Non-ferrous metal smelting extended-range nonlinear strengthening waste heat recovery device and method

Abstract

The invention relates to the technical field of non-ferrous metal metallurgy high-temperature flue gas waste heat recovery and energy conservation, and discloses a non-ferrous metal metallurgy range-extending type non-linear strengthening waste heat recovery device and a non-ferrous metal metallurgy range-extending type non-linear strengthening waste heat recovery method. The multi-stage grid array type flow guide device comprises a fence type baffle plate and a nail head fin baffle plate; the method comprises the steps that equal-proportion modeling is carried out on the non-ferrous metal smelting range-extending type nonlinear strengthening waste heat recovery device, and local grid encryption is carried out on main internal parts and a water cooling wall; the flow track and the temperature change process of flue gas and particles in the waste heat recovery device are simulated; according to waste heat recovery devices of different sizes and styles, the positions of a fence type baffle and a nail head fin baffle, the plate oblique angle size and the nail head angle and length are changed, and the smoke temperature and the particle deposition rate of the surface of the heat exchanger are extracted. According to the invention, a safe, economical and green integrated waste heat recovery scheme can be obtained.

Description

Technical Field

[0001] This invention relates to the field of high-temperature flue gas waste heat recovery and energy-saving technology in non-ferrous metallurgy, and particularly to a range-extended nonlinear enhanced waste heat recovery device and method for non-ferrous metal smelting. Specifically, it relates to a waste heat recovery device and method that induces the flue gas to form a range-extended vortex flow by setting up grid-type baffles and nail-head fin baffles in the radiant chamber of a waste heat boiler, thereby enhancing heat transfer in a nonlinear manner, reducing flue gas temperature, and reducing ash accumulation in heat exchangers. This invention is particularly applicable to the working conditions where high-temperature dust-laden flue gas generated in non-ferrous metal smelting systems such as copper, lead, zinc, and nickel (e.g., flash furnaces, side-blown / top-blown furnaces, reduction furnaces, etc.) is used in conjunction with vertical or horizontal waste heat boilers, achieving efficient recovery of flue gas waste heat and reducing energy consumption. Background Technology

[0002] Non-ferrous metal smelting processes generate large amounts of high-temperature, dust-laden flue gas. To recover the heat energy carried by this gas, waste heat boilers are often installed after the smelting furnace to generate steam. However, traditional waste heat boilers suffer from low heat exchange efficiency and high exhaust gas temperature due to structural and flow limitations. On the one hand, the flue gas at the smelting furnace outlet often exhibits a strong jet or vortex pattern, resulting in significant differences in flue gas velocity and temperature distribution across the boiler cross-section. When flue gas from multiple smelting furnaces or multiple flues converges, localized "high-speed channels" and "low-speed dead zones" often coexist, causing extremely uneven heating and wear of the tube bundles. On the other hand, in the high-speed flue gas channel region, the high flue gas velocity and high dust concentration cause strong scouring and erosion of the heated tube bundles, easily forming so-called "channeling" and even leading to tube bundle wear and leakage. In the low-speed dead zone, the low flue gas velocity and weak vortex allow dust to remain and adhere for extended periods, easily inducing slagging and dust accumulation, causing local blockages and further deteriorating heat transfer. Furthermore, the uneven flow of high-temperature, dust-laden flue gas within the boiler leads to insufficient heat transfer in localized areas. In direct flow mode, the contact and disturbance between the flue gas and the heated surfaces are limited, restricting the potential for improving the heat transfer coefficient. This results in higher exhaust gas temperatures, insufficient waste heat utilization, and reduced energy recovery efficiency. These problems significantly reduce the effective heating area of ​​the waste heat boiler, leading to a decrease in overall heat exchange efficiency and frequent tube bundle failures. Simultaneously, uneven heat exchange causes drastic fluctuations in the temperature and flow rate of the flue gas entering the acid production system, affecting the stable operation of the acid production section. To improve heat exchange efficiency, several heat transfer enhancement measures have been applied to boilers and heat exchangers, such as increasing the heat exchange area (e.g., installing finned tubes) and using flow-disrupting elements like spiral baffles or twisted bands. These traditional enhancement methods can improve the heat transfer coefficient to some extent, but often exhibit linear or near-linear effects, requiring a significant increase in equipment complexity or flow resistance to achieve limited heat transfer improvements. In high-temperature, dust-laden flue gas environments, many delicate structures (such as small-pitch fins) are easily covered or worn by dust, limiting their practical application. Therefore, there is an urgent need to develop a new flow guiding structure and system suitable for waste heat boilers in non-ferrous metal smelting, which can achieve uniform flow distribution at multiple scales, reduce the risk of slagging and erosion, and significantly improve waste heat recovery efficiency.

[0003] Prior art 1, application number 202411677292.2, discloses a low-temperature waste heat recovery system for acid production from non-ferrous smelting flue gas, belonging to the field of acid production and waste heat recovery technology. It solves the technical problems of poor efficiency and high cost in existing acid production and waste heat recovery systems. This low-temperature waste heat recovery system for acid production from non-ferrous smelting flue gas includes a high-temperature absorption tower, an evaporator, a deoxygenated water heater, a deaerator, and a demineralized water heater. The high-temperature absorption tower has a first packing layer and a second packing layer inside. A first spray absorption system is installed above the first packing layer, and a second spray absorption system is installed above the second packing layer. An air inlet is provided on the high-temperature absorption tower. The lower end of the high-temperature absorption tower is connected to a high-temperature circulation tank via a recovery pipe. The high-temperature circulation tank is connected to a high-temperature circulating acid pump via a pipe. The high-temperature circulating acid pump is connected to the sulfuric acid inlet of the evaporator via a pipe. While it has the advantages of improving acid production and waste heat recovery, and reducing operating costs, it does not specifically address the problem of heat exchange efficiency degradation caused by particulate matter deposition in high-temperature flue gas. During long-term operation, dust adhering to the heat exchange surface will significantly reduce heat transfer performance, increase maintenance frequency and energy consumption. It lacks an active enhancement mechanism for flue gas flow and heat exchange processes, relying on static packing and spraying, which is insufficient for flue gas turbulence disturbance, and has limited adaptability to high-dust, high-temperature smelting flue gas.

[0004] Prior art 2, application number 202011473897.1, discloses a waste heat utilization system and method for a metallurgical air separation system. Addressing the issue that existing air separation centrifugal air compressors waste a large amount of heat energy during the cooling process using a cooling water system, while the electrolyte in the non-ferrous smelting electrolysis process requires a large amount of saturated steam heating, and the electrolyte heating temperature is only around 63 degrees Celsius, the following solution is proposed: a three-stage heat recovery system and a four-stage heat recovery system. The three-stage heat recovery system includes an air filter, and the four-stage heat recovery system includes an air separation compressor connected to a check valve, which in turn is connected to a circulating pump. While fully utilizing the waste heat generated by the air separation compressor to meet the heating needs of non-ferrous smelting electrolyte and replace low-pressure saturated steam can enable non-ferrous enterprises to save energy and reduce consumption, the waste heat recovery scenario is limited, only targeting the waste heat of the air separation system and not covering the deep recovery of core high-temperature flue gas in smelting (such as radiation chambers and convection chambers). It does not involve the synergistic optimization of flue gas purification and heat exchange, and in particular, it lacks the design for controlling the deposition of dust-laden flue gas during the heat exchange process, making it difficult to directly apply to the high-dust-load smelting flue gas environment.

[0005] The prior art 3, application number 202110923109.2, discloses a method for capturing mercury from sulfur-containing and mercury-containing flue gas by mercury chloride-selenium deposition, including the following steps: (1) After the non-ferrous smelting raw flue gas is dusted and waste heat recovered, a certain amount of water mist is sprayed into it to lower its temperature to near the dew point, so that the selenium dioxide in the flue gas is reduced to active elemental selenium that can react rapidly with mercury in the flue gas under the combined action of sulfur dioxide and water vapor, and under the action of HCl in the flue gas, a mercury chloride-selenium compound that is easy to be deposited is generated; (2) Then the flue gas is brought into contact with the matrix material, and through its surface induction effect, the generation and deposition of mercury chloride-selenium are accelerated, so that the mercury in the flue gas is captured to the matrix surface. Although efficient mercury capture and recovery can be achieved in the semi-dry state of flue gas, preventing excessive mercury from entering downstream washing acid or acid production systems and causing secondary pollution problems such as decreased recovery rate and cross-media transfer, it is not coupled with the waste heat recovery process. Spraying water to cool down the flue gas results in the loss of a large amount of sensible heat from the medium and high temperature flue gas, leading to a decrease in waste heat quality. The lack of active control over the flue gas flow pattern, relying on passive deposition on the matrix surface, may increase system resistance and affect the efficiency of subsequent heat exchange units.

[0006] Current technologies 1, 2, and 3 suffer from problems in the recovery of waste heat from high-temperature flue gas in non-ferrous metal smelting, including decreased heat exchange efficiency due to particle deposition, crude flow heat transfer control, and insufficient synergy between heat recovery and environmental protection processes. This invention provides a range-extended nonlinear enhanced waste heat recovery device and method for non-ferrous metal smelting. Summary of the Invention

[0007] The main objective of this invention is to provide a range-extended nonlinear enhanced waste heat recovery device and method for nonferrous metal smelting, in order to solve the problems in the existing technology of high-temperature flue gas waste heat recovery in nonferrous smelting, such as decreased heat exchange efficiency due to particle deposition, crude flow heat transfer control, and insufficient synergy between heat recovery and environmental protection processes.

[0008] To achieve the above objectives, the present invention provides the following technical solution: A range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting, comprising a waste heat boiler body and a multi-stage grid-array flow guiding device installed in the radiant chamber of the waste heat boiler, wherein the multi-stage grid-array flow guiding device consists of a set of grid-type baffles and a set of nail-head fin baffles. The grid-type baffle is used to force the high-temperature flue gas to deflect, causing its flow direction to tilt and rotate; the grid-type baffle and the nail-head fin baffle, through their tilt angle and arrangement, create multiple large-scale rotating vortices on the cross-section of the radiation chamber, with adjacent vortices alternating between clockwise and counterclockwise directions.

[0009] As a further improvement of the present invention, the fence-type baffle is a louvered slat structure that is installed across the cross section of the flue gas passage, with the slats being parallel to each other or forming an angle and arranged at an inclined angle.

[0010] As a further improvement of the present invention, the nail-head fin baffle is composed of 8 nail heads installed on the cylindrical surface, which are installed across the cross section of the flue gas passage. Each slat has the same shape and size. The nail head protrusions of the nail-head fin baffle cause the airflow to generate a strong three-dimensional separation vortex and form a large-scale and asymmetric turbulent vortex region.

[0011] As a further improvement of the present invention, the fence-type baffle is composed of a plurality of flow-guiding grid units arranged in an array; each flow-guiding grid unit is composed of a flow-guiding plate, and the plurality of fence-type baffles are arranged in parallel at a predetermined interval and fixed on the support frame.

[0012] As a further improvement of the present invention, the grid-type baffle adopts a multi-stage series arrangement, with two or more stages of grid array structure set along the flue gas flow direction; the first-stage grid array changes the macroscopic flow direction; the second-stage grid array eliminates residual uneven areas; In each level of the grid array, the array of grid-like baffles is arranged in a unidirectional parallel pattern or in a grid-like cross pattern, forming a mesh-like grid structure.

[0013] As a further improvement of the present invention, it also includes an ascending flue, a radiant heat exchange tube screen, an ash hopper, a radiant chamber, a convection heat exchange tube screen, and a convection chamber; The rising flue has a radiation chamber installed on the right side, and an ash hopper installed at the bottom left side of the radiation chamber. Above the radiation chamber, from left to right, are a grid-type baffle, a nail-head finned baffle, and multiple radiation chamber heat exchange tube panels. A convection chamber is installed on the right side of the radiation chamber, and multiple convection chamber heat exchange tube panels are installed above the convection chamber.

[0014] To achieve the above objectives, the present invention also provides the following technical solution: A range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting, applied to the aforementioned range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting, comprising the following steps: A scale model of a range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting was constructed, and local mesh refinement was applied to the main internal components and water-cooled walls. The MP-PIC method was used to simulate the flow trajectory of flue gas and particles and the temperature change process in the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting. For non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery devices of different sizes and styles, the positions, plate angles, nail angles, and lengths of the grid-type baffles and nail-head finned baffles were changed to extract the flue gas temperature and particle deposition rate on the heat exchanger surface; it was confirmed whether the exhaust gas temperature and particle deposition rate reached the target values. If the target values ​​were not reached, the positions, plate angles, nail angles, and lengths of the grid-type baffles and nail-head finned baffles were further changed. High-temperature flue gas containing dust is introduced into the inlet of the radiant chamber of the waste heat boiler through an ascending flue. The high-temperature flue gas first passes through a grid-type baffle arranged at the inlet of the radiant chamber. Under the action of the inclined angle of the grid-type baffle, the flue gas gains a tangential velocity component and forms multiple rotating vortices downstream of the baffle. A nail-head finned baffle is set downstream of the grid-type baffle, which causes the flue gas to generate a strong three-dimensional separation vortex and recirculation zone near the nail-head fins. This enhances the convective and radiative heat transfer between the flue gas and the heat exchange tube bundle of the radiant chamber, while weakening the adhesion and deposition of particles on the surface of the tube bundle. The low-temperature flue gas, after being enhanced by the range-extended vortex heat transfer, enters the convection chamber heat exchange section and the dust removal and acid production process units in sequence.

[0015] As a further improvement of the present invention, the automatic adjustment process of the fence-type baffle includes the following steps: Multiple differential pressure and temperature array sensors integrated into the device cross section synchronously collect raw pressure and temperature distribution data of the flue gas flow cross section; perform grid-based spatial gradient calculation and global statistical variance analysis on the raw pressure and temperature distribution data, and the fusion processing result is a real-time flow field imbalance index; When the real-time flow field imbalance index exceeds the preset threshold, the control system activates its embedded multi-dimensional response program; using the current and historical flow field imbalance index sequences as input, combined with the pre-stored grid angle-flow field response relationship spectrum, parallel simulation is performed; the simulation output is a specific grid angle adjustment scheme, each scheme includes the target angle value, the estimated flow field homogenization improvement factor and the estimated system resistance change, which together constitute a structured set of candidate strategies; The system receives a set of candidate strategies and imports the allowable thermal fluctuation range and the maximum system resistance limit under the current operating conditions as constraints. Based on the minimum action amplitude and the minimum stability risk criteria, a final execution strategy is selected from the set. The target angle of the final execution strategy is converted into a series of discrete adjustment step instructions with successively decreasing angle increments. The drive device receives and executes the adjustment step instructions in sequence to realize the gradual physical change of the grid angle.

[0016] As a further improvement of the present invention, the process of performing parallel simulation and deduction includes the following steps: The continuous current and historical flow field imbalance indices are converted into a set of multi-dimensional data points describing the dynamic characteristics of the system, forming the starting point for the inference. Using the starting point as a reference, and referring to the pre-stored relationship map that records the system behavior under different grid angles, we conduct multi-directional exploration; each exploration direction simulates a possible grid adjustment action, and deduces a series of state changes caused by this action, forming multiple independent future change trajectories; Each simulated future trajectory is evaluated; the evaluation includes the final flow field homogenization effect achieved by the trajectory, as well as the expected increase in system drag during the entire adjustment process; each trajectory, its corresponding target grid angle, and the evaluation results are packaged into a complete scheme; after summarizing all schemes, a candidate strategy set is obtained.

[0017] To achieve the above objectives, the present invention also provides the following technical solution: An electronic device includes a processor and a memory coupled to the processor, the memory storing program instructions executable by the processor; when the processor executes the program instructions stored in the memory, it implements the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting as described above.

[0018] To achieve the above objectives, the present invention also provides the following technical solution: A storage medium storing program instructions, which, when executed by a processor, implement the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting as described above.

[0019] This invention enables the systematic completion of flow guide structure selection and parameter design, flow field and heat exchange performance prediction of key parts of waste heat boiler, pressure drop and safety margin verification, and multi-objective optimization under the premise of given smelting flue gas operating conditions and waste heat utilization indicators, through a unified mathematical model and digital simulation platform, thereby obtaining a safe, economical and green integrated waste heat recovery solution. Attached Figure Description

[0020] Figure 1 This is a schematic flowchart of one embodiment of the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting according to the present invention. Figure 2 This is a flowchart illustrating the steps of an embodiment of the extended-range nonlinear enhanced waste heat recovery method for nonferrous metal smelting according to the present invention. Figure 3 This is a schematic diagram of the automatic adjustment steps of a fence-type baffle in an embodiment of the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting of the present invention. Figure 4 This is a schematic diagram illustrating the steps of performing grid-based spatial gradient calculation and global statistical variance analysis on the original pressure and temperature distribution data in an embodiment of the extended-range nonlinear enhanced waste heat recovery method for nonferrous metal smelting of the present invention. Figure 5 This is a schematic diagram of the steps in a parallel simulation of an embodiment of the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting of the present invention. Figure 6 This is a schematic diagram of the functional modules of an embodiment of the non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device of the present invention. Figure 7 This is a structural diagram of a grid-type baffle of an embodiment of the non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device of the present invention. Figure 8 This is a schematic diagram of the nail-head finned baffle structure of one embodiment of the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting according to the present invention. Figure 1 ; Figure 9 This is a schematic diagram of the nail-head finned baffle structure of one embodiment of the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting according to the present invention. Figure 2 ; Figure 10 This is a schematic diagram of the structure of an embodiment of the electronic device of the present invention; Figure 11 This is a schematic diagram of the structure of one embodiment of the storage medium of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention 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 the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0022] The terms "first," "second," and "third" used in this invention are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first," "second," or "third" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. All directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of this invention are only used to explain the relative positional relationships and movements between components in a specific orientation (as shown in the accompanying drawings). If the specific orientation changes, the directional indications also change accordingly. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices.

[0023] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0024] like Figure 1 As shown, this embodiment provides an example of a range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting. In this embodiment, the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting specifically includes the following steps: Step S1: Model the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting at a scale, and refine the local mesh for the main internal components and water-cooled walls; use the MP-PIC method to simulate the flow trajectory of flue gas and particles and the temperature change process in the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting. Step S2: For non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery devices of different sizes and styles, change the position, plate angle, nail head angle and length of the grid baffle and nail head fin baffle, and extract the flue gas temperature and particle deposition rate on the heat exchanger surface; confirm whether the flue gas temperature and particle deposition rate have reached the target values. If they have not reached the target values, continue to change the position, plate angle, nail head angle and length of the grid baffle and nail head fin baffle. Step S3: The dust-laden high-temperature flue gas is introduced into the inlet of the radiant chamber of the waste heat boiler through the rising flue. The high-temperature flue gas first passes through the grid-type baffles arranged at the inlet of the radiant chamber. Under the action of the inclined angle of the grid-type baffles, it gains a tangential velocity component and forms multiple rotating vortices downstream of the baffles. A nail-head finned baffle is set downstream of the grid-type baffles, so that the flue gas generates a strong three-dimensional separation vortex and recirculation zone near the nail-head fins, which enhances the convective and radiative heat transfer between the flue gas and the heat exchange tube bundle of the radiant chamber, while weakening the adhesion and deposition of particles on the surface of the tube bundle. The low-temperature flue gas after the enhanced heat transfer by the range-extending vortex enters the convection chamber heat exchange section and the dust removal and acid production process units in sequence.

[0025] Preferably, this embodiment achieves the following comprehensive technical effects by combining various technical features of the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting: In the modeling and simulation stage, proportional modeling and local mesh refinement ensure accurate characterization of the device's geometry and the flow and heat transfer characteristics of key areas. The MP-PIC method is used to achieve high-precision numerical simulation of the multiphase flow trajectory and temperature changes of flue gas and particles, providing a reliable basis for device performance analysis and optimization. In the parameter optimization stage, parameters such as the position, plate angle, nail head angle, and length of the grid-type baffle and nail-head finned baffle are adjusted systematically. Based on the simulation results, flue gas temperature and particle deposition rate data are extracted, achieving iterative optimization of the device structure. This allows the exhaust gas temperature and particle deposition rate to effectively approach the target values, thereby determining the optimal design configuration for enhanced heat transfer and suppression of deposition. During the operation phase, the high-temperature, dust-laden flue gas is guided by the grid-type baffles to generate tangential velocity components and form multiple rotating vortices, enhancing the turbulent mixing of the flue gas. Subsequently, the nail-head finned baffles further generate three-dimensional separation vortices and recirculation zones, significantly strengthening the convective and radiative heat transfer intensity between the flue gas and the heat exchange tube bundle in the radiation chamber. At the same time, the flow field disturbance weakens the tendency of particles to adhere and deposit on the heat exchange surface. Finally, after sufficient heat exchange and cooling, the flue gas smoothly enters the subsequent process unit (see appendix for details). Figure 2 ).

[0026] In summary, this embodiment improves the heat exchange efficiency of the waste heat recovery device, effectively reducing the flue gas temperature; it significantly reduces the deposition of particulate matter on the heat exchange surface, lowers the risk of equipment blockage and corrosion, and extends the operating cycle; and through a design method combining simulation and optimization, it ensures that the device can achieve the expected performance targets under different size and style conditions.

[0027] This embodiment provides a range-extended vortex organization and quantitative design method for smelting flue gas conditions. It changes the traditional design mode of guiding structures that relies on experience and localized experimental adjustments. It establishes a quantitative mapping relationship between operating parameters such as smelting flue gas volume, temperature, dust concentration, and fluctuation characteristics, and the cross-sectional dimensions of the waste heat boiler radiant chamber, the geometric parameters and arrangement of the grid-type baffles and nail-head finned baffles, and the allowable pressure drop range. This enables predictable design of flue gas path, residence time, and vortex structure strength, avoiding localized high-speed scouring, low-speed stagnation, and heat exchange dead zones caused by simply stacking baffles or blindly increasing resistance. It also provides an integrated collaborative design method encompassing operating conditions, structure, and heat exchange performance. This section bridges the gap between smelting conditions, waste heat recovery requirements, and boiler structure and guide component design. It integrates process requirements such as furnace load fluctuations, flue gas composition and dust characteristics, and target steam parameters with structural parameters such as the layout of the radiation / convection chambers, and the number, angle, spacing, and opening ratio of the grid-type and nail-head finned baffles into a unified design framework. This forms a synergistic matching relationship between the flue gas flow field, temperature field, particle concentration field, and the heat transfer surface's resistance to abrasion and slagging, ensuring stable and efficient waste heat recovery even under complex and fluctuating conditions. It also provides a simulation-driven digital design process for range-extended vortex nonlinear enhanced waste heat recovery, combining 3D CFD with MP-PIC. Multiphase flow numerical simulation is directly embedded in the design process of flow guiding devices and key components of waste heat boilers. A reusable parametric geometric model library and automated simulation calculation module are constructed, enabling designers to predict and perform sensitivity analysis on the velocity field, temperature field, particle transport, and ash / slag distribution within the radiant chamber at the initial design stage. This allows for the timely identification of potential problems such as localized overheating, insufficient heat transfer, excessive pressure drop, and erosion risks, facilitating targeted structural adjustments and parameter optimizations before final design approval. Furthermore, a constraint function and multi-objective optimization index system are established for non-ferrous metal waste heat boilers, forming… The corresponding optimization method involves transforming the boiler's total pressure drop, heat flux density and wall temperature of the heating surface, safe wear rate and slagging risk indicators, flue gas temperature and waste heat recovery rate, and flue gas temperature and flow stability entering the acid production system into a set of calculable constraints and evaluation indicators. Combined with intelligent optimization algorithms, the geometric dimensions, number of layers and positions, tilt angle combination and opening ratio of the grid-type baffle and the nail-head finned baffle are optimized for multiple objectives. Under the premise of meeting safety and reliability constraints, the overall optimal balance between uniform flow, enhanced heat transfer, reduced wear and slagging, and stable downstream processes is achieved.

[0028] This embodiment provides a range-extended vortex nonlinear enhanced waste heat recovery device and method for non-ferrous metal waste heat boilers. Under the premise of given smelting flue gas operating conditions and waste heat utilization indicators, it is possible to systematically complete the selection and parameter design of the flow guiding structure, prediction of the flow field and heat transfer performance of key parts of the waste heat boiler, verification of pressure drop and safety margin, and multi-objective optimization through a unified mathematical model and digital simulation platform, thereby obtaining a safe, economical and green integrated waste heat recovery solution.

[0029] Furthermore, steps S1 and S2 also specifically include the following steps: Numerical simulations of grid-type baffles and nail-head finned baffles with different structural parameters were performed using CFD software. Prior to the calculations, local mesh refinement was performed to ensure mesh accuracy in key areas (such as the inner boundary of the baffle and the boundary of the furnace wall / water-cooled wall in the radiant chamber). The flow process of flue gas and particulate matter in the waste heat boiler was simulated using the multiphase particle-in-cell (MP-PIC) method. In this method, gas phase motion is described by the volume-averaged Navier-Stokes equations within the Euler framework, while particle motion is tracked using Newton's second law within the Lagrange framework. The mass, momentum, and energy conservation equations for the gas phase are expressed as follows:

[0030] In equations (1) to (3), Time is used to describe the evolution of flow and temperature over time; The volume fraction of gas represents the volume fraction occupied by gas in a calculation unit volume, and is used to ensure the volume constraint of gas and solid phases in terms of volume fraction. , and Let represent the enthalpy, velocity vector, and density of the gas, respectively; where, It reflects the amount of heat energy carried by the gas and is the main heat characterization variable in the gas phase energy equation, used to calculate sensible heat transport and temperature change; For the pressure of the gas phase, It is the acceleration due to gravity; Represents the momentum exchange between phases; heat flux of a gas. enthalpy diffusion term The equation is:

[0031] In the formula and These represent the effective thermal conductivity of the gas and its temperature, respectively. It is the turbulent mass diffusivity related to viscosity, and its formula is:

[0032] In the formula For turbulent gas viscosity; The value of is the turbulent Schmidt number, which is 0.9. In equation (2), Let be the gas stress tensor, and its expression is:

[0033] In the formula For laminar viscosity, The turbulent viscosity is given by the Smagorinsky model. The expression is:

[0034] In the formula The model constant has a value of 0.1; a length scale is used. Filter the variables; Convective heat transfer between the gas and the wall in equation (3) Convective heat transfer between gas and solid phases The equations are as follows:

[0035] In the formula The wall temperature; and These represent the convective heat transfer coefficient (HTC) between the gas and the wall, and the heat transfer area, respectively. In the MP-PIC method, the basic approach to analyzing solid phases involves "packaging" a group of real solid particles with similar properties (such as particle size, density, chemical properties, etc.) together as a single computational particle for analysis. This method can process large amounts of particle data in a short time, significantly reducing simulation time and improving computational efficiency. The dynamics of solid particles are described by solving the particle distribution function (PDF), which is a correlation function of particle velocity, position, and temperature, and can be described by the following equation:

[0036] In the formula Represents particle velocity. Let be the particle distribution function. and These represent the local mass-average particle velocity and the collision damping time in the particle distribution function, respectively. The acceleration equation used to evaluate particle velocity can be expressed as:

[0037] In the formula This represents the drag coefficient. Represents particle density, The local mass-averaged velocity of the solid phase can be used to calculate the instantaneous relevant parameters of the solid phase at a specific location using the PDF function; Representing the solid volume fraction, it indicates the volume fraction of particles in this unit, reflecting the local particle concentration, and is used to describe the crowding and accumulation behavior in high-concentration areas. It is calculated using the following expression:

[0038] In the formula and These represent the mass and temperature of the particle, respectively; in the particle acceleration equation, It is the normal stress of particle collision, and its expression is:

[0039] In the formula and , These are model constants. This represents the concentration of the solid phase in a close-packed state. Since the heat transfer mechanisms of specific particles need to be considered, including radiative heat transfer with the environment and convective heat transfer with the gas phase, the energy equation for the solid phase can be expressed as follows:

[0040] In the formula The specific heat capacity of solid particles and These represent heat transfer from gas convection and heat transfer from radiation, respectively; the expression is:

[0041] In the formula Represents the Stefan-Boltzmann constant. Represents the radiative emissivity of particles; It refers to the temperature of the surrounding environment; The particle Nusselt number represents the amplification factor of convective heat transfer intensity compared to pure conduction; a Ranz-Marshall type correlation is generally used.

[0042] In the formula and These represent the particle Reynolds number and Prandtl number, respectively. The former reflects the relative magnitudes of momentum diffusion and thermal diffusion, and its expression is:

[0043] here This represents the particle size.

[0044] Preferably, this embodiment provides a range-extended vortex nonlinear enhanced waste heat recovery device. By cleverly setting up grid-type baffles and nail-head finned baffles in the radiant chamber of the waste heat boiler, high-speed flue gas is guided to form a range-extended vortex flow in a rotating circulation, thereby extending the path and residence time of the flue gas in the furnace. Simultaneously, it reduces the phenomenon of molten particles accumulating on the heat exchanger surface, significantly enhancing the heat exchange effect and reducing the flue gas outlet temperature. Furthermore, to quantitatively optimize the structural parameters of the aforementioned grid-type baffles and nail-head finned baffles, CFD and MP-PIC numerical simulation methods are preferably used as design tools. The main objective is to clarify the influence of baffle position, plate angle, nail head angle, and length on the flue gas flow field and particle distribution, ensuring applicability to waste heat recovery devices of different sizes and styles.

[0045] Furthermore, such as Figure 3 As shown, the automatic adjustment process of the fence-type baffle in step S3 specifically includes the following steps: Step S31: Multiple differential pressure and temperature array sensors integrated into the device cross section synchronously collect the original pressure and temperature distribution data of the flue gas flow cross section; perform grid-based spatial gradient calculation and global statistical variance analysis on the original pressure and temperature distribution data, and fuse the results into a single numerical parameter, namely the real-time flow field non-uniformity index. Step S32: When the real-time flow field imbalance index exceeds the preset threshold, the control system activates its embedded multi-dimensional response program; using the current and historical flow field imbalance index sequences as input, combined with the pre-stored grid angle-flow field response relationship map, parallel simulation is performed; the simulation output is a specific grid angle adjustment scheme, each scheme includes the target angle value, the estimated flow field homogenization improvement factor and the estimated system resistance change, which together constitute a structured set of candidate strategies; Step S33: Receive the candidate strategy set and import the thermal allowable fluctuation range and the maximum system resistance limit under the current operating conditions as constraints; based on the minimum action amplitude and the minimum stability risk criterion, select a final execution strategy from the set; the target angle of the final execution strategy is converted into a series of discrete adjustment step instructions with successively decreasing angle increments; the drive device receives and executes the adjustment step instructions in sequence to realize the gradual physical change of the grid angle.

[0046] Preferably, in this embodiment, the automatic adjustment process of the fence-type baffle achieves dynamic optimization control of the flue gas flow cross-section through the synergistic effect of three stages: multi-sensor data acquisition and processing, intelligent strategy generation, and optimized execution. Its technical effects are mainly reflected in the following aspects: The sensor array synchronously collects cross-sectional pressure and temperature distribution data, which are then fused into a real-time flow field imbalance index after spatial gradient calculation and statistical variance analysis. This index can accurately quantify the flow uniformity state, providing a precise basis for adjustment. When the index exceeds a threshold, the system performs parallel simulation and deduction based on historical data and preset response maps, generating a structured strategy set including angle adjustment values, uniformity improvement factors, and resistance changes, achieving multi-objective prediction and rapid strategy generation. The strategy selection stage introduces the thermal fluctuation range and system resistance limit as constraints, combines minimum action amplitude and stability risk criteria to select the final strategy, and decomposes the target angle into progressive adjustment commands to ensure that the adjustment process is completed smoothly within the safety boundary, while reducing disturbances to system operation.

[0047] In summary, this embodiment achieves fully closed-loop automated control from flow state perception and autonomous generation of adjustment strategies to precise execution, effectively improving the uniformity of flue gas flow while taking into account both system operational stability and resistance control requirements.

[0048] Furthermore, such as Figure 4 As shown, step S31, which involves performing grid-based spatial gradient calculation and global statistical variance analysis on the original pressure and temperature distribution data, specifically includes the following steps: Step S311: Map the synchronously acquired raw pressure and temperature distribution data to a preset regular grid; process to obtain gridded pressure field data and gridded temperature field data covering the entire cross section; Step S312: For the gridded pressure field data, obtain the local changes of each node in two orthogonal directions, synthesize the pressure gradient magnitude of the nodes and record their gradient direction angle; perform the same processing on the gridded temperature field data to obtain the temperature gradient magnitude and its direction angle. Step S313: Based on the pressure gradient direction angles of all nodes, obtain the pressure gradient direction consistency coefficient; based on the temperature gradient direction angles, obtain the temperature gradient direction consistency coefficient; simultaneously, obtain the statistical dispersion of the pressure gradient amplitudes of all nodes as the pressure gradient amplitude variability, and obtain the statistical dispersion of the temperature gradient amplitudes as the temperature gradient amplitude variability; input the four consistency and variability coefficients for nonlinear data fusion, and output the real-time flow field imbalance index.

[0049] Preferably, this embodiment utilizes grid-based spatial gradient calculation and global statistical variance analysis to achieve high-precision quantitative characterization of the flow cross-section state through structured data processing and multi-dimensional feature extraction. Its technical advantages are mainly reflected in the following aspects: It maps raw pressure and temperature data to a preset regular grid, forming a fully covered gridded field data, providing a unified spatial benchmark and discretized data structure for subsequent analysis, ensuring the consistency and comparability of calculations. It calculates the local changes in two orthogonal directions for each node of the gridded pressure and temperature field data, synthesizes the gradient amplitude, and records the direction angle. This process accurately captures the spatial variation intensity and directional characteristics of local flow and thermodynamic properties within the field, providing a fine-grained physical quantity description for non-uniformity analysis. Based on the gradient direction angles of all nodes, it calculates the directional consistency coefficient, reflecting the overall directional coordination of flow or temperature changes within the field; simultaneously, it calculates the statistical dispersion of the gradient amplitude as the amplitude variability, characterizing the uniformity of the distribution of change intensity within the field. By nonlinearly fusing four coefficients—the directional consistency of pressure and temperature, and the amplitude variability—a single real-time flow field non-uniformity index is generated. This index comprehensively reflects the spatial non-uniformity of the flow cross-section in both intensity and direction dimensions, achieving efficient integration and state condensation of multiple physical quantities and characteristics, and providing a reliable and comprehensive quantitative basis for regulation decisions.

[0050] Furthermore, such as Figure 5 As shown, the parallel simulation process in step S32 includes the following steps: Step S321: Convert the continuous current and historical flow field imbalance indices into a set of multi-dimensional data points describing the dynamic characteristics of the system, forming the starting point for the deduction; Step S322: Using the starting point as a reference, and referring to the pre-stored relationship map that records the system behavior under different grid angles, conduct multi-directional exploration; each exploration direction simulates a possible grid adjustment action, and deduces a series of state changes caused by this action, forming multiple independent future change trajectories; Step S323: Evaluate the results of each simulated future trajectory; the evaluation includes the flow field homogenization effect achieved by the trajectory and the expected increase in system drag during the entire adjustment process; each trajectory, its corresponding target grid angle, and the evaluation results are packaged into a complete scheme; after summarizing all schemes, a candidate strategy set is obtained.

[0051] Preferably, the parallel simulation process in this embodiment achieves intelligent generation and optimized pre-selection of adjustment strategies through multi-path exploration and forward-looking evaluation. Its technical effects are mainly reflected in the following aspects: It converts continuous historical and current flow field imbalance indices into a multi-dimensional data point set, constructing a starting state describing the dynamic evolution characteristics of the system, providing an accurate time series basis and system state characterization for simulation. Based on the starting state, it simultaneously explores in multiple directions by referring to pre-stored grid angle-flow field response relationship maps. Each exploration direction simulates a possible grid adjustment action and its resulting state change trajectory, realizing parallel computation and future state prediction on multiple potential adjustment paths. It evaluates the results of each simulation trajectory, comprehensively assessing the final flow field homogenization effect and the expected increase in system drag, and packages the target angle, homogenization improvement factor, and drag change into a complete scheme, ultimately forming a structured set of candidate strategies. It achieves rapid deduction and quantitative comparison of multiple adjustment possibilities starting from a single state, providing sufficient and clearly expected strategy options for strategy selection, enhancing the systematicness and forward-looking nature of decision-making.

[0052] like Figure 6 As shown, this embodiment also provides an embodiment of a range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting. In this embodiment, the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting is applied to the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting as described in the above embodiment. The range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting includes a rising flue 10, a grid-type baffle 20, a nail-head finned baffle 21, a radiation chamber heat exchange tube screen 22, an ash hopper 23, a radiation chamber 24, a convection chamber heat exchange tube screen 30, and a convection chamber 31.

[0053] Among them, a radiation chamber 24 is installed on the right side of the rising flue 10, and an ash hopper 23 is installed at the bottom left side of the radiation chamber 24; above the radiation chamber 24, from left to right, are installed a grid-type baffle 20, a nail-head finned baffle 21, and multiple radiation chamber heat exchange tube panels 22; a convection chamber 31 is installed on the right side of the radiation chamber 24, and multiple convection chamber heat exchange tube panels 30 are installed above the convection chamber 31; the structure of the grid-type baffle 20 is as follows: Figure 7 As shown; the structure of the nail head fin baffle 21 is as follows Figure 8 and Figure 9 As shown.

[0054] Preferably, the working principle of the non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device in this embodiment is as follows: high-temperature flue gas containing dust is introduced into the inlet of the radiant chamber 24 of the waste heat boiler through the rising flue 10; the high-temperature flue gas first passes through the grid-type baffle 20 arranged at the inlet of the radiant chamber 24, and obtains a tangential velocity component under the action of the inclined angle of the grid-type baffle 20, and forms multiple rotating vortices downstream of the grid-type baffle 20; a nail-head finned baffle 21 is set downstream of the grid-type baffle 20, so that the flue gas passing through generates a strong three-dimensional separation vortex and recirculation zone near the nail-head fins, which enhances the convective and radiative heat exchange between the flue gas and the heat exchange tube bundle of the radiant chamber 24, while weakening the adhesion and deposition of particles on the surface of the tube bundle; the low-temperature flue gas after range-extended vortex enhanced heat exchange enters the convection chamber heat exchange section and subsequent dust removal, acid production and other process units in sequence.

[0055] The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device of the present invention includes a waste heat boiler body and a multi-stage grid-array flow guiding device installed in the radiation chamber 24 of the waste heat boiler. The multi-stage grid-array flow guiding device consists of a set of grid-type baffles 20 and a set of nail-head finned baffles 21. The grid-type baffles 20 are slatted structures resembling louvers, installed across the cross-section of the flue gas passage, with the slats parallel to each other or forming an angle and arranged at a certain tilt angle. When high-temperature flue gas enters the radiation chamber 24 at high speed, it is forced to deflect by impacting the grid-type baffles 20, and its flow direction tilts and rotates. By rationally designing the tilt angle and arrangement of the grid-type baffles 20 and the nail-head finned baffles 21, multiple large-scale rotating vortices can be formed on the entire cross-section (adjacent vortices are alternately distributed in clockwise and counterclockwise directions). The vortex flow field induced by the flow guiding plates causes the flue gas to no longer pass through the heating surface in a straight line, but to spiral forward around the waste heat boiler tube bundle. In simple terms, after the high-speed flue gas is "intercepted" by the flow guiding structure, it changes direction and swirls around inside the waste heat boiler, repeatedly flowing around the heat exchange tube bundle. The nail-head finned baffle 21 consists of 8 nail heads mounted on the cylindrical surface, installed across the cross-section of the flue gas passage. Each fin has the same shape and size. The protrusions of the nail heads on the nail-head finned baffle 21 will generate strong three-dimensional separation vortices in the airflow and form a large-scale, asymmetric turbulent vortex region, which will lead to a significant increase in the turbulence intensity in the wake region, significantly changing the wake vortex and particle trajectory, and thus affecting the ash accumulation distribution on the heat exchanger surface.

[0056] The specific plan is as follows: Waste heat boiler body: A typical non-ferrous smelting waste heat boiler includes a rising flue 10, a radiation chamber 24, a radiation chamber heat exchange tube panel 22, an ash hopper 23, a convection chamber 31, and a convection chamber heat exchange tube panel 30. High-temperature dust-laden flue gas enters the boiler through the rising flue 10 and flows through each heat exchange component in sequence, transferring heat to the water / steam side medium.

[0057] Array-type flow guiding device: Installed at the front end of the radiant chamber 24 of the waste heat boiler or at a critical section before the flue gas enters the main heat exchange section, it consists of several flow guiding grid units arranged in an array; each flow guiding grid unit is composed of a high-temperature and corrosion-resistant flow guiding plate (or grid-type baffle 20), and multiple grid-type baffles 20 are arranged in parallel at predetermined intervals and fixed on the support frame to form a structure similar to louvers or grilles. The grid-type baffles 20 should preferably be made of alloy steel or ceramic-coated metal resistant to high-temperature sulfur corrosion to withstand the high temperature, high dust, and sulfur-containing environment of the flue gas; Multi-stage arrangement: The flow guide grid can be arranged in a multi-stage series, that is, two or more stages of grid structure are set along the flue gas flow direction; the first stage grid can mainly change the macroscopic flow direction and weaken large-scale jets or rotating vortices; the subsequent second stage grid further refines the flow field and eliminates residual non-uniform regions. Each stage of the grid can be installed at different locations as needed, and the stage spacing is optimized through simulation calculations to achieve the best flow uniformity effect with the minimum pressure drop increment; The array configuration of the fence-type baffles 20: In each level of the grid array, the fence-type baffles 20 can be arranged either in a unidirectional parallel pattern or in a "grid-like" intersecting pattern (i.e., one set of fence-type baffles 20 is perpendicular to another set of fence-type baffles 20), forming a grid-like structure. For example, several fence-type baffles 20 in the first-level grid array can be arranged horizontally, and the fence-type baffles 20 in the second-level grid array can be arranged vertically, thus forming a porous grid in the overall cross-section. The intersecting fence-type baffles 20 divide the cross-section into multiple small unit channels, achieving multi-scale flow uniformity control: controlling the overall flow distribution of the cross-section while promoting local mixing within each small grid. The angle and opening of the grid-type baffle 20: The grid-type baffle 20 can be set at a certain angle relative to the horizontal plane or the mainstream direction of flue gas to guide the flue gas flow direction; preferably, the angle between the first-stage grid-type baffle 20 and the horizontal plane can be adjusted within a certain range to change the local deflection of the flue gas; the second-stage grid-type baffle 20 is at a certain angle to the vertical plane to disrupt the flow deviation in the vertical direction; the spacing (opening ratio) between the grid-type baffles 20 is designed according to the flue gas volume, so that the overall opening ratio is sufficient to pass the design flow rate and can effectively throttle and diffuse the high-speed jet. The thickness and length of the grid-type baffle 20 are also designed with trade-offs: the thickness is sufficient to provide structural strength and durability, and the length (depth of insertion into the flow field) is sufficient to generate the required wake vortex street to enhance mixing.

[0058] Modular design and maintenance: The entire grid-type flow guiding device adopts a modular design and can be detachably installed inside the flue. Each module contains several grid-type baffles 20 and their frames, facilitating inspection, replacement, or cleaning. Considering the deposition of dust in the flue gas, the surface of the flow guiding grid can be designed with a smooth or self-cleaning structure (e.g., equipped with a rapping device or using flue gas flushing for self-cleaning), and can be used in conjunction with conventional soot blowers during boiler operation to prevent severe ash accumulation on the grid.

[0059] Optional adaptive adjustment: To adapt to fluctuations in flue gas conditions, an adjustable grid mechanism can be further introduced into this system. For example, the grid is hinged to the frame via a rotating shaft and connected to a drive device (such as an electric actuator or linkage mechanism), allowing the angle of the grid-type baffle 20 to be adjusted synchronously under control system commands. When flue gas flow or temperature changes significantly, adjusting the opening of the grid-type baffle 20 can alter local resistance characteristics and dynamically optimize flow field uniformity. This adaptive grid array ensures that flue gas enters the waste heat boiler uniformly under different operating conditions. However, even without an active adjustment mechanism, the fixed grid array structure in this embodiment, through its multi-stage, multi-hole design, can already cover the range of conventional operating conditions and significantly improve flow uniformity.

[0060] To achieve the aforementioned vortex effect, the structure and arrangement of the grid-type baffle 20 and the nail-head finned baffle 21 are specially designed in this embodiment. For example, at the inlet of the radiation chamber 24, a set of inclined heat-resistant metal strips can be arranged perpendicular to the mainstream flue gas direction to partially block the cross-section in a manner similar to louvers; a certain distance is maintained between the heat-resistant metal strips to ensure flue gas flow and avoid ash blockage; adjacent heat-resistant metal strips are arranged with opposite inclination directions or in layers and staggered to form alternating vortex regions. Multiple grid-type baffles 20 and nail-head finned baffles 21 can also be arranged in segments along the flue gas flow direction to further extend the flue gas flow path and form a multi-stage vortex structure. The entire flow guiding assembly is made of high-temperature and wear-resistant materials, which can withstand the scouring of dusty flue gas and high-temperature radiant heat; in addition, by optimizing the fin shape of the nail-head finned baffle 21, adjusting the surface structure or arrangement, a stable recirculation flow is formed between the fins, which can effectively reduce particle retention and adhesion. Through the above design, when the flue gas passes through the guide baffle area, it will be forced to rotate and undergo secondary flow. This establishes a stable range-extended rotating circulating flow field inside the waste heat boiler.

[0061] Working Process: After entering the radiant chamber 24, the dust-laden, high-temperature flue gas first impacts the grid-type baffles 20, being separated into multiple streams flowing through the gaps in the baffles 20. Due to the inclination of the baffles, the flue gas acquires a tangential velocity component, which then converges behind the baffles to form a rotating vortex. These vortices fill the cross-section of the radiant chamber, causing the flue gas to rotate and rise around the tube bundle. Under the action of the vortex, the flue gas flow path is "stretched": the airflow needs to make multiple turns to pass through the radiant chamber 24, which is much longer than the straight path without the grid-type baffles 20 and the nail-head finned baffles 21. The vortex flow also generates strong turbulent disturbances and fluid mixing, causing the flue gas to repeatedly contact the heat exchange tube wall, continuously disrupting the boundary layer, thereby significantly improving the heat transfer coefficient. Subsequently, under the action of the nail-head finned baffles 21, the flue gas cloud is further dispersed and the particulate matter in the flue gas is separated more quickly, increasing the heat exchange area between the flue gas and the heat exchanger, and reducing the accumulation of molten particulate matter on the heat exchanger surface. Finally, after releasing more heat and experiencing a significant temperature drop, the flue gas leaves the radiation chamber 24 and enters the subsequent convection heat exchange section or dust removal device.

[0062] This embodiment achieves nonlinear enhancement of flue gas waste heat recovery through range-extended vortex flow, which has the following significant advantages compared to traditional technologies: (1) Extending the flue gas path and significantly increasing residence time: With the help of a special flow guiding structure, the flue gas is forced to swirl in the waste heat boiler, making several more loops. Industrial test data show that after adding the grid-type baffle 20 and the nail-head finned baffle 21, the average residence time of the flue gas in the waste heat boiler increased from about 10 seconds to 13-14 seconds, an increase of more than 30%, which fully demonstrates the significant extension of the flue gas path. In addition, the deposition rate of molten particulate matter on the heat exchanger surface decreased from 13% to 5%; this means that the flue gas has more time to transfer heat to the heating surface, and the service life and heat exchange rate of the heat exchanger are significantly improved, thus increasing the waste heat recovery rate.

[0063] (2) Multi-scale flow uniformity to achieve comprehensive and uniform distribution: Through the combination of multi-level, porous grids, large-scale deviations in the overall flow field can be corrected, and velocity non-uniformity in small areas can be smoothed. Compared with the limitation of a single baffle acting only on a local area, this embodiment covers the entire cross-section and is divided into numerous small unit channels, which greatly reduces the deviation of flue gas velocity and temperature at various points in the cross-section. Experiments or simulations show that after installing the grid array (grid-type baffle 20, nail-head finned baffle 21), the velocity non-uniformity coefficient (e.g., the ratio of maximum velocity to average velocity or standard deviation) on the key cross-section of the waste heat boiler is significantly reduced, and the temperature field is also more uniform; ensuring that the heat absorbed by each heat exchange tube tends to be consistent, avoiding efficiency loss caused by local overheating or undercooling.

[0064] (3) Reduced ash accumulation and slag formation and delayed equipment wear: Because the grid array eliminates the low-velocity stagnation zone, dust no longer stays in one place for a long time, and the tendency to adhere and deposit is significantly reduced. At the same time, the high-speed scouring zone is weakened, and the scouring intensity of flue gas on the tube bundle is reduced; the combined effect of these two aspects slows down the growth of slag thickness on the heating surface of the waste heat boiler, extends the ash removal cycle, and reduces tube bundle wear; it not only extends the service life of the heating surface, but also reduces the risk of unplanned shutdown maintenance caused by ash blockage and wear. Especially in environments where sulfur-containing flue gas is prone to slagging when it cools, maintaining an appropriate flow velocity distribution can prevent the large-scale formation of sulfate agglomerates.

[0065] (4) Enhanced heat transfer and improved waste heat utilization: The turbulence effect of the grid array improves the heat transfer coefficient on the flue gas side, achieving higher heat transfer performance under the same flue gas inlet parameters. This means that the waste heat boiler can produce more steam or lower the flue gas temperature, thereby recovering more heat energy. It is estimated that under typical operating conditions, adding a grid array structure can increase the heat transfer coefficient of the convection section by more than 10% (the specific value depends on the flue gas properties and grid design), correspondingly increasing the boiler heat recovery efficiency by several percentage points. For smelting flue gas with huge total energy, even an increase of several percentage points is a very considerable economic benefit. In addition, due to the heat transfer enhancement and flow equalization effect, some originally inefficient heating surfaces are more fully utilized, which is equivalent to increasing the effective heat exchange area and alleviating the pressure of compact equipment layout to a certain extent.

[0066] (5) Nonlinear enhancement effect with minimal effort: This embodiment achieves a significant increase in heat transfer by simply arranging a baffle structure inside the furnace and introducing a small amount of additional resistance loss. The increase in flue gas pressure drop caused by vortex guidance is very limited, but the heat transfer coefficient and heat transfer volume achieve superlinear growth. In other words, a small increase in pressure drop (fan power consumption) results in a significant increase in heat transfer, which is a typical nonlinear enhancement effect. Compared with traditional linear enhancement methods that require a large amount of energy or complex structures to achieve a slight gain, this embodiment fully leverages the system's potential through the ingenious small intervention of vortex disturbance, achieving energy-saving benefits far exceeding the linear ratio. This is completely consistent with the expectations of nonlinear enhancement theory.

[0067] (6) Stabilizing Downstream Processes and Enhancing Energy and Emissions: With the help of the grid system, the temperature and flow rate of the flue gas entering the acid production system are more stable. Uniform heat exchange reduces the fluctuation of flue gas temperature at the boiler outlet and avoids sudden increases and decreases in flow rate caused by changes in the flow field. The acid production section can operate under relatively stable conditions, improving the efficiency of sulfur dioxide conversion and sulfuric acid production, and reducing fluctuations in SO2 emissions from the tail gas. In addition, the lower and more stable boiler outlet temperature helps the safe operation of downstream equipment (such as bag filters), reducing the risk of high-temperature damage and sulfuric acid dew point corrosion. From the perspective of energy conservation and environmental protection, this embodiment fully explores the waste heat potential of smelting flue gas, improving energy utilization while reducing thermal pollution caused by the wasteful emission of waste heat.

[0068] In summary, this embodiment, through its ingenious flow-guiding structure design, enables high-speed flue gas to form a rotating, circulating flow within the waste heat boiler. This significantly extends the flue gas flow path and enhances heat transfer, while substantially reducing ash accumulation on the heat exchanger surface. Its nonlinear enhancement characteristic manifests as the replacement of simple straight-line flow with complex vortex turbulence, resulting in a leapfrog improvement in heat transfer efficiency. Applying this embodiment maximizes the recovery and utilization of waste heat from high-temperature smelting flue gas, optimizing flow distribution and improving heat transfer performance. It overcomes the problems of insufficient flow uniformity and inability to handle multiple scales in traditional technologies, demonstrating significant industrial application value.

[0069] This embodiment introduces a multi-level grid-type flow guiding structure at the inlet or key parts of the waste heat boiler to form a graded cross-flow guiding network, which performs layer-by-layer rectification and flow equalization of the flue gas entering the boiler; the design takes into account both large-scale flow shaping and small-scale turbulent mixing, and has better flow equalization effect and higher adaptability than traditional single baffles.

[0070] like Figure 10 As shown, this embodiment provides an embodiment of an electronic device. In this embodiment, the electronic device 40 includes a processor 401 and a memory 420 coupled to the processor 401.

[0071] The memory 402 stores program instructions for implementing the range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting in any of the above embodiments.

[0072] The processor 401 is used to execute program instructions stored in the memory 402 to perform range-extended nonlinear enhanced waste heat recovery in nonferrous metal smelting.

[0073] The processor 401 can also be referred to as a CPU (Central Processing Unit). The processor 401 may be an integrated circuit chip with signal processing capabilities. The processor 401 can also be a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. A general-purpose processor can be a microprocessor or any conventional processor.

[0074] Furthermore, Figure 11 This is a schematic diagram of the structure of a storage medium according to an embodiment of this application. The storage medium 50 of this embodiment stores program instructions 501 capable of implementing all the above methods. These program instructions 501 can be stored in the storage medium in the form of a software product, including several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) or processor to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks, or terminal devices such as computers, servers, mobile phones, and tablets.

[0075] In the several embodiments provided by this invention, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection between apparatuses or units through some interfaces, and may be electrical, mechanical, or other forms.

[0076] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated units described above can be implemented in hardware or as software functional units. The above are merely embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

[0077] The specific embodiments of the invention have been described in detail above, but these are merely examples, and the invention is not limited to the specific embodiments described above. For those skilled in the art, any equivalent modifications or substitutions to the invention are also within the scope of this invention. Therefore, all equivalent transformations, modifications, and improvements made without departing from the spirit and principles of this invention should be included within the scope of this invention.

Claims

1. A range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting, characterized in that, The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device includes a waste heat boiler body and a multi-stage grid array flow guiding device installed in the radiant chamber of the waste heat boiler. The multi-stage grid array flow guiding device consists of a set of grid baffles and a set of nail head fin baffles. The grid-type baffle is used to force the high-temperature flue gas to deflect, causing its flow direction to tilt and rotate; the grid-type baffle and the nail-head fin baffle, through their tilt angle and arrangement, create multiple large-scale rotating vortices on the cross-section of the radiation chamber, with adjacent vortices alternating between clockwise and counterclockwise directions.

2. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device according to claim 1, characterized in that, The louvered baffle is a slatted structure that spans the cross-section of the flue gas passage. The slats are parallel to each other or form an angle and are arranged at an inclined angle.

3. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device according to claim 1, characterized in that, The spiked fin baffle consists of eight spikes mounted on a cylindrical surface, spanning the cross section of the flue gas passage. Each fin has the same shape and size. The spike protrusions of the spiked fin baffle generate strong three-dimensional separation vortices in the airflow and form a large-scale and asymmetric turbulent vortex region.

4. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device according to claim 1, characterized in that, The fence-type baffle is composed of several flow-guiding grid units arranged in an array; each flow-guiding grid unit is composed of a flow-guiding plate, and multiple fence-type baffles are arranged in parallel at predetermined intervals and fixed on the support frame.

5. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device according to claim 1, characterized in that, The grid-type baffle adopts a multi-stage series arrangement, with two or more stages of grid array structure set along the flue gas flow direction; the first-stage grid array changes the macroscopic flow direction; the second-stage grid array eliminates residual uneven areas; In each level of the grid array, the array of grid-like baffles is arranged in a unidirectional parallel pattern or in a grid-like cross pattern, forming a mesh-like grid structure.

6. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery device according to claim 1, characterized in that, It also includes rising flue, radiant heat exchanger tube panel, ash hopper, radiant chamber, convection heat exchanger tube panel, and convection chamber; The rising flue has a radiation chamber installed on the right side, and an ash hopper installed at the bottom left side of the radiation chamber. Above the radiation chamber, from left to right, are a grid-type baffle, a nail-head finned baffle, and multiple radiation chamber heat exchange tube panels. A convection chamber is installed on the right side of the radiation chamber, and multiple convection chamber heat exchange tube panels are installed above the convection chamber.

7. A range-extended nonlinear enhanced waste heat recovery method for nonferrous metal smelting, applied to the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting as described in any one of claims 1 to 6, characterized in that, The method for range-extended nonlinear enhanced waste heat recovery in nonferrous metal smelting includes the following steps: A scale model of a range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting was constructed, and local mesh refinement was applied to the main internal components and water-cooled walls. The MP-PIC method was used to simulate the flow trajectory of flue gas and particles and the temperature change process in the range-extended nonlinear enhanced waste heat recovery device for nonferrous metal smelting. For non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery devices of different sizes and styles, the positions, plate angles, nail angles, and lengths of the grid-type baffles and nail-head finned baffles were changed to extract the flue gas temperature and particle deposition rate on the heat exchanger surface; it was confirmed whether the exhaust gas temperature and particle deposition rate reached the target values. If the target values ​​were not reached, the positions, plate angles, nail angles, and lengths of the grid-type baffles and nail-head finned baffles were further changed. High-temperature flue gas containing dust is introduced into the inlet of the radiant chamber of the waste heat boiler through an ascending flue. The high-temperature flue gas first passes through a grid-type baffle arranged at the inlet of the radiant chamber. Under the action of the inclined angle of the grid-type baffle, the flue gas gains a tangential velocity component and forms multiple rotating vortices downstream of the baffle. A nail-head finned baffle is set downstream of the grid-type baffle, which causes the flue gas to generate a strong three-dimensional separation vortex and recirculation zone near the nail-head fins. This enhances the convective and radiative heat transfer between the flue gas and the heat exchange tube bundle of the radiant chamber, while weakening the adhesion and deposition of particles on the surface of the tube bundle. The low-temperature flue gas, after being enhanced by the range-extended vortex heat transfer, enters the convection chamber heat exchange section and the dust removal and acid production process units in sequence.

8. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery method according to claim 7, characterized in that, The automatic adjustment process of the fence-type baffle includes the following steps: Multiple differential pressure and temperature array sensors integrated into the device cross section synchronously collect raw pressure and temperature distribution data of the flue gas flow cross section; perform grid-based spatial gradient calculation and global statistical variance analysis on the raw pressure and temperature distribution data, and the fusion processing result is a real-time flow field imbalance index; When the real-time flow field imbalance index exceeds the preset threshold, the control system activates its embedded multi-dimensional response program; using the current and historical flow field imbalance index sequences as input, combined with the pre-stored grid angle-flow field response relationship spectrum, parallel simulation is performed; the simulation output is a specific grid angle adjustment scheme, each scheme includes the target angle value, the estimated flow field homogenization improvement factor and the estimated system resistance change, which together constitute a structured set of candidate strategies; The system receives a set of candidate strategies and imports the allowable thermal fluctuation range and the maximum system resistance limit under the current operating conditions as constraints. Based on the minimum action amplitude and the minimum stability risk criteria, a final execution strategy is selected from the set. The target angle of the final execution strategy is converted into a series of discrete adjustment step instructions with successively decreasing angle increments. The drive device receives and executes the adjustment step instructions in sequence to realize the gradual physical change of the grid angle.

9. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery method according to claim 8, characterized in that, The process of performing grid-based spatial gradient calculation and global statistical variance analysis on the raw pressure and temperature distribution data includes the following steps: The synchronously acquired raw pressure and temperature distribution data are mapped to a preset regular grid; the data are then processed to obtain gridded pressure field data and gridded temperature field data covering the entire cross section. For the gridded pressure field data, the local changes of each node in two orthogonal directions are obtained, the pressure gradient magnitude of each node is synthesized and its gradient direction angle is recorded; the same processing is performed on the gridded temperature field data to obtain the temperature gradient magnitude and its direction angle. Based on the pressure gradient direction angles of all nodes, the pressure gradient direction consistency coefficient is obtained; based on the temperature gradient direction angles, the temperature gradient direction consistency coefficient is obtained; simultaneously, the statistical dispersion of the pressure gradient amplitudes of all nodes is obtained as the pressure gradient amplitude variability, and the statistical dispersion of the temperature gradient amplitudes is obtained as the temperature gradient amplitude variability; the four consistency and variability coefficients are input for nonlinear data fusion, and the real-time flow field imbalance index is output.

10. The non-ferrous metal smelting range-extended nonlinear enhanced waste heat recovery method according to claim 8, characterized in that, The process of performing parallel simulation and deduction includes the following steps: The continuous current and historical flow field imbalance indices are converted into a set of multi-dimensional data points describing the dynamic characteristics of the system, forming the starting point for the inference. Using the starting point as a reference, and referring to the pre-stored relationship map that records the system behavior under different grid angles, we conduct multi-directional exploration; each exploration direction simulates a possible grid adjustment action, and deduces a series of state changes caused by this action, forming multiple independent future change trajectories; Each simulated future trajectory is evaluated; the evaluation includes the final flow field homogenization effect achieved by the trajectory, as well as the expected increase in system drag during the entire adjustment process; each trajectory, its corresponding target grid angle, and the evaluation results are packaged into a complete scheme; after summarizing all schemes, a candidate strategy set is obtained.

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