<p>Under the “dual carbon” strategy, the copper smelting industry faces severe pressure for energy conservation and emission reduction. The oxygen-enriched top-blown smelting process suffers from relatively low oxygen concentration and copper matte grade, relying heavily on carbonaceous fuels for heat supply, resulting in high energy consumption and carbon emission intensity. This study systematically investigated the process characteristics and optimization strategies through industrial data analysis, multiphase non-equilibrium thermodynamic modeling, and industrial trials. Statistical analysis under varying oxygen concentrations (59 to 65 vol pct) and copper matte grades (56 to 61 wt pct) revealed that the oxygen-to-concentrate ratio is the dominant parameter for controlling copper matte grade, with a functional substitution relationship between lump coal and the sulfur content in the feed material. Thermodynamic calculations supplemented key parameters of the smelting system, including temperature, oxygen potential, sulfur potential, and Fe<sub>3</sub>O<sub>4</sub> content in slag. The results indicated that under high oxygen concentration and high copper matte grade conditions, the sharp increase in smelting temperature and the enrichment of Fe<sub>3</sub>O<sub>4</sub> in slag are the critical factors constraining process stability. Industrial trials implementing an “oxygen-increasing and coal-reducing” strategy produced matte with a grade of 64.62 wt pct at a concentrate throughput of 150 t/h and an oxygen concentration of 66 vol pct, with the temperature stably maintained within 1200&#xa0;°C to 1250&#xa0;°C. Under these conditions, the approximately lump coal consumption was 40.55 kg per ton of copper matte produced. This work provides a theoretical foundation and engineering verification for the low-carbon upgrading of oxygen-enriched top-blown smelting.</p>

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Process Analysis and Low-Carbon Optimization of Oxygen-Enriched Top-Blown Copper Smelting

  • Tao Xiao,
  • Zhengping Lu,
  • Xin Zhou,
  • Linshan Li,
  • Songsong Wang,
  • Zhiguo Zhang,
  • Yinbin Zhu,
  • Qinmeng Wang

摘要

Under the “dual carbon” strategy, the copper smelting industry faces severe pressure for energy conservation and emission reduction. The oxygen-enriched top-blown smelting process suffers from relatively low oxygen concentration and copper matte grade, relying heavily on carbonaceous fuels for heat supply, resulting in high energy consumption and carbon emission intensity. This study systematically investigated the process characteristics and optimization strategies through industrial data analysis, multiphase non-equilibrium thermodynamic modeling, and industrial trials. Statistical analysis under varying oxygen concentrations (59 to 65 vol pct) and copper matte grades (56 to 61 wt pct) revealed that the oxygen-to-concentrate ratio is the dominant parameter for controlling copper matte grade, with a functional substitution relationship between lump coal and the sulfur content in the feed material. Thermodynamic calculations supplemented key parameters of the smelting system, including temperature, oxygen potential, sulfur potential, and Fe3O4 content in slag. The results indicated that under high oxygen concentration and high copper matte grade conditions, the sharp increase in smelting temperature and the enrichment of Fe3O4 in slag are the critical factors constraining process stability. Industrial trials implementing an “oxygen-increasing and coal-reducing” strategy produced matte with a grade of 64.62 wt pct at a concentrate throughput of 150 t/h and an oxygen concentration of 66 vol pct, with the temperature stably maintained within 1200 °C to 1250 °C. Under these conditions, the approximately lump coal consumption was 40.55 kg per ton of copper matte produced. This work provides a theoretical foundation and engineering verification for the low-carbon upgrading of oxygen-enriched top-blown smelting.