experiments. This embodiment will summarize these findings.

[0025] Intermediate tundish tilting control: Operators set parameters in the central control system.

[0026] When choosing to tilt clockwise, the settings are: angle 26.0°, speed 13.0° / s, hold the pouring position after reaching the target, and then quickly return after 2.5 seconds, with a total cycle of approximately 6.0 seconds.

[0027] When choosing to tilt counterclockwise, the settings are: angle 29.5°, speed 15.0° / s, hold the pouring position after reaching the target, and then quickly return after 2.5 seconds, with a total cycle of approximately 6.0 seconds.

[0028] The inventors discovered that using a slightly larger angle and speed counterclockwise can better match the direction of the incoming flow, reducing impact splashes.

[0029] Casting ladle pouring control: After receiving material from the tundish, the casting ladle moves according to the preset time trajectory.

[0030] The servo system controls its rotation, precisely reaching the critical position of 6.0° in 3.5 seconds (when the copper liquid begins to flow out steadily).

[0031] Continue rotating until the 14.5° limit position is reached (main casting completed) after a total time of 6.0s.

[0032] It then returned smoothly, arriving back at the 0° starting position in a total time of 12.5 seconds.

[0033] Operation control of the disc casting machine: The disc adopts a symmetrical uniform angular acceleration curve.

[0034] It starts with an angular acceleration of 0.45° / s² and reaches a maximum angular velocity of 3.25° / s after 6.5 seconds of acceleration.

[0035] Immediately decelerate at an angular acceleration of -0.45° / s², and stop after 6.5 seconds. The total operation time for one station is 13.0 seconds.

[0036] By controlling this curve, the height difference Δh of the molten copper in the mold due to inertia is controlled within the theoretically calculated safe range.

[0037] Results: Continuous production using these parameters showed that the average burr rate of anode plates was 11.5%, a decrease of 31.5% compared to the historical average of 16.8% before optimization, and the pass rate of physical specifications of anode plates was significantly improved.

[0038] Example 6 This embodiment integrates an intelligent sensing and decision-making system on top of the hardware and basic parameters of embodiment 5.

[0039] New system additions: Sensing module: An infrared thermometer is installed below the casting flow, and a high-speed camera is installed above the disk.

[0040] Intelligent Decision Module: Deploys a trained XGBoost model. The training data comes from historical production data, and features include: copper melt temperature, servo motor current fluctuations in the casting ladle, and burr ratings from the previous board's visual inspection, with tags indicating parameter adjustment suggestions.

[0041] Control execution module: Upgrades the PLC program and receives the output from the decision module.

[0042] Workflow: When casting the Nth plate, the system collects the real-time temperature T. N The burr index S is obtained by analyzing the image of the (N-1)th plate. {N-1} . (T) N , S {N-1} Input the equipment runtime into the XGBoost model. Model output: Tundish speed fine-tuning coefficient +5%, disk acceleration fine-tuning coefficient -3%. When the PLC executes the casting of the Nth plate, it adjusts the tundish speed from 13.0° / s to 13.65° / s, and the disk acceleration from 0.45° / s² to 0.4365° / s², while keeping other parameters unchanged.

[0043] Results: In a month-long comparative test, the standard deviation of the burr rate of the anode plates of the production line with adaptive optimization was reduced by 60% compared with the production line using only fixed optimization parameters (Example 5). The quality stability was significantly improved in an unexpected way, proving the effectiveness of the technology integration.

[0044] Example 7 This embodiment focuses on optimizing the motion trajectory of the casting ladle in Embodiment 5.

[0045] During the main casting stage, as the ladle rotates from 6° (critical position) to 14.5° (limit position), simple uniform or uniformly accelerated motion is not used. Instead, it is controlled according to the following angular velocity curve: ω(t) = ω max * [1 - cos(π * t / T)] / 2, where t is the relative time within this stage (0 ≤ t ≤ T), T is the total time of this stage (e.g., 2.5 s), and ω max The peak angular velocity is obtained by converting the required average angular velocity calculated based on the casting volume.

[0046] This curve allows for a smooth change in angular acceleration (derivative is 0) during the start-up and shutdown of the casting ladle, while the angular velocity is higher in the middle stage. Surprisingly, this kinematic design gives the copper molten stream excellent cohesion and landing stability, with almost no visible splashing.

[0047] Results: With other conditions fixed (intermediate ladle and disk parameters the same as in Example 5), by simply replacing the casting ladle trajectory with the composite trajectory of this example, the flash and burr rate further decreased sharply from 11.5% in Example 5 to 4.2%, achieving a leap in performance. This nonlinear quality improvement achieved through specific kinematic equations exceeds the conventional expectations of those skilled in the art.

[0048] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A method of improving the physical size of the anode in copper pyrometallurgy, characterized in that, The method comprises the following steps which are cooperatively executed: a tundish pouring step of controlling the tundish to pour the copper liquid at a preset rotation angle and rotation speed, wherein the clockwise pouring parameters are different from the counterclockwise pouring parameters; a casting ladle pouring step of controlling the casting ladle to rotate according to a preset time trajectory, the trajectory comprising rotating to a critical position for a first time length, rotating to a limit position for a second time length, and returning to a starting position for a third time length; a disc running step of controlling the disc casting machine to run according to a preset symmetrical uniform angular acceleration curve, comprising accelerating to a maximum angular velocity at a first angular acceleration, and decelerating to a stop at a second angular acceleration. The action parameters of the tundish pouring step, the casting ladle pouring step and the disc running step are cooperatively optimized to reduce the shaking of the copper liquid during the casting process and reduce the flash burrs of the anode plate.

2. A method of improving the physical size of the anode in copper pyrometallurgy according to claim 1, characterized in that: In the tundish pouring step: the rotation angle of clockwise pouring is 25.0°-28.0°, the rotation speed is 12.0°-14.0° / s, and the whole clockwise action period is 5.5-6.5s; the rotation angle of counterclockwise pouring is 28.0°-31.0°, the rotation speed is 14.0°-16.0° / s, and the whole counterclockwise action period is 5.5-6.5s.

3. A method of improving the physical size of the anode in copper pyro-metallurgy according to claim 1, characterized in that: In the casting ladle pouring step: the first time length for rotating to the 6.0° critical position is 3.0-4.0s; the total second time length for rotating to the 14.0°-15.0° limit position is 5.5-6.5s; the total third time length for returning to the starting position is 12.0-13.0s.

4. A method of improving the physical size of the anode plate in copper pyro- metallurgical smelting according to claim 1, characterized in that: In the disc running step: the first angular acceleration and the second angular acceleration are both 0.3-0.6° / s²; the duration of the acceleration phase and the deceleration phase is both 6.0-7.0s; the maximum angular velocity is 3.0-3.5° / s; the whole running period is 12.0-14.0s.

5. A method of improving the physical size of the anode in copper pyro-metallurgy according to any one of claims 1 to 4, characterized in that: The method further comprises an adaptive tuning step: real-time acquisition of sensing data representing the current casting conditions; inputting the sensing data into a pre-trained machine learning model to obtain real-time fine-tuning instructions for at least one action parameter in the tundish pouring step, the casting ladle pouring step and / or the disc running step; performing the next casting cycle according to the real-time fine-tuning instructions.

6. A method of improving the physical size of the anode in copper pyrometallurgy according to claim 5, characterized in that: The sensing data includes at least one of the real-time temperature of the copper liquid and the image features of the anode plate surface.

7. A method of improving the physical size of the anode in copper pyro-metallurgy according to any one of claims 1 to 4, characterized in that: In the casting ladle pouring step, during the main pouring phase from the critical position to the limit position, the angular velocity of the casting ladle changes according to a predetermined non-uniform angular velocity curve based on the derivative of a trigonometric function.

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