Copper Rotation-Suspension Smelting Nozzle Dynamics
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Solution Overview
Problem
Current pyrometallurgical copper smelting processes face issues such as low oxygen availability, high smoke rates, severe erosion corrosion, and incomplete material reaction due to direct current jet techniques, which fail to meet the requirements of high feeding amounts, high oxygen concentration, and high working rates.
Innovation Solution
A copper rotation-suspension smelting process utilizing a nozzle with a swirling gas channel and Venturi channel to create a high-speed swirling flow that contacts copper concentrate or matte powders within a smelting furnace, enhancing reaction efficiency and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If direct current jet technique is used for space suspension smelting, then oxidization reaction can be completed instantaneously with huge surface area, but oxygen availability is low and smoke rate is high
Solution Approach 1:
The patent transforms the static direct current jet into a dynamic rotating jet that can change its direction and coverage area. The rotating jet technique allows the gas stream to dynamically sweep across the concentrate layer, improving oxygen distribution and reducing localized smoke generation while maintaining high reaction speed.
Solution Approach 2:
The patent adds a rotational dimension to the traditional linear jet technique. By rotating the jet 360 degrees around the reaction tower, the system transforms from a one-dimensional linear flow to a three-dimensional rotating flow, enhancing oxygen availability throughout the reaction zone while distributing smoke generation more evenly.
2Productivity
If direct current jet technique is used, then high reaction rate is achieved, but severe erosion corrosion on furnace liners occurs
Solution Approach 1:
The rotating jet continuously changes its impact position on the furnace liner, preventing concentrated erosion at any single location. The dynamic rotation distributes the mechanical and thermal stress across different areas of the liner over time, reducing severe localized erosion corrosion while maintaining high reaction rates.
3Ease of operation
If swirl injection technique is used, then gas spirally flows to contact material particles, but working effectiveness is not ideal and cannot meet high feeding amount and high load requirements
Solution Approach 1:
The rotating jet technique provides a more dynamic and forceful gas-material contact compared to gentle swirl injection. The high-velocity rotating jet actively penetrates and mixes with the concentrate particles, enabling effective contact even at high feeding amounts and loads that would overwhelm a passive swirl system.
4Reliability
If conventional smelting process is used, then stable operation is maintained, but raw material pile accumulation occurs without complete reaction
Solution Approach 1:
The rotating jet continuously moves and renews its contact with the concentrate layer, preventing dead zones where unreacted material could accumulate. The dynamic rotation ensures all areas of the reaction tower receive periodic oxygen supply, eliminating pile accumulation while maintaining stable operation through consistent reaction conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process improves oxygen availability, reduces residue copper content, decreases fume incidence, and increases sulfur dioxide content in flue gas, while accommodating fluctuating feed amounts and enhancing productivity.
Implementation Method 1
allowing a reaction gas to form a swirling flow under an action of a swirler of the nozzle
Implementation Method 2
passing through a Venturi channel of the nozzle under a guidance of the swirling gas channel
Implementation Method 3
a process in which sulfur and iron in the metal sulfide concentrate are removed by reacting them with oxygen
Implementation Method 4
subjecting the swirling flow which has been subjected to high-speed expansion through the Venturi channel to a contact reaction with the mixed material within the reaction tower
Implementation Method 5
separating a melt generated by the contact reaction which falls into a settling tank of the smelting furnace into a residue layer and a product layer
Data Source
AI summary
Disclosed in the present application is a copper rotation-suspension smelting process comprising: mixing a flux and/or fume with dried copper-containing mineral powders to form a mixed material, which enters into a smelting furnace through a material channel; allowing a reaction gas to form a swirling flow under an action of a swirler, which enters into the smelting furnace through a Venturi channel under a guidance of a swirling gas channel; replenishing the reaction gas and/or a fuel to the smelting furnace through an auxiliary oxygen channel and an auxiliary fuel channel; subjecting the swirling flow which has been subjected to high-speed expansion through the Venturi channel and enters into the smelting furnace to a contact reaction with the mixed material; separating a melt generated by the reaction which falls into a settling tank into a residue layer and a copper-containing product layer.