Particle size distribution calculation device and particle size distribution calculation method

Abstract

To provide a particle size distribution calculator capable of highly accurately calculating a change in a particle size distribution of mats caused by collision of a plurality of slags and a plurality of mat droplets with each other falling in a reaction tower provided in a flash-smelting furnace.SOLUTION: This particle size distribution calculator calculates particle size distributions of mats and slags generated when a smelting raw material supplied from the top of a reaction tower reacts with a reaction gas, and comprises: a first particle size distribution calculation unit that calculates the particle size distributions of mats and slags; a region setting unit that sets a prescribed region in the reaction tower as a calculation region; an arrangement setting unit that arranges the mats and the slags in the calculation region and sets the initial state arrangement of the mats and the slags; and a second particle size distribution calculation unit that calculates dynamic changes in position and shape caused by motion of the mats and the slags of the initial state arranged in the calculation region by a particle method using a potential model, and calculates a particle size distribution of the mats after collision of the mats and the slags with each other.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a particle size distribution calculation device and a particle size distribution calculation method. [Background technology]

[0002] Copper sulfide concentrate (copper concentrate) is a powdery solid sulfide, and is supplied as a smelting material to a self-smelting furnace (hereinafter referred to as a self-smelting furnace), which is one type of smelting furnace, to produce and separate two types of solutions, mainly matte and slag.

[0003] In a self-smelting furnace, copper concentrate, silicate ore, auxiliary fuels such as heavy oil, and molten materials such as flux are blown into the reaction shaft (reaction tower) along with reaction gases such as oxygen-enriched air, which are separately delivered from a concentrate burner located at the top of the reaction shaft. Inside the reaction shaft, the copper concentrate reacts with the reaction gases to produce two types of solubility (matt and slag). The matt and slag fall in droplet form inside the reaction shaft and are collected in a settler. Inside the settler, the matt and slag separate into layers due to their difference in specific gravity, and the matt layer and slag layer are formed in that order from the bottom of the settler.

[0004] The larger the particle size of the mat falling through the reaction shaft, the greater the settling velocity of the mat in the slag layer, and the easier it is for the mat in the slag layer to move into the mat layer. Therefore, estimating the particle size of the mat when it reaches the settler is important for increasing the amount of mat recovered in the settler.

[0005] As a method for calculating the particle size distribution of the solution within the reaction shaft, for example, a method has been disclosed in which the volume fractions of multiple particle phases classified according to the particle size of the concentrate particles are calculated using the Euler method, and a combustion simulation of a self-smelting furnace is performed in which the particle size of the particle phases is expressed based on the change in volume fraction (see, for example, Patent Document 1).

[0006] In the method for performing combustion simulation of a self-smelting furnace described in Patent Document 1, the collision probability between two particle phases is calculated for all combinations of two particle phases from among multiple particle phases. When a collision occurs between the particle phase with a larger particle size and the particle phase with a smaller particle size within a combination, the volume fraction of the particle phase with a smaller particle size is added to the volume fraction of the particle phase with a larger particle size, and the change in particle growth due to the collision is represented by the change in volume fraction. In this method, the particle size of the concentrate particles is represented as gradually increasing in volume fraction toward larger particle sizes as one moves from the top of the reaction shaft towards the settler side, and it has the advantage of being able to be incorporated into thermal fluid calculations within the self-smelting furnace. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Patent No. 4367298 [Overview of the project] [Problems that the invention aims to solve]

[0008] However, the method described in Patent Document 1 treats the impacting objects as particles and cannot take into account the behavior of the solution present in the reaction shaft of the self-melting furnace, such as the deformation, rotation, and splitting of droplets composed of mat and slag upon impact. Furthermore, the method described in Patent Document 1 does not take into account the time lag until the mats coalesce when droplets composed of multiple mats and slags collide. Therefore, the method described in Patent Document 1 cannot accurately grasp the changes in the particle size distribution of the mats due to collisions between the slag and mats as they fall through the reaction shaft.

[0009] One aspect of the present invention aims to provide a particle size distribution calculation device that can accurately calculate the change in the particle size distribution of a mat caused by the collision of droplets consisting of multiple mats and slag falling inside a reaction tower installed in a self-melting furnace. [Means for solving the problem]

[0010] One aspect of the particle size distribution calculation device according to the present invention is a particle size distribution calculation device that calculates the particle size distributions of matte and slag generated by reacting reaction gas supplied into a reaction tower with a smelting raw material supplied from the top of the reaction tower while the smelting raw material falls toward a settler located below the reaction tower, a first particle size distribution calculation unit that calculates the particle size distributions of the matte and the slag, a region setting unit that sets a predetermined region in the reaction tower as a calculation region, an arrangement setting unit that arranges the matte and the slag in the calculation region and sets the initial arrangement of the matte and the slag, a second particle size distribution calculation unit that calculates the dynamic changes in the positions and shapes of the matte and the slag in the initial state arranged in the calculation region due to the movement of the matte and the slag by a particle method using a potential model, and calculates the particle size distribution of the matte after the collision of the matte and the slag, and includes.

Advantages of the Invention

[0011] One aspect of the particle size distribution calculation device according to the present invention can accurately calculate changes in the particle size distribution of matte due to collisions of droplets composed of matte and slag falling in a reaction tower provided in a self-smelting furnace.

Brief Description of the Drawings

[0012] [Figure 1] It is a diagram showing a schematic configuration of a self-smelting furnace to which the particle size distribution calculation device according to an embodiment of the present invention is applied. [Figure 2] It is a block diagram showing the functions of the particle size distribution calculation device according to an embodiment of the present invention. [Figure 3] It is a diagram showing the dispersion state of matte and slag in a calculation region. [Figure 4] It is a diagram showing the change amount of the volume of matte before and after the collision. [Figure 5] It is a flowchart for explaining the particle size distribution calculation method according to an embodiment of the present invention. [Figure 6]It is a flowchart for explaining the step of calculating the composition and generation amount of matte and slag (step S12). [Figure 7] It is a hardware configuration diagram of a particle size distribution calculation device.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described in detail. For ease of understanding the description, the same reference numerals are given to the same components in each drawing, and duplicate descriptions are omitted. Also, the scales of the respective members in the drawings may be different from the actual ones.

[0014] In describing the particle size distribution calculation device according to an embodiment of the present invention, the configuration of a self-fluxing smelting furnace (self-smelting furnace) to which the particle size distribution calculation device according to this embodiment is applied will be described.

[0015] <Self-smelting furnace> FIG. 1 is a diagram showing a schematic configuration of a self-smelting furnace to which the particle size distribution calculation device according to this embodiment is applied. As shown in FIG. 1, the self-smelting furnace 1 includes a reaction tower (reaction shaft) 10, a settler 20, a flue 30, and an electric smelting furnace 40. The self-smelting furnace 1 generates two types of melts, slag and matte (copper grade 60% - 65%), from copper concentrate (copper grade 20% - 30%) which is a smelting raw material SP supplied into the reaction shaft 10 within the reaction shaft 10, and in the settler 20, the slag and matte are separated into layers, and the matte with a high copper grade is recovered.

[0016] The smelting raw material refers to valuable minerals containing the target metal to be extracted, useless minerals (gangue), etc., and examples include copper concentrate. In this embodiment, the case where the smelting raw material is copper concentrate will be described.

[0017] Copper concentrate is a copper ore having a particle size of, for example, 1 μm to 300 μm, and is a powdery solid sulfide (Cu - Fe - S) containing copper, iron, and sulfur.

[0018] Matt is a mixture mainly composed of copper sulfide (Cu2S) and iron sulfide (FeS), and is a solution with a high copper content. Slag is a solution mainly composed of iron oxide silicate (2FeO·SiO2), and is a solution with a high iron content.

[0019] The reaction shaft 10 is a hollow structure with a bottomed cylindrical top. The reaction shaft 10 is equipped with a concentrate burner 11 at its top 10a. Note that there may be one or more concentrate burners 11.

[0020] In the reaction shaft 10, the average internal temperature is set to, for example, about 1300°C. In the reaction shaft 10, copper concentrate burns as it falls through the shaft, undergoing melting and oxidation, which generates two types of solutions (matt and slag) and sulfur dioxide gas.

[0021] The settler 20 is located below the reaction shaft 10 and is connected to the lower part of the reaction shaft 10 at one end (left side in Figure 1). The settler 20 collects the mat and slag generated in the reaction shaft 10 inside. Within the settler 20, the mat and slag are separated into layers due to the difference in specific gravity between the mat and slag, and the mat layer and slag layer are formed in this order from the bottom side of the settler 20. The settler 20 has one or more slag holes 21, which are slag outlets, and one or more mat holes 22, which are mat outlets, on its side.

[0022] The flue pipe 30 is formed in a cylindrical shape, with one end connected to the top of the other end (right side in Figure 1) of the settler 20, and the other end connected to the boiler 31, supplying the high-temperature sulfur dioxide gas generated in the reaction shaft 10 to the boiler 31.

[0023] The electric slag furnace 40 recovers the slag discharged from the settler 20 through the slag hole 21, and separates and recovers the trace amounts of matte contained in the slag.

[0024] In the self-smelting furnace 1, copper concentrate, along with silicate ore, auxiliary fuels such as heavy oil, solubility materials such as flux, and reaction gases such as oxygen-enriched air delivered separately, is blown into the reaction shaft 10 from the top 10a of the reaction shaft 10 via the concentrate burner 11. The copper concentrate blown into the reaction shaft 10 is heated by the combustion heat of the fuel, the sensible heat of the reaction gas, and the radiant heat within the furnace wall of the reaction shaft 10, causing the sulfur in the smelting material to instantly react with the reaction gas and burn. The combustion heat generated by the combustion of the sulfur in the smelting material causes the dissolution and oxidation of the copper concentrate particles (concentrate particles) in the smelting material to proceed, mainly through the reactions shown in equations (1) and (2) below, producing two types of solutions (matt (Cu2S-FeS) and slag (FeO-SiO2)) and sulfur dioxide gas. CuFeS2+O2→Cu2S-FeS+FeO+SO2···(1) FeO + SiO2 → FeO - SiO2···(2)

[0025] The mat and slag generated in the reaction shaft 10 fall into the settler 20 as droplets and are collected within the settler 20. At this time, the droplets consisting of mat and slag (mat and slag droplets) repeatedly collide within the reaction shaft 10, increasing in particle size as they fall. Within the settler 20, the mat and slag separate into layers due to their difference in specific gravity, and the mat layer and slag layer are formed in that order at the bottom of the settler 20.

[0026] The mat in the settler 20 is extracted in appropriate amounts from the mat hole 22 according to the request from the converter (not shown), which is the destination, and the slag in the settler 20 is discharged as needed from the slag hole 21. The slag discharged from the slag hole 21 is introduced into the electric smelting furnace 40 and heated and maintained by heat transfer through the energization of the electrodes 41. Some of the mat in the self-smelting furnace slag layer is discharged with the slag without settling at the bottom of the settler 20, and further settles at the bottom of the furnace during the residence time in the electric smelting furnace 40, so that a mat layer and a slag layer are also formed in the electric smelting furnace 40. The mat in the electric smelting furnace 40 is recovered, and only the slag containing a small amount of copper is discharged outside the furnace from the outlet 42.

[0027] In this way, in the self-smelting furnace 1, the copper concentrate is separated into slag and matte, and the copper content in the recovered matte is set to 60-65%.

[0028] Furthermore, the high-temperature sulfur dioxide gas generated in the reaction shaft 10 is discharged through the settler 20 and flue 30 and cooled in the boiler 31.

[0029] <Particle size distribution calculator> Next, the in-furnace reaction calculation device according to this embodiment will be described. Figure 2 is a block diagram showing the functions of the particle size distribution calculation device according to this embodiment. As shown in Figure 2, the particle size distribution calculation device 100 according to this embodiment includes an input unit 110, a first particle size distribution calculation unit 120, a region setting unit 130, a layout setting unit 140, a second particle size distribution calculation unit 150, and an output unit 160.

[0030] The inventors of this application focused on the fact that in the specific gravity separation of mat and slag in the settler 20 and the electric slag furnace 40, the larger the particle size of the mat, the greater the settling velocity, and the faster the separation from the slag proceeds. Therefore, estimating the particle size of the mat droplets when the mat reaches the settler 20 is important for increasing the recovery rate of the mat in the settler 20 or the electric slag furnace 40. Accordingly, the inventors of this application found that by calculating the interfacial tension of the two types of solutions (mat and slag) using a particle method with a potential model, it is possible to accurately evaluate the particle size distribution of the mat that has changed due to the collision of droplets consisting of mat and slag falling within the reaction shaft 10.

[0031] The input unit 110 receives input conditions such as the amount of copper concentrate supplied, the particle size distribution of the copper concentrate, the composition of the copper concentrate, the mass percentage of Cu in the mat upon reaching the settler 20 (mat grade), and the concentration of the droplet space (solution space concentration) in the reaction shaft 10.

[0032] The supply amount of copper concentrate is the mass flow rate of copper concentrate supplied to the self-smelting furnace 1. The supply amount of copper concentrate can be determined from a flow meter (not shown) installed in a supply means (not shown) that supplies copper concentrate to the reaction shaft 10.

[0033] The particle size distribution of copper concentrate can be obtained, for example, by measuring it with a microtrac particle size distribution analyzer.

[0034] The composition of copper concentrate is, for example, the grade of copper concentrate such as Cu, Fe, S, CaO, MgO, SiO2, Al2O3, and can be determined by chemical analysis and X-ray fluorescence analysis.

[0035] The mass percentage of Cu in the mat upon reaching Settler 20 represents the copper grade in the mat and is generally 70% or less.

[0036] The concentration of droplets in the reaction shaft 10 is appropriately determined by the amount of copper concentrate supplied, the amount of reaction air supplied, the shape of the reaction shaft 10 and the concentrate burner 11, etc. The concentration of droplets in the reaction shaft 10 may also be determined, for example, from the results of a separate thermal fluid calculation.

[0037] The first particle size distribution calculation unit 120 calculates the particle size distribution of the mat and slag.

[0038] The first particle size distribution calculation unit 120 calculates the composition and amount of slag and mat produced after the reaction from the above input conditions, namely the composition of the copper concentrate and the mass percentage of Cu in the mat when it reaches the settler 20.

[0039] The first particle size distribution calculation unit 120 estimates the density of the mat and slag from the composition of the obtained mat and slag, and calculates the particle size distribution of the mat and slag from the density and supply amount of copper concentrate, the particle size distribution of copper concentrate, and the amount and density of mat and slag produced.

[0040] The region setting unit 130 sets a predetermined region within the reaction shaft 10 as the calculation region.

[0041] The calculation domain shall be a cubic or rectangular prism, as shown in Figure 3. The size of the calculation domain shall be large enough to include a sufficient number of mats and slags to evaluate the particle size distribution in the droplet unification calculation described later. For example, the size of the calculation domain may be a cube or rectangular prism with sides of several millimeters (e.g., 1 mm).

[0042] The calculation domain may directly simulate the height of the reaction shaft 10 of the self-smelting furnace 1, but it is preferable to use periodic boundary conditions to set the calculation domain in order to reduce the computational load.

[0043] The placement setting unit 140 places the mat and slag within the calculation area to set the initial placement of the mat and slag.

[0044] The placement setting unit 140 may randomly place the mats and slags within the calculation area using random numbers.

[0045] The second particle size distribution calculation unit 150 uses a particle method with a potential model to perform a fluid analysis of the solution, taking into account surface tension and interfacial tension, from the initial state of the mat and slag droplets placed within the calculation domain. It then calculates the dynamic changes in position and shape due to the motion (fall) of the mat and slag droplets, and calculates the particle size distribution of the mat after the collision of the mat and slag droplets.

[0046] As particle methods using potential models, for example, the SPH (Smoothed Particle Hydrodynamics) method, the MPS (Moving Particle Semi-implicit) method, the MPM (Material Point Method), and the DPD (Dispersed Particle Dynamics) method can be used.

[0047] This section explains the use of the SPH method as a particle method.

[0048] The second particle size distribution calculation unit 150 calculates the kernel function W used for weighting surrounding particle information using Wendland's equation shown in equation (I) below.

[0049]

number

[0050] In this embodiment, the computational particle i in equation (I) above refers to an SPH computational particle that simulates mat and slag, and similarly, the computational particle i used in each of the following equations also refers to an SPH computational particle that simulates mat and slag.

[0051] The second particle size distribution calculation unit 150 uses the kernel function W obtained by equation (I) above to calculate the density and pressure of the calculated particle i from the following equations (II) and (III).

[0052]

number

[0053] The second particle size distribution calculation unit 150 calculates the velocity of the calculated particle i using the following equation (IV).

[0054]

number

[0055] Here, surface tension Fs,i It is calculated by the following formulas (V) and (VI).

[0056]

Equation

[0057] The second particle size distribution calculation unit 150 updates the position information of the calculation particle i by the following formula (VII) from u obtained by the above formula (IV). i

[0058]

Equation

[0062] The output unit 160 outputs information regarding the change in particle size distribution before and after the collision of the mat, which is output by the second particle size distribution calculation unit 150. That is, the output unit 160 can output information regarding the particle size distribution of the mat before the collision of the solution, which is output by the second particle size distribution calculation unit 150, and the particle size distribution of the mat after the collision, which is output by the second particle size distribution calculation unit 150.

[0063] The output unit 160 can display information regarding the change in particle size distribution before and after the mat impact, as shown in Figure 4, which is output by the second particle size distribution calculation unit 150. For example, a monitor can be used as the output unit 160.

[0064] <Particle size distribution calculation method> Next, the particle size distribution calculation method according to this embodiment will be described using the particle size distribution calculation device according to this embodiment. The particle size distribution calculation method according to this embodiment calculates the particle size distribution of mat and slag produced when copper concentrate supplied from a concentrate burner 11 located at the top 10a of the reaction shaft 10 falls toward the settler 20 and reacts with the reaction gas supplied into the reaction shaft 10, in a self-smelting furnace 1 having the configuration shown in Figure 1.

[0065] Figure 5 is a flowchart illustrating the particle size distribution calculation method according to this embodiment. As shown in Figure 5, the particle size distribution calculation device 100 receives input conditions such as the composition of the copper concentrate, the amount of copper concentrate supplied, the particle size distribution of the copper concentrate, the mass percentage of Cu in the mat upon arrival at the settler 20, and the droplet space concentration in the reaction shaft 10 via the input unit 110 (input step: step S11).

[0066] Next, the particle size distribution calculation device 100 uses the first particle size distribution calculation unit 120 to calculate the composition and amount of mat and slag produced after the reaction, based on the composition of the copper concentrate and the mass percentage of Cu in the mat upon arrival at the settler 20, which are input as input conditions to the input unit 110 (calculation process of composition and amount of mat and slag: step S12).

[0067] The details of the calculation process for the composition and production amount of matte and slag (step S12) will be explained. Figure 6 is a flowchart illustrating the calculation process for the composition and production amount of matte and slag (step S12). As shown in Figure 6, the particle size distribution calculation device 100 uses the first particle size distribution calculation unit 120 to calculate the supply amount (unit: t / h) of each composition in the copper concentrate from the supply amount (unit: t / h) and composition (e.g., Cu concentration) of copper concentrate input as input conditions to the input unit 110 (calculation process for the supply amount of each composition in the copper concentrate: step S121).

[0068] Of these, we assume that the entire supply of Cu (in t / h) in the copper concentrate will be matte.

[0069] Next, the particle size distribution calculation device 100 uses the first particle size distribution calculation unit 120 to calculate the amount of sulfur (unit: t / h) and the amount of feline (unit: t / h) in the mat from the mass percentage of Cu in the mat when it reaches the settler 20 (calculation process of the amount of sulfur and feline in the mat: step S122).

[0070] Next, the particle size distribution calculation device 100 calculates the composition and amount of slag produced using the first particle size distribution calculation unit 120 (slag composition and amount calculation step: step S123).

[0071] The composition of the slag is calculated as the remaining components after subtracting the sulfur that is oxidized and removed from the copper concentrate within the matte and reaction shaft 10.

[0072] The amount of slag produced (in units of t / h) is calculated from the supply amounts (in units of t / h) of each composition of copper concentrate.

[0073] Next, as shown in Figure 5, the particle size distribution calculation device 100 uses the first particle size distribution calculation unit 120 to determine the respective densities (unit: t / m³) of the mat and slag from the obtained mat and slag composition. 3 ) is estimated (mat and slag density estimation process: step S13).

[0074] The particle size distribution calculation device 100 calculates the particle size (droplet diameter) distribution of mat and slag from the density and supply amount of copper concentrate, the particle size distribution of copper concentrate, and the amount and density of mat and slag produced by the first particle size distribution calculation unit 120 (step S14: calculation of particle size distribution of mat and slag).

[0075] Next, the particle size distribution calculation device 100 sets the calculation area using the area setting unit 130 (calculation area setting step: step S15).

[0076] As described above, the calculation domain shall be a cubic or rectangular prism analysis domain, and the size of the calculation domain shall be large enough to include a sufficient number of particles (droplets) to evaluate the particle size distribution of the mat and slag after collision resulting from the coalescence of the mat and slag. The calculation domain may directly simulate the height of the reaction shaft 10 of the self-smelting furnace 1, but periodic boundary conditions may be applied to reduce the computational load.

[0077] Next, the particle size distribution calculation device 100 uses the arrangement setting unit 140 to arrange the mat and slag calculated in the mat and slag particle size distribution calculation step (step S14) within the created calculation area, thereby setting the initial arrangement of the mat and slag (initial state setting step for mat and slag droplets: step S16).

[0078] Next, the particle size distribution calculation device 100, using its second particle size distribution calculation unit 150, solves the Navier-Stokes equation, which is the fluid's equation of motion, using a particle method with a potential model, based on the initial arrangement of the mat and slag droplets set in the initial state setting step (step S16). Then, the particle size distribution calculation device 100, using its second particle size distribution calculation unit 150, evaluates the surface tension and interfacial tension of the initial state of the mat and slag arranged within the calculation domain, performs a fluid analysis of the solution, and calculates the dynamic changes in position and shape due to the motion of the mat and slag (calculation step of dynamic changes of mat and slag droplets: step S17).

[0079] As particle methods, SPH (Smoothed Particle Hydrodynamics), MPS (Moving Particle Semi-implicit), MPM (Material Point Method), and DPD (Dispersed Particle Dynamics) can be used. In this embodiment, the case in which the SPH method is used as the particle method will be described.

[0080] The particle size distribution calculation device 100 uses a second particle size distribution calculation unit 150 to calculate a kernel function W used for weighting surrounding particle information, using Wendland's equation shown in equation (I) above.

[0081] The particle size distribution calculation device 100 uses the kernel function W obtained by equation (I) above to calculate the density and pressure of the calculated particle i from equations (II) and (III) above, using the second particle size distribution calculation unit 150.

[0082] The particle size distribution calculation device 100 calculates the velocity of the calculated particle i using the above equation (IV) with the second particle size distribution calculation unit 150, and the interfacial tension F s,i This is calculated using the above formulas (V) and (VI).

[0083] Furthermore, the particle size distribution calculation device 100 uses the second particle size distribution calculation unit 150 to calculate the u obtained by the above formula (IV). iThe position information of the calculated particle i may be updated using the following equation (VII).

[0084] Furthermore, the particle size distribution calculation device 100 may perform the above calculations (I) to (VII) for all calculation particles i using the second particle size distribution calculation unit 150 to update the positions of all calculation particles i that constitute the droplet.

[0085] Next, the particle size distribution calculation device 100 uses the second particle size distribution calculation unit 150 to determine whether the position or residence time of the mat and slag satisfies the termination conditions (termination condition determination step: step S18).

[0086] If the particle size distribution calculation device 100 determines, based on the second particle size distribution calculation unit 150, that the positions of all mats and slags satisfy the termination conditions (step S18: Yes), it counts the number of continuously existing mats (calculated particle i in the above formulas (I) to (VII)), converts them into volume and particle size of the mats (calculated particle i in the above formulas (I) to (VII)), and calculates the particle size distribution of the mats and slags after the collision (step S19: calculation of particle size distribution of mats and slags after collision).

[0087] The particle size distribution calculation device 100 outputs the particle size distribution of the mat and slag after impact obtained in the step of calculating the particle size distribution of the mat and slag after impact (step S19) using the second particle size distribution calculation unit 150 (output step of particle size distribution of mat and slag after impact: step S20).

[0088] Output methods include displaying the data on a monitor or similar device.

[0089] On the other hand, if the particle size distribution calculation device 100 determines, by the second particle size distribution calculation unit 150, that the position or residence time of all mats and slags does not meet the termination conditions (step S18: No), it returns to the calculation step for the dynamic changes of the mats and slags (step S17) and recalculates the dynamic changes in the position and shape of the mats and slags due to their movement.

[0090] The particle size distribution calculation method according to this embodiment, by using the particle size distribution calculation device 100, can take into account the balance of forces including the surface tension and interfacial tension of the mat and slag, and as shown in Figure 3, it can represent the behavior of droplets, such as deformation, rotation, and splitting due to collisions between mat and slag droplets. Therefore, according to the particle size distribution calculation method according to this embodiment, changes in collision probability due to deformation and rotation of mat and slag droplets, a decrease in droplet diameter due to splitting, and the time lag until the mat and slag merge upon collision can be evaluated with high accuracy, and the change in the particle size distribution of the mat due to collisions of droplets consisting of multiple slag and mat falling inside the reaction shaft 10 can be calculated with high accuracy.

[0091] <Hardware configuration of particle size distribution calculator> Next, an example of the hardware configuration of a particle size distribution calculation device will be described. Figure 7 is a hardware configuration diagram of the particle size distribution calculation device. As shown in Figure 7, the particle size distribution calculation device 100 is composed of, for example, an information processing device (computer), and physically it can be configured as a computer system including a CPU (Central Processing Unit: processor) 101 which is the arithmetic processing unit, RAM (Random Access Memory) 102 and ROM (Read Only Memory) 103 which are the main memory, auxiliary storage device 104, input / output interface 105, and display device 106 which is the output device. These are interconnected by a bus 107. Note that the auxiliary storage device 104 and the display device 106 may be provided externally.

[0092] The CPU 101 controls the overall operation of the particle size distribution calculation device 100 and performs various information processing. The CPU 101 executes the particle size distribution calculation program stored in the ROM 103 or auxiliary storage device 104 and controls the display operation of the measurement recording screen and the analysis screen.

[0093] In this embodiment, the particle size distribution calculation device 100 may use a GPU (Graphics Processing Unit) in addition to the CPU 101. The GPU is a dedicated processor for high-speed rendering, but it can also be operated by a program. Since the GPU has a higher calculation speed than the CPU 101, it can, for example, achieve 100 times or more performance than the CPU in particle method simulations.

[0094] RAM102 is used as the work area of ​​CPU101 and may include non-volatile RAM for storing major control parameters and information.

[0095] ROM103 stores basic input / output programs, etc. The particle size distribution calculation program may also be stored in ROM103.

[0096] The auxiliary storage device 104 is a storage device such as an SSD (Solid State Drive) or HDD (Hard Disk Drive), and stores various data, files, etc., necessary for the operation of the particle size distribution calculation program and the particle size distribution calculation device 100.

[0097] The input / output interface 105 includes both a user interface such as a touch panel, keyboard, display screen, and operation buttons, and a communication interface that takes in information from an external data acquisition server and outputs the analyzed information to other electronic devices.

[0098] The display device 106 is a monitor display or the like. The display device 106 displays the measurement recording screen and the analysis screen, and the screen is updated in response to input / output operations via the input / output interface 105.

[0099] Each function of the particle size distribution calculation device 100 shown in Figure 7 is realized by loading simulation software (including a calculation program for in-furnace reactions) into the main memory or auxiliary memory 104, such as RAM 102 or ROM 103, and executing the particle size distribution calculation program stored in RAM 102, ROM 103, or auxiliary memory 104 using the CPU 101, thereby reading and writing data to RAM 102, etc., and operating the input / output interface 105 and display device 106.

[0100] The particle size distribution calculation program can use a program with the following configuration. In other words, the particle size distribution calculation program is a program that causes a computer to perform at least a particle size distribution calculation to calculate the particle size distribution of matte and slag produced when smelting raw materials supplied from the top of the reaction tower fall toward a settler located below the reaction tower and react with reaction gas supplied into the reaction tower. A first particle size distribution calculation step for calculating the particle size distribution of the mat and the slag, A region setting step in which a predetermined region within the reaction tower is set as the calculation region, A setup step involves arranging the mat and the slag within the calculation domain to set the initial arrangement of the mat and the slag, A second particle size distribution calculation step calculates the particle size distribution of the mat and slag after collision by calculating the dynamic changes in position and shape due to the movement of the initial state of the mat and slag placed within the calculation domain using a particle method with a potential model, A program can be used that causes a computer to perform particle size distribution calculations, including those mentioned above.

[0101] The particle size distribution calculation program is stored in a computer's storage device, such as the main memory or auxiliary storage device 104, which may be a RAM 102 or ROM 103. Alternatively, part or all of the particle size distribution calculation program may be transmitted via a transmission medium such as a communication line and received and recorded (including installation) by a communication module or the like in the computer. Furthermore, part or all of the particle size distribution calculation program may be stored on a portable storage medium such as a CD-ROM, DVD-ROM, or flash memory, and then recorded (including installation) into the computer.

[0102] As described above, the particle size distribution calculation device 100 according to this embodiment comprises a first particle size distribution calculation unit 120, a region setting unit 130, a placement setting unit 140, and a second particle size distribution calculation unit 150. The particle size distribution calculation device 100 calculates the particle size distribution of the mat and slag in the first particle size distribution calculation unit 120, sets the calculation region within the reaction shaft 10 in the region setting unit 130, and sets the initial arrangement of the mat and slag within the calculation region in the placement setting unit 140. Then, the particle size distribution calculation device 100 calculates the dynamic changes in position and shape due to the movement of the initial state mat and slag placed within the calculation region using a particle method that uses a potential model for interfacial tension evaluation, and calculates the shape changes of the mat and slag when they collide. The second particle size distribution calculation unit 150 uses a particle method with a potential model for evaluating interfacial tension, enabling it to calculate the surface tension and force balance including interfacial tension of the mat and slag, and to represent the behavior of droplets, such as deformation, rotation, and splitting due to collisions between mat and slag droplets (see Figure 3). As a result, the second particle size distribution calculation unit 150 can represent changes in collision probability due to deformation and rotation of the mat and slag, the decrease in droplet diameter due to splitting, and the time lag until the mat and slag merge upon collision, which could not be represented by conventional methods. Consequently, the second particle size distribution calculation unit 150 can evaluate the change in mat particle size distribution (degree of mat particle growth) due to collisions between two types of solutions (mat and slag) in the reaction shaft 10 with higher accuracy compared to conventional methods (see Figure 4).

[0103] Therefore, the particle size distribution calculation device 100 can accurately calculate the change in the particle size distribution of the mat caused by the collision of droplets consisting of multiple slags and mats falling inside the reaction shaft 10 provided in the self-melting furnace 1.

[0104] The particle size distribution calculation device 100 can use the composition of the copper concentrate, the supply amount of the copper concentrate, the particle size distribution of the copper concentrate, the mass percentage of Cu in the mat upon arrival at the settler 20, and the droplet space concentration in the reaction shaft 10 as input conditions in its first particle size distribution calculation unit 120. As a result, the particle size distribution calculation device 100 can accurately calculate the particle size distribution of the mat and slag before collision in its first particle size distribution calculation unit 120. Therefore, the particle size distribution calculation device 100 can also calculate the particle size distribution of the mat after collision with the mat and slag in the reaction shaft 10 with high accuracy.

[0105] The particle size distribution calculation device 100 can calculate the composition and amount of slag and mat from the composition of the copper concentrate and the mass percentage of Cu in the mat when it reaches the settler 20, using the first particle size distribution calculation unit 120. As a result, the particle size distribution calculation device 100 can calculate in detail the particle size distribution of the mat and slag before collision using the first particle size distribution calculation unit 120. Therefore, the particle size distribution calculation device 100 can also calculate the particle size distribution of the mat after collision with the mat and slag in the reaction shaft 10 with high accuracy.

[0106] The particle size distribution calculation device 100, in its first particle size distribution calculation unit 120, estimates the density of the mat and slag from the composition of the mat and slag, and calculates the particle size distribution of the mat and slag from the density and supply amount of copper concentrate, the particle size distribution of the copper concentrate, and the amount and density of the mat and slag produced. As a result, the particle size distribution calculation device 100 can calculate the particle size distribution of the mat and slag before collision with even greater accuracy in its first particle size distribution calculation unit 120. Therefore, the particle size distribution calculation device 100 can also calculate the particle size distribution of the mat after collision with the mat and slag in the reaction shaft 10 with high accuracy.

[0107] The particle size distribution calculation device 100 can use periodic boundary conditions to set the calculation domain in the domain setting unit 130. This reduces the load required for the first particle size distribution calculation unit 120 and the second particle size distribution calculation unit 150 to calculate the particle size distribution of the mat and slag. Therefore, the particle size distribution calculation device 100 can reduce the burden required to evaluate the particle size distribution of the mat after collision with the mat and slag in the reaction shaft 10.

[0108] The particle size distribution calculation device 100 can randomly arrange mats and slags within the calculation domain using random numbers in the arrangement setting unit 140. This allows the particle size distribution calculation device 100 to arrange mats and slags within the calculation domain in the arrangement setting unit 140 while considering the actual dispersion state of mats and slags in the reaction shaft 10. Therefore, the particle size distribution calculation device 100 can calculate the particle size distribution of slags and mats before and after collision within the reaction shaft 10 in a manner that approximates the actual dispersion state of mats and slags in the reaction shaft 10.

[0109] The particle size distribution calculation device 100 can use the SPH method, MPS method, MPM, DPD method, etc., as particle methods in its second particle size distribution calculation unit 150. This allows the particle size distribution calculation device 100 to represent changes in collision probability due to deformation and rotation of the mat and slag passing through the calculation domain, the decrease in droplet diameter due to splitting, and the time lag until the mat and slag merge upon collision. Therefore, the particle size distribution calculation device 100 can accurately evaluate the change in the particle size distribution of the mat after collision with the mat and slag within the reaction shaft 10.

[0110] The particle size distribution calculation device 100, in its second particle size distribution calculation unit 102, performs particle method calculations for all mats and slags to update the positions of all mats and slags, and can repeat the calculation until the termination condition is met. As a result, the particle size distribution calculation device 100 can predict the particle size distribution of mats and slags generated from all copper concentrates supplied into the reaction shaft 10 after collision. Therefore, the particle size distribution calculation device 100 can evaluate the particle size distribution of mats after collisions with slags in the reaction shaft 10 with even greater accuracy.

[0111] The particle size distribution calculation device 100, in its second particle size distribution calculation unit 150, counts the number of continuously existing mats after the calculation is completed and converts this into the volume and particle size of the mats, thereby obtaining the particle size distribution of the mats and slag after the collision. As a result, the particle size distribution calculation device 100 can accurately obtain the particle size distribution of the mats generated from the copper concentrate supplied into the reaction shaft 10. Therefore, the particle size distribution calculation device 100 can evaluate the particle size distribution of the mats after the collision of mats and slag in the reaction shaft 10 with even greater accuracy.

[0112] As described above, the particle size distribution calculation device 100 can evaluate the change in the particle size distribution of the mat before and after the collision of the mat and slag, taking into account the coalescence behavior due to the collision of two types of solutions within the reaction shaft 10, and obtain these particle size distributions after the collision. Therefore, it can be effectively used for preliminary studies on equipment improvements for the self-smelting furnace 1, investigations into the operating conditions of the self-smelting furnace 1, and the effects of changing the type of smelting raw material supplied to the self-smelting furnace.

[0113] As described above, embodiments have been explained, but these embodiments are presented as examples only, and the present invention is not limited by these embodiments. The above embodiments can be implemented in various other forms, and various combinations, omissions, substitutions, and modifications are possible without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents. [Explanation of Symbols]

[0114] 1 Flash-melting furnace 10. Reaction tower (reaction shaft) 11. Concentrate Burner 20 Settler 30 Flue flue 40 Electric smelting furnace 100 Particle size distribution calculator 110 Input Section 120 First particle size distribution calculation unit 130 Area setting section 140 Placement setting section 150 Second particle size distribution calculation unit 160 Output section

Claims

1. A particle size distribution calculating device for calculating the particle size distribution of matte and slag produced when smelting raw materials supplied from the top of the reaction tower fall toward a settler located below the reaction tower and react with reaction gas supplied into the reaction tower, A first particle size distribution calculation unit uses the supply amount of the smelting raw material, the particle size distribution of the smelting raw material, the composition of the smelting raw material, the mass percentage of copper in the mat when it reaches the settler, and the droplet space concentration in the reaction tower as input conditions, calculates the composition and amount of the mat and slag from the composition of the smelting raw material and the mass percentage of copper in the mat when it reaches the settler, estimates the density of the mat and slag from the composition of the mat and slag, and calculates the particle size distribution of the mat and slag from the density and supply amount of the smelting raw material, the particle size distribution of the smelting raw material, and the amount and density of the mat and slag, A region setting unit that sets a predetermined region within the reaction tower as a calculation region, A placement setting unit that places the mat and the slag within the calculation domain and sets the initial arrangement of the mat and the slag, A second particle size distribution calculation unit calculates the dynamic changes in position and shape due to the movement of the mat and slag in their initial state, which are placed within the calculation domain, using a particle method based on a potential model, and calculates the particle size distribution of the mat after the collision of the mat and slag. A particle size distribution calculation device equipped with the following features.

2. The particle size distribution calculation apparatus according to claim 1, wherein the domain setting unit uses periodic boundary conditions for setting the calculation domain.

3. The particle size distribution calculation device according to claim 1 or 2, wherein the arrangement setting unit randomly arranges the mat and the slag within the calculation area using random numbers.

4. The particle size distribution calculation apparatus according to any one of claims 1 to 3, wherein the second particle size distribution calculation unit uses the SPH method, MPS method, MPM or DPD method for the particle method.

5. The particle size distribution calculation device according to any one of claims 1 to 4, wherein the second particle size distribution calculation unit performs the particle method calculation for all of the mats and slag to update the positions of all of the mats and slag, and repeats the calculation until the termination condition is met.

6. The particle size distribution calculating device according to claim 5, wherein the second particle size distribution calculating unit calculates the particle size distribution of the mats and slag after the collision by counting the number of mats that exist consecutively after the completion of the calculation and converting them into the volume and particle size of the mats.

7. A particle size distribution calculation method for calculating the particle size distribution of matte and slag produced when smelting raw materials supplied from the top of the reaction tower fall toward a settler located below the reaction tower and react with reaction gas supplied into the reaction tower, A first particle size distribution calculation step, which uses the supply amount of the smelting raw material, the particle size distribution of the smelting raw material, the composition of the smelting raw material, the mass percentage of copper in the mat when it reaches the settler, and the droplet space concentration in the reaction tower as input conditions, calculates the composition and amount of the mat and slag from the composition of the smelting raw material and the mass percentage of copper in the mat when it reaches the settler, estimates the density of the mat and slag from the composition of the mat and slag, and calculates the particle size distribution of the mat and slag from the density and supply amount of the smelting raw material, the particle size distribution of the smelting raw material, and the amount and density of the mat and slag, A region setting step in which a predetermined region within the reaction tower is set as the calculation region, A setup step involves arranging the mat and the slag within the calculation domain to set the initial arrangement of the mat and the slag, A second particle size distribution calculation step calculates the particle size distribution of the mat after collision with the mat and slag by calculating the dynamic changes in position and shape due to the movement of the initial state of the mat and slag placed within the calculation domain using a particle method with a potential model, A method for calculating particle size distribution, including the following.

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