A method for controlling the heat preservation and operation of a blister copper tank based on the balance between sticking and melting

Abstract

The present application relates to the technical field of metallurgical equipment operation control, and particularly relates to a rough copper sluice heat preservation and operation control method based on bonding-melting balance, comprising the following steps: establishing a bonding strength-melting rate-temperature-preservation parameter correlation model, and determining a critical temperature interval when bonding and melting are balanced; according to the balance model and real-time production data, the temperature of the inner wall of the sluice is monitored in real time through a temperature sensor, when the temperature is lower than the critical temperature interval, the electric heat tracing device is started to supplement heat, when the temperature is higher than the critical temperature interval, the opening degree of the heat preservation cover plate is adjusted; before the rough copper is discharged, the heat preservation system is started in advance, and the sluice is preheated to the lower limit of the critical temperature interval; during the discharge process, the rough copper flow rate is controlled; after the discharge is completed, the heat preservation system is kept running. Through the whole-process management and control of preheating, operation process regulation and control and subsequent heat preservation, the dynamic balance of bonding and melting of the rough copper on the inner wall of the sluice is realized.

Description

Technical Field

[0001] This invention relates to the field of metallurgical equipment operation control technology, specifically to a method for heat preservation and operation control of crude copper chute based on bonding-melting balance. Background Technology

[0002] In non-ferrous metal smelting, especially copper smelting, sluices are crucial conduits connecting different smelting units and transporting high-temperature molten copper. The core function of a crude copper sluice is to stably and efficiently transport the high-temperature crude copper molten copper generated in a blowing furnace or flash furnace to subsequent refining processes such as the anode furnace. The stability of this transport process directly determines the continuity of the entire production line and the quality of the final product. Therefore, effective thermal management of crude copper sluices to ensure that the high-temperature crude copper molten copper maintains a suitable temperature and good fluidity during transport has become a long-standing technical focus in this field.

[0003] Currently, most existing crude copper discharge chutes are made of refractory prefabricated components, with a surface layer of magnesia powder and water glass to mitigate the erosion of the prefabricated components by the molten metal and facilitate subsequent cleaning. To address the thermal management challenges in transporting high-temperature molten metal, existing technologies primarily focus on optimizing chute structure, material selection, and heating / cooling methods. Specifically, some technologies employ active cooling to address losses caused by overheating and molten metal erosion. For example, Chinese patent CN202793024U discloses a copper water jacket for a flash furnace chute, which achieves efficient heat dissipation through multiple cooling channels inside the chute, thereby protecting the chute body and preventing damage from overheating. Meanwhile, another approach focuses on preventing solidification and adhesion of the molten metal due to rapid cooling through insulation and compensatory heating. US patent US7700036B2 describes a chute for transporting molten copper, which utilizes refractory materials and an insulation layer structure, and incorporates resistance heaters on the chute cover to ensure the metal remains molten throughout the process.

[0004] However, whether it's the traditional chute structure and operation mode or the existing thermal management technology mentioned above, there are still many key problems that need to be solved when applied to the specific scenario of a crude copper chute. First, the insulation effect of traditional chutes is poor, and existing technologies generally lack a deep understanding and quantitative control of the dynamic balance between the two physical states of crude copper "adhesion" and "melting" on the inner wall of the chute. Whether it is simple forced cooling, simple heating and insulation, or the traditional protection method of laying damp soil, it is difficult to accurately maintain the temperature of the chute within the ideal narrow range. This causes the temperature of the crude copper melt to drop too quickly during the transportation process, making it easy to adhere to the inner wall of the chute. This not only makes cleaning difficult but also greatly increases the labor intensity of employees, with an average daily working time of 6 hours. At the same time, the process of cleaning the adhered material can easily damage the inner wall of the chute. Secondly, existing technologies mostly employ passive insulation or open-loop heating modes, lacking a closed-loop control system based on real-time temperature feedback. This prevents dynamic responses to changes in melt flow rate, ambient temperature, and other operating conditions, leading to uneven temperature distribution within the sluice. Combined with the insulation deficiencies of traditional structures, this further exacerbates fluctuations in the fluidity of the crude copper melt, greatly increasing the risk of melt overflow accidents. Furthermore, the extensive use of magnesium powder and water glass in traditional sluices generates harmful magnesium oxide impurities, directly impacting the quality of the smelted products. Finally, existing technological solutions are fragmented, focusing either on structural improvements or material optimization, failing to form a systematic solution integrating scientific models, optimized structures, precise control, and standardized operation. Traditional sluices also lack precise insulation and operational control mechanisms, making it impossible to achieve a dynamic balance between bonding and melting. Summary of the Invention

[0005] To address the problems existing in the prior art, the present invention provides a method for heat preservation and operation control of crude copper chute based on bonding-melting balance.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows:

[0007] A method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium includes the following steps:

[0008] (1) Constructing a bonding-melting equilibrium model: The bonding strength and melting rate of crude copper on the inner wall of the chute under different temperatures and insulation structures were measured by experiments. A correlation model of bonding strength-melting rate-temperature-insulation parameters was established to determine the critical temperature range when bonding and melting are in equilibrium.

[0009] (2) Temperature control: The top of the chute is equipped with an openable and closable heat-insulating cover, and the outer wall of the chute is equipped with an electric heat tracing device. According to the balance model and real-time production data, the temperature of the inner wall of the chute is monitored in real time by a temperature sensor. When the temperature is lower than the critical temperature range, the electric heat tracing device is activated to supplement the temperature, and the supplementary temperature power is 3-5kW / m; when the temperature is higher than the critical temperature range, the opening degree of the heat-insulating cover is adjusted to 30%-50%.

[0010] (3) Sluice box operation: Before discharging crude copper, start the heat preservation system 30-40 minutes in advance to preheat the sluice box to the lower limit of the critical temperature range; during the discharge process, control the crude copper flow rate to 0.8-1.2 m / s, and record the temperature and adhesion data every 2 hours; after the discharge is completed, keep the heat preservation system running for 15-20 minutes.

[0011] Furthermore, the coarse chute adopts a double-layer insulation structure. The inner layer is a high-temperature and corrosion-resistant castable material layer with a thickness of 80-100mm, and the outer layer is an aluminum silicate fiber insulation layer with a thickness of 50-70mm. Ceramic fiber felt is provided on the inner side of the openable insulation cover plate.

[0012] Furthermore, the high-temperature and corrosion-resistant castable is made by mixing alumina, silicon carbide and chromium oxide in a mass ratio of (5-6):(2-3):1, with 5%-8% sodium silicate added as a binder.

[0013] Furthermore, the inner wall of the chute is equipped with 4-6 temperature sensors, which are platinum-rhodium thermocouples with a data acquisition frequency of 1 time / 5min.

[0014] Furthermore, the electric heat tracing device uses explosion-proof ceramic electric heat tracing tape, which is evenly arranged along the length of the chute with a spacing of 150-200mm.

[0015] Furthermore, the crude copper flow rate is controlled by adjusting the tilt angle of the chute, which is controlled by a hydraulic device, and the tilt angle ranges from 15° to 20°.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0017] This invention provides a method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium. By constructing a bond-melt equilibrium model to clarify the critical temperature range, and combining it with real-time temperature monitoring, precise dynamic control of the chute temperature is achieved. This effectively solves the problem of crude copper melt bonding caused by poor heat preservation and imprecise temperature control in traditional and existing technologies, significantly reducing cleaning difficulty and labor intensity, and avoiding damage to the inner wall of the chute during cleaning. The optimized double-layer insulation structure, combined with an openable insulation cover and an explosion-proof ceramic electric heating device, improves the uniformity of heat preservation and ensures the temperature inside the chute. The even distribution of the molten copper ensures stable flow and effectively prevents melt overflow accidents. Furthermore, it eliminates the need for humid soil made from magnesium powder and water glass, reducing the generation of harmful magnesium oxide impurities from the source and ensuring the quality of smelted products. Through comprehensive control of the entire process—preheating, operation regulation, and subsequent insulation—this invention achieves a dynamic balance between the adhesion and melting of molten copper on the inner wall of the chute. This significantly extends the chute's service life, reduces refractory material consumption and production costs, and ultimately achieves safe, efficient, and low-cost stable operation of the molten copper chute, providing a reliable guarantee for the continuity and product quality of the copper smelting production line. Attached Figure Description

[0018] The embodiments of the present invention will be further described below with reference to the accompanying drawings, wherein:

[0019] Figure 1 A process flow diagram of the present invention is shown. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0021] Reference Appendix Figure 1 A method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium includes the following steps:

[0022] (1) Constructing a bonding-melting equilibrium model: The bonding strength and melting rate of crude copper on the inner wall of the chute under different temperatures and insulation structures were measured by experiments. A correlation model of bonding strength-melting rate-temperature-insulation parameters was established to determine the critical temperature range when bonding and melting are in equilibrium.

[0023] (2) Temperature control: The top of the chute is equipped with an openable and closable heat-insulating cover, and the outer wall of the chute is equipped with an electric heat tracing device. According to the balance model and real-time production data, the temperature of the inner wall of the chute is monitored in real time by a temperature sensor. When the temperature is lower than the critical temperature range, the electric heat tracing device is activated to supplement the temperature, and the supplementary temperature power is 3-5kW / m; when the temperature is higher than the critical temperature range, the opening degree of the heat-insulating cover is adjusted to 30%-50%.

[0024] (3) Sluice box operation: Before discharging crude copper, start the heat preservation system 30-40 minutes in advance to preheat the sluice box to the lower limit of the critical temperature range; during the discharge process, control the crude copper flow rate to 0.8-1.2 m / s, and record the temperature and adhesion data every 2 hours; after the discharge is completed, keep the heat preservation system running for 15-20 minutes.

[0025] In one embodiment of the present invention, the coarse chute adopts a double-layer insulation structure, the inner layer is a high-temperature and corrosion-resistant castable material layer with a thickness of 80-100mm, the outer layer is an aluminum silicate fiber insulation layer with a thickness of 50-70mm, and ceramic fiber felt is provided on the inner side of the openable insulation cover plate.

[0026] In one embodiment of the present invention, the high-temperature and corrosion-resistant castable is made by mixing alumina, silicon carbide and chromium oxide in a mass ratio of (5-6):(2-3):1, and adding 5%-8% sodium silicate as a binder.

[0027] In one embodiment of the present invention, the inner wall of the chute is provided with 4-6 temperature sensors, the temperature sensors are platinum-rhodium thermocouples, and the data acquisition frequency is 1 time / 5min.

[0028] In one embodiment of the present invention, the electric heat tracing device uses explosion-proof ceramic electric heat tracing tape, which is evenly arranged along the length of the chute with a spacing of 150-200mm.

[0029] In one embodiment of the present invention, the crude copper flow rate is controlled by adjusting the tilt angle of the chute, the tilt angle of the chute is controlled by a hydraulic device, and the tilt angle of the chute is in the range of 15°-20°.

[0030] Example 1

[0031] This embodiment is applied to a crude copper conveying system in a small metallurgical plant. The chute is 5m long and 0.4m wide. The specific implementation steps of the crude copper chute insulation and operation control method are as follows:

[0032] (1) Construction of bonding-melting equilibrium model: The bonding strength and melting rate of crude copper on the inner wall of the chute under different temperatures and insulation structures were measured by experiments. A correlation model of bonding strength-melting rate-temperature-insulation parameters was established, and the critical temperature range of bonding and melting equilibrium suitable for this working condition was determined to be 1140-1180℃.

[0033] (2) Temperature control: The top of the chute is equipped with an openable and closable heat-insulating cover plate with a double-layer heat-insulating structure. The inner layer is a high-temperature and corrosion-resistant castable material layer with a thickness of 80mm, and the outer layer is an aluminum silicate fiber heat-insulating layer with a thickness of 50mm. Ceramic fiber felt is provided on the inner side of the openable and closable heat-insulating cover plate. The high-temperature and corrosion-resistant castable material is made by mixing alumina, silicon carbide and chromium oxide in a mass ratio of 5:2:1, with 5% sodium silicate added as a binder. Four platinum-rhodium thermocouple temperature sensors are installed on the inner wall of the chute. The data acquisition frequency is 1 time / 5min to capture temperature changes in real time. When the monitored temperature is below 1140℃, the explosion-proof ceramic electric heating tape is activated for heat supplementation. The heat supplementation power is set to 3kW / m. The electric heating tape is evenly arranged along the length of the chute with a spacing of 150mm until the temperature rises back to the critical range. When the temperature is above 1180℃, the opening degree of the heat-insulating cover plate is adjusted to 30% to maintain temperature balance through natural heat dissipation.

[0034] (3) Before discharging crude copper, start the heat preservation system 30 minutes in advance to preheat the chute to 1140℃; adjust the tilt angle of the chute to 15° using the hydraulic device to stabilize the crude copper flow rate at 0.8m / s; during the discharge process, record the temperature of the inner wall of the chute and the data on the adhesion of crude copper every 2 hours to ensure that the operating parameters are without deviation; after the discharge is completed, keep the heat preservation system running for 15 minutes to prevent the residual crude copper from cooling and adhering quickly, thus reducing the difficulty of cleaning.

[0035] This embodiment has been running continuously for 4 months without any melt overflow or blockage in the chute. The average daily labor intensity of employees has been reduced to 55 minutes. The production of harmful impurities such as magnesium oxide has been reduced by 90%, and the total capture rate of sulfur dioxide has reached 99.9%, meeting the production needs of small metallurgical plants.

[0036] Example 2

[0037] This embodiment is applied to the crude copper conveying section of a large non-ferrous metal smelting enterprise. The chute is 12m long and 0.8m wide. The specific implementation steps of the crude copper chute insulation and operation control method are as follows:

[0038] (1) Construction of the bonding-melting equilibrium model: Same as in Example 1, the critical temperature range of bonding and melting equilibrium suitable for this working condition is determined to be 1160-1210℃.

[0039] (2) Temperature control: The top of the chute is equipped with an openable and closable heat-insulating cover plate, which adopts a double-layer heat-insulating structure. The inner layer is a high-temperature and corrosion-resistant castable material layer with a thickness of 100mm, and the outer layer is an aluminum silicate fiber heat-insulating layer with a thickness of 70mm. Ceramic fiber felt is provided on the inner side of the openable and closable heat-insulating cover plate. The high-temperature and corrosion-resistant castable material is made by mixing alumina, silicon carbide and chromium oxide in a mass ratio of 6:3:1, with 8% sodium silicate added as a binder. The inner wall of the chute is equipped with 6 platinum-rhodium thermocouple temperature sensors, and the data acquisition frequency is 1 time / 5min. When the temperature is below 1160℃, the explosion-proof ceramic electric heating tape is activated for heat supplementation, with a heat supplementation power of 5kW / m and a spacing of 200mm between the electric heating tapes. When the temperature is above 1210℃, the opening degree of the heat-insulating cover plate is adjusted to 50% to accelerate heat dissipation and avoid overheating of the chute.

[0040] (3) Sluice box operation: The insulation system is started 40 minutes before the crude copper is discharged, and the temperature is preheated to 1160℃. The tilt angle of the sluice box is adjusted to 20° by the hydraulic device so that the crude copper flow rate reaches 1.2m / s to meet the needs of large capacity conveying. During the discharge process, the temperature and adhesion data are recorded every 2 hours to dynamically adapt to changes in production load. After the discharge is completed, the insulation system continues to run for 20 minutes to ensure that the crude copper remaining on the inner wall of the sluice box is completely melted and flowed out, and to ensure the cleanliness of the sluice box.

[0041] This embodiment has been running for 6 months. The chute is operating stably and reliably without any safety accidents. The average daily labor intensity of employees has been reduced to 50 minutes. The production of magnesium oxide has been reduced by 94%, and the total capture rate of sulfur dioxide has been maintained at 99.9%, which has significantly improved the company's production efficiency and economic benefits.

[0042] Example 3

[0043] This embodiment applies to a crude copper conveying equipment in a medium-sized metallurgical processing plant. The chute is 8m long and 0.6m wide. The specific implementation steps of the crude copper chute insulation and operation control method are as follows:

[0044] (1) Construction of the bonding-melting equilibrium model: Same as in Example 1, the critical temperature range of bonding and melting equilibrium suitable for this working condition is determined to be 1150-1195℃.

[0045] (2) Temperature control: The top of the chute is equipped with an openable and closable heat-insulating cover plate, which adopts a double-layer heat-insulating structure. The inner layer is a high-temperature and corrosion-resistant castable material layer with a thickness of 90mm, and the outer layer is an aluminum silicate fiber heat-insulating layer with a thickness of 60mm. Ceramic fiber felt is provided on the inner side of the openable and closable heat-insulating cover plate. The high-temperature and corrosion-resistant castable material is made by mixing alumina, silicon carbide and chromium oxide in a mass ratio of 5.5:2.5:1, and adding 6.5% sodium silicate as a binder. Five platinum-rhodium thermocouple temperature sensors are installed on the inner wall of the chute, and the data acquisition frequency is 1 time / 5min. When the temperature is below 1150℃, the explosion-proof ceramic electric heating tape is activated for heat supplementation, with a heat supplementation power of 4kW / m and a heating tape spacing of 175mm, accurately supplementing the temperature to the critical range; when the temperature is above 1195℃, the opening degree of the heat-insulating cover plate is adjusted to 40% to achieve gentle heat dissipation and maintain temperature stability.

[0046] (3) Sluice operation: Start the heat preservation system 35 minutes before the crude copper is discharged and preheat to 1150℃; adjust the tilt angle of the sluice to 17.5° through the hydraulic device to control the crude copper flow rate at 1.0m / s; record relevant data every 2 hours during the discharge process, and promptly detect and deal with abnormal situations; after the discharge is completed, the heat preservation system continues to run for 18 minutes to ensure that there are no residual adhesives on the inner wall of the sluice.

[0047] This embodiment has been running continuously for 5 months with no malfunctions in the chute. The average daily labor intensity of employees has been reduced to 53 minutes, magnesium oxide production has been reduced by 92%, and the total sulfur dioxide capture rate has reached 99.9%. It is suitable for medium-sized enterprises.

[0048] This invention provides a method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium. By constructing a bond-melt equilibrium model to clarify the critical temperature range, and combining it with real-time temperature monitoring, precise dynamic control of the chute temperature is achieved. This effectively solves the problem of crude copper melt bonding caused by poor heat preservation and imprecise temperature control in traditional and existing technologies, significantly reducing cleaning difficulty and labor intensity, and avoiding damage to the inner wall of the chute during cleaning. The optimized double-layer insulation structure, combined with an openable insulation cover and an explosion-proof ceramic electric heating device, improves the uniformity of heat preservation and ensures the temperature inside the chute. The even distribution of the molten copper ensures stable flow and effectively prevents melt overflow accidents. Furthermore, it eliminates the need for humid soil made from magnesium powder and water glass, reducing the generation of harmful magnesium oxide impurities from the source and ensuring the quality of smelted products. Through comprehensive control of the entire process—preheating, operation regulation, and subsequent insulation—this invention achieves a dynamic balance between the adhesion and melting of molten copper on the inner wall of the chute. This significantly extends the chute's service life, reduces refractory material consumption and production costs, and ultimately achieves safe, efficient, and low-cost stable operation of the molten copper chute, providing a reliable guarantee for the continuity and product quality of the copper smelting production line.

[0049] The foregoing descriptions have outlined some exemplary embodiments of the present invention. It is understood that these embodiments are merely illustrative and do not constitute a limitation on the scope of protection of the present invention. Features in these embodiments can be rearranged in suitable ways, and the resulting solutions remain within the scope of protection claimed by the present invention. All other embodiments obtained by those skilled in the art based on the foregoing embodiments without inventive effort, i.e., all modifications, equivalent substitutions, and improvements made within the spirit and principles of this application, fall within the scope of protection claimed by the present invention.

Claims

1. A method for heat preservation and operation control of a crude copper chute based on bond-melt equilibrium, characterized in that, Includes the following steps: (1) Constructing a bonding-melting equilibrium model: The bonding strength and melting rate of crude copper on the inner wall of the chute under different temperatures and insulation structures were measured by experiments. A correlation model of bonding strength-melting rate-temperature-insulation parameters was established to determine the critical temperature range when bonding and melting are in equilibrium. (2) Temperature control: The top of the chute is equipped with an openable and closable heat-insulating cover, and the outer wall of the chute is equipped with an electric heat tracing device. According to the balance model and real-time production data, the temperature of the inner wall of the chute is monitored in real time by a temperature sensor. When the temperature is lower than the critical temperature range, the electric heat tracing device is activated to supplement the temperature, and the supplementary temperature power is 3-5kW / m; when the temperature is higher than the critical temperature range, the opening degree of the heat-insulating cover is adjusted to 30%-50%. (3) Sluice box operation: Before discharging crude copper, start the heat preservation system 30-40 minutes in advance to preheat the sluice box to the lower limit of the critical temperature range; during the discharge process, control the crude copper flow rate to 0.8-1.2 m / s, and record the temperature and adhesion data every 2 hours; after the discharge is completed, keep the heat preservation system running for 15-20 minutes.

2. The method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium according to claim 1, characterized in that, The coarse chute adopts a double-layer insulation structure. The inner layer is a high-temperature and corrosion-resistant castable material layer with a thickness of 80-100mm, and the outer layer is an aluminum silicate fiber insulation layer with a thickness of 50-70mm. Ceramic fiber felt is provided on the inner side of the openable insulation cover plate.

3. The method for heat preservation and operation control of crude copper chute based on bonding-melting equilibrium according to claim 2, characterized in that, The high-temperature and corrosion-resistant castable is made by mixing alumina, silicon carbide and chromium oxide in a mass ratio of (5-6):(2-3):1, with 5%-8% sodium silicate added as a binder.

4. The method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium according to claim 1, characterized in that, The inner wall of the chute is equipped with 4-6 temperature sensors, which are platinum-rhodium thermocouples, and the data acquisition frequency is 1 time / 5min.

5. The method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium according to claim 1, characterized in that, The electric heat tracing device uses explosion-proof ceramic electric heat tracing tape, which is evenly arranged along the length of the chute with a spacing of 150-200mm.

6. The method for heat preservation and operation control of crude copper chute based on bond-melt equilibrium according to claim 1, characterized in that, The flow rate of crude copper is controlled by adjusting the tilt angle of the chute, which is controlled by a hydraulic device, and the tilt angle range is 15°-20°.

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