风淬造粒实验研究及铜渣底吹风淬过程多相流动数值模拟

Experimental study of wind quench granulation and numerical simulation of multiphase flow of copper slag in bottom-blowing air quenching process

  • 摘要: 铜的火法冶炼过程中高温铜渣通常采用水淬冷却,造成大量的高品质余热资源被浪费。本文提出了一种底吹风淬造粒的方法,气流自下而上喷出将熔体流股冲击为液膜,并进一步破碎为液滴,液滴被气体冷却后凝固为颗粒。气流吸收熔体的热量后进入余热锅炉,从而实现余热回收。通过设计搭建实验台,使用液态石蜡分别进行侧吹和底吹风淬实验,得出底吹风淬法能够在较低风压和较小风量条件下将液相全部破碎为液滴,且造粒过程稳定,有利于推广至工业应用。建立了底吹风淬多相流动过程数学模型,使用实验数据对模拟结果进行了验证。模拟计算了铜渣的底吹风淬过程,分析了气体流速、熔体出口和气体出口直径比对风淬过程的影响。结果表明,气体流速太小则难以形成稳定液膜,流速过大则会堵塞熔体出口,气体流速为100 m/s时可将熔体冲击为液膜并破碎为液滴。减小直径比可将熔体风淬为粒度更小、更加均匀的液滴。虽然直径比过大时能够形成液膜,但气流冲击不足使得液膜破碎后形成直径较大的团块。

     

    Abstract: The high-temperature copper slag is usually cooled by water quenching in the pyrometallurgical process of copper, resulting in the waste of a large amount of high-quality waste heat resources. This study proposed a bottom-blowing air quenching granulation method, in which the gas jet was sprayed from the bottom to impact the melt stream to a liquid film and further break it into droplets. Then, the airflow cooled the liquid droplets and solidified them into particles. The airflow absorbed the heat of the melt and entered the waste heat boiler to realize the waste heat recovery. Experimental platforms of bottom-blowing air-quenching were designed and constructed. Side-blowing and bottom-blowing air quenching experiments were conducted by using liquid wax. Results show that the bottom-blowing air quenching can break the liquid wax into droplets under the conditions of low pressure and low blowing rate, and the granulation process is stable, which is beneficial for extending to industrial applications. A mathematical model of bottom-blowing air quenching multiphase flow was constructed, and the simulations were in good agreement with experimental data. Air quenching process of copper slag was simulated, and the effects of gas flow rate, ratio of melt outlet and gas outlet diameter were analyzed. Results show that it is hard to form a stable liquid film when the gas flow rate is too small, the melt outlet will be blocked when the flow rate is too large, and the melt can form into a liquid film and then break the film into liquid droplets when the flow rate is 100 m/s. Reducing the diameter ratio can quench the melt into smaller, more uniform droplets. Although the film could be formed when the diameter ratio is large, the film will form larger diameter clumps because of the lack of airflow.

     

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