A Study Of Systematic Energy Saving Based Energy Consumption Analysis For Copper Smelting Processes

Under the pressures of both high energy consumption in copper smelting processes and the rising energy costs, energy saving of copper smelting enterprises is confronted with new challenges. Recently, the systematic energy saving method is used to provide new energy saving perspectives for industry, especially for the process industry. Therefore, for copper smelting enterprises, it makes contributions to find energy saving potential to save more energy by using systematic energy saving method to analyze the energy utilization during processes.In this thesis, energy utilization in copper smelting processes has been analyzed from two different perspectives based on the systematic energy saving method. One was to establish the material flow model and input-output model for energy consumption analysis through the whole smelting processes, which was based on analysis of a large number of production statistical data of the overall process. In the material flow model, there has been an ideal material flow process set up as a standard, and then the effects on energy consumption caused by the actual cupreous material flows deviating from the standard situation could be achieved. Input-output model has been used to calculate quantity relation between input products and output products, through which the production plans and energy consumption could be calculated. Additionally, optimization model has been builded to minimize energy consumption in copper smelting processes on the basis of the input-output model. The other was to establish the dynamic model of converting process to analyze the process energy consumption, which was based on the reaction mechanism. Then, using Fortran language solved the dynamic model and using orthogonal test and variance analysis method analyzed the influence on the residual heat by varying the main factors.The results show that different types of cupreous material flow have different effects on energy consumption of per ton copper. The material flow imported from outside turns out to bring down the energy consumption, but the material flow returned to the upstream processes as well as the material flow exported to outside from the process cause the comprehensive energy consumption rise. For a specific enterprise, the impact on energy consumption from different material flow can be calculated in order to estimate the energy saving potential of the material flow. On the premise of achieve profits targets, optimizing the product structure by the optimization model based on the input-output model can reduce the energy consumption to some extent. The calculation results of converting process dynamic model show that, in order to control the temperature, the residual heat during the slag making stage turns out to be0at first, and then gradually increase and finally be stable; however the residual heat during the copper making stage turns out to increase gradually at beginning, and finally be stable. These results can provide theoretical basis for putting materials during the process to absorb the residual heat. Under the reasonable scope of the actual production conditions, the residual heat can be increased by reducing the matte grade or blast velocity or increasing oxygen enrichment rate. The results provide new perspectives for energy saving of copper smelting enterprises.