NOUFERROUS METALLURGICAL EQUIPMENT

Abstract:碳封存（CCS）技术作为应对气候变化的关键手段，其安全性与高效监测技术紧密相关。本文深入剖析了光纤监测技术在碳封存领域的应用现状，尤其聚焦于光纤布拉格光栅（FBG）与分布式声波传感（DAS）技术。FBG技术凭借高精度测量应变、温度等参数的优势，可实时监测储层压力与泄漏风险；DAS技术则利用其分布式声波感知能力，动态追踪CO2羽流迁移及诱发地震活动。通过多技术融合，如光纤与地震、化学监测的协同，显著提升了监测系统的综合性能，实现了对封存过程的全方位覆盖。然而，光纤监测技术在高温高压环境下的适应性、低频信号敏感性不足以及经济性等方面仍面临挑战。未来，需通过优化传感器设计、开发智能算法、推动标准化应用等途径，提升技术可靠性与规模化潜力，为碳封存安全提供坚实保障。

Abstract:煤炭作为我国主体消耗能源，随着浅部资源枯竭，开采深度和规模增加，矿井突水灾害成为制约煤矿安全生产的重大隐患，约80%的矿井突水事故与断裂构造相关。本文聚焦采动情况下承压含水层工作面断层引发的底板突水问题，在底板裂隙岩石损伤破坏特征方面，总结了基于损伤特性和渗流特性的裂隙岩体研究成果；对于断层诱发底板突水机理，阐述了底板断层采动受力特征及突水机理；在承压含水层工作面底板断层防突水技术上，介绍了防突水措施、突水性评价和预测的研究进展。同时指出当前研究在底板裂隙岩体损伤渗流多场耦合机制、底板断层突水机理以及智能监测预警装备与治理技术等方面存在不足，为煤矿防治水的发展提供理论依据。

Abstract:With the development of the non-ferrous metal industry, the treatment of nickel-containing solid waste has become an important issue for resource recycling and environmental protection. Traditional pyrometallurgical processes for treating nickel-containing solid waste suffer from low efficiency and poor metal recovery rates. The study aims to develop a novel composite smelting furnace for the efficient treatment of secondary resources such as nickel-containing solid waste and nickel-bearing slag, to achieve stable production of nickel matte, and to enhance the recovery rates of valuable metals such as Ni, Cu, and Co. Through optimization of process control, research on slag composition, and adjustment of slag discharge operations, the smelting process has been tested and optimized. The project was completed and put into production in February 2025. After a series of trial production adjustments, a mature and complete process control technology system and operational model have been established, achieving an advanced indicator of reducing the nickel content in slag to approximately 025% on average. The application of the novel composite smelting furnace has significantly improved the treatment efficiency of nickel-containing solid waste, realized efficient recovery of valuable metals, and promoted the innovation and upgrading of technologies for processing nickel secondary resources.

Abstract:Industrial hydrogen pipelines serve a crucial function in the hydrogen energy supply chain, while hydrogen-induced material failures present substantial safety concerns. The study conducts a systematic analysis of hydrogen-induced damage mechanisms in pipeline materials, with particular emphasis on elucidating the microscopic processes and influencing factors of both hydrogen embrittlement (low-temperature hydrogen damage) and hydrogen corrosion (high-temperature chemical reactions). Through comparative evaluation of domestic and international standards, hydrogen compatibility differences among common materials including carbon steel and austenitic stainless steel are assessed. The analysis demonstrates that low-carbon steel is appropriate for medium- and low-pressure applications, whereas austenitic stainless steel represents the optimal solution for high-pressure and high-purity hydrogen environments. By incorporating engineering case studies from fossil fuel-based hydrogen production, industrial by-product hydrogen, and renewable energy-based hydrogen production systems, comprehensive material selection strategies and protective measures are developed. The research findings establish a theoretical framework for standardized design and safe operation of hydrogen pipeline materials, while providing valuable insights for improving the lightweight characteristics and reliability of hydrogen infrastructure.

Abstract:To address silicon phase coarsening and inhomogeneous particle distribution in Al-Si alloys caused by non-uniform cooling rates during rapid solidification, the study innovatively integrates single-roller rapid solidification, lanthanum (La) modification, and acid etching. The influence of the synergistic effect of La modification and rapid solidification process on the morphology evolution and electrochemical performances of eutectic silicon in Al-12 wt.% Si alloy was investigated through XRD, SEM, EDS, XPS, CV, and GITT analyses. Results demonstrate that under 10m/s roller speed, 1% La modification achieves nanoscale refinement of eutectic silicon, transforming micron-sized dendritic structures into 50~150nm nanoparticles. The structural optimization reduces the average pore size from 18.81nm to 15.51nm and decreases the specific surface area to 61.88m²/g. Concurrently, the electrochemical performance of the prepared silicon anodes is improved. La-1% silicon anode delivers an initial Coulombic efficiency of 88.3% and a reversible specific capacity of 1421.4mAh/g after 50 cycles at 0.5A/g with reduced RSEI and Rct values. And La-1% silicon anode displays outstanding rate performance, achieving a reversible specific capacity of 1117.24mAh/g at 2.0A/g with enhanced D_Li+. The D_Li+ during intercalation and deintercalation are 2.3×10-¹²~1.9×10^-11cm²/s and 3.2×10^-12~5.8×10^-11cm²/s, respectively. The preparing strategy provides a new idea for the controllable and large-scale preparation of high-performance silicon anode.

Abstract:With the rapid development of titanium industry technology, titanium sponge, as the core raw material in titanium material processing, its structural characteristics have become the key indicators for performance evaluation. The paper, based on the generation principle of titanium sponge, studies the changes in its structural characteristics during the formation process by measuring the height of titanium lumps in the production process. The research results show that when the feeding amount is 16t and 21t, the contraction rates of titanium lumps are 37% and 55% respectively; the average height of titanium lumps formed at high feeding speed (approximately 630kg/h) is 7cm higher than that at low feeding speed (approximately 420kg/h); the contraction rates of titanium lumps formed in 50~60h and 60~70h of distillation are 33% and 41% respectively. It can be seen that too low feeding speed, too much feeding amount and too long distillation time are not conducive to the formation of loose titanium sponge structure. Through in-depth analysis, the paper reveals the internal mechanism of how these parameters affect the height of titanium lumps, and proposes strategies and methods for optimizing the structure of titanium sponge in a targeted manner.

Abstract:Analyzing the texture evolution and room-temperature formability of magnesium-manganese alloy thin sheets during warm rolling is of great significance for the development of high-performance magnesium alloy industrial materials. In this study, magnesium-manganese alloy sheets formed by synchronous rolling technology were subjected to large reduction asynchronous warm rolling. Starting from the mechanism of texture weakening in magnesium alloys, a finite element constitutive model of magnesium-manganese alloy was constructed based on the crystal plasticity theory before and after rolling. The tensile, cupping, and rigid die bulging tests were conducted to discuss the specific effects of the above rolling methods on the mechanical and formability properties of magnesium alloy sheets. It was found that there were no significant changes in the texture anisotropy in all directions before and after rolling, but the texture distribution changed significantly, and some grains rotated obviously in the ND direction. The pole density of the basal texture of the initial thin sheet was 29.49mud, while that after rolling was 15.57mud. The peak value of the pole density of the basal texture decreased, and the intensity distribution became more dispersed, indicating that the basal texture of the sheet weakened. The tensile strength of the asynchronous warm rolled sheet was up to 253.9MPa, and the maximum elongation was 10.9%. In a room-temperature environment, the deformation amplitude of the sheet was relatively small, and the maximum cupping depth could reach 2.7mm. The forming limit diagram (FLD) of the warm rolled sheet was drawn through the rigid die bulging experiment. The rigid die bulging experiment was simulated by the finite element analysis method, and the simulation data were compared with the numerical simulation FLD. The results showed that the two were highly consistent in the forming limit. Asynchronous warm rolling weakens the texture by the rotation and recrystallization of grains during sheet deformation, thereby improving the formability of the sheet, providing a possibility for the development of high-performance magnesium alloy thin sheets and even foils.

Abstract:In the study, the vacuum diffusion welding process was used to successfully weld T2 copper and 1060Al. The scanning electron microscope and energy dispersive spectrometer were utilized to analyze the microstructure and phase composition of the diffusion layer. Corrosion immersion tests and research on the electrochemical corrosion performance were carried out in a 3.5wt%NaCl solution to study and compare the corrosion resistance of each diffusion layer and the base materials. The results show that a diffusion layer composed of the AlCu layer, Al₂Cu layer, and Al₄Cu₉ layer was formed at the interface of the T2 copper/1060Al vacuum diffusion joint. The corrosion resistance varied in different regions of the diffusion layer. The corrosion degree in the diffusion layer region on the copper side was relatively mild. In the diffusion layer region on the aluminum side, the pitting holes developed into pitting pits, and with the passage of time, irregular deep gullies were formed, which eventually developed into exfoliation corrosion. In terms of the corrosion resistance, the base materials and each diffusion layer were ranked as follows: T₂Cu ＞ Al₄Cu₉ ＞ AlCu ＞ Al₂Cu ＞ 10₆0Al.

Abstract:In the molybdenum beneficiation process, the combined use of column and cell (joint application of flotation column and flotation cell) is generally regarded as an efficient and advantageous technological process. Molybdenum flotation recovery is faced with characteristics such as fine embedding particle size and high oxidation degree of ores. Aiming at the existing flotation process, the flotation dynamics tests and analyses of molybdenum flotation column and flotation cell were carried out. The air dispersion test shows that the air dispersion degrees of each flotation cell and flotation column are all greater than 2, the air is uniformly dispersed on the cross-section of the tank, and the air dispersion effect is ideal. The bubble loading rate test indicates that the shedding probability of coarse particle minerals during the upward transportation process is small, and the recovery effect is good, while fine particle minerals are not effectively enriched, and the recovery effect is poor. The slurry suspension capacity and gas holdup tests show that the overall distribution of gas holdup in the flotation cell is relatively uniform, there is no obvious particle size stratification in the tank, but there is a slight concentration stratification phenomenon. The residence time distribution test results show that the actual flotation time is longer than the ideal flotation time, and there may be dead zones inside the flotation cell.

Abstract:The gas-particle mixing and reaction characteristics in a copper flash smelting furnace are significantly influenced by the feed rate, but the mechanism by which feed rate variations affect the dispersion of the two-phase system and heterogeneous reactions remains unclear. Based on the CFD-DEM coupling method, a multi-physics coupling simulation model for the copper flash smelting process was established in this study. Through simulations of four typical feed conditions, the influence of feed rate changes on the two-phase flow, dispersion, and chemical reaction characteristics in the furnace was systematically studied. The results show that the average residence time of particles on the melt surface of the settling is less than 1s, and it decreases as the feed rate increases. At a lower feed rate (161t/h), the enhanced circumferential non-uniformity of particle distribution at the nozzle outlet leads to significant distortion of the conical distribution of the gas-particle two-phase flow in the reaction shaft, resulting in a notably lower reaction rate within the 3.0-meter range below the shaft roof compared to other conditions. This research reveals the mechanism by which the feed rate affects the reaction efficiency by changing the spatial distribution of gas-particle, providing a theoretical basis for optimizing process parameters in flash smelting.

Abstract:High-temperature flue gas will be generated in the flash smelting process of copper concentrate. During normal operation, the high-temperature flue gas is recovered by the waste heat boiler and enters the dust chamber and electric dust collector for purification. The purified flue gas is sent to the acid making process by the high-temperature exhaust fan. In the event of a boiler or subsequent process equipment failure, the high-temperature flue gas from the flash furnace needs to be rapidly cooled by the accident flue and sent to the subsequent dust collection and desulfurization system. Based on the process flow and characteristics, the paper developed a spray cooling box for flash furnace emergency flue. High temperature flue gas enters from the bottom of the box and flows vertically upward. The atomized droplets are sprayed vertically downward through the nozzle and downward in the direction of flue gas flow. The two countercurrent contact, mix, and exchange heat in all directions. The tiny droplets quickly evaporate and vaporize under the effect of high temperature of flue gas. The sensible heat of flue gas is converted into latent heat of water vapor, which makes the flue gas temperature rapidly cool to the required temperature and then flow out through the top exhaust port. Through the practical verification of the flash furnace production in the copper smelting technology improvement and renovation project of a certain non-ferrous group, the overall layout is reasonable, the process flow is smooth, there is no liquid water in the cooling box, and various technical indicators meet the design requirements.

Abstract:The continuous copper smelting technology has developed rapidly in recent years, among which the double-side blowing smelting multi-lance top blowing continuous converting technology has gradually become one of the mainstream process flows adopted in new copper smelting projects. The article systematically reviews the latest development and application status of the process, comprehensively analyzes the characteristics and advantages of the technology, and elaborates in detail on the design innovation concept and production technology indicators of the process. Reduction of adhesion and maintenance of the side blowing furnace waste heat boiler flue, smoke and dust injection, multi-mode operation of multi-lance top blowing furnace, and APC intelligent control technology have been successfully applied in the Houma North Copper Project. After being put into operation, it has been continuously and stably running for more than a year, with a system operating rate of over 98.5%. The annual output has increased from 80000 tons to 200000 tons, and the energy consumption per unit product indicator has been reduced by 50%. The application practice of this project has solved the previous production problems of the double-side blowing smelting multi-lance top blowing continuous converting process, and further promoted and improved the safety, automation level, production indicators and environmental protection indicators of the process.

Abstract:The study focuses on selecting the shaft hoisting system for a mining operation facing reduced resource reserves, with the shaft already constructed and partial equipment ordered, aiming to minimize investment. By comparing the original design (two independent hoisting systems with tower arrangement) against three optional solutions, i.e., single hoisting system with tower layout, single system with headframe layout, and single system utilizing pre-ordered equipment with tower layout. The study evaluates their technical parameters, investment costs, advantages, and disadvantages. Key findings reveal that while the original design involves the highest investment, it benefits from ready-to-use equipment, minimal retrofitting, sufficient hoisting capacity to reliably meet production targets, and the lowest risk.Although single-system options (Options 1 and 2) reduce investment, they entail equipment cancellation (with penalty risks), shaft retrofitting, tight operational capacity, and elevated construction risks.Option 3, despite having the lowest investment, fails to meet demand due to inadequate hoisting capacity.Considering reliability, production stability, and long-term costs, the original design is recommended as the optimal solution.

Abstract:The leachate from waste incineration projects is characterized by complex composition, high salinity, high pollutant concentration, and strong corrosiveness, making the stable operation of its lifting system meet a persistent challenge in design and maintenance. At present, the commonly used leachate lifting devices in garbage incineration projects include submersible leachate lifting devices and self-priming leachate lifting devices. For submersible leachate lifting devices, the main equipment is submerged in the leachate during operation. By improving the material of the submersible sewage pump, it is impossible to avoid the corrosion of the lifting device by garbage leachate, and the difficulties in operation cannot be completely solved. The paper proposes an improved leachate lifting system incorporating an automatic water replenishment device for self-priming pumps, a water replenishment pipeline and solenoid valve are added to the self-priming pump storage chamber, after receiving the pump signal, the system firstly monitors the water level in the storage chamber through a liquid level device and ensures that the storage chamber is automatically replenished to full water, which effectively addresses the unstable startup issue of the pumps, significantly reduces maintenance frequency during operation, and greatly enhances system reliability. In actual project operation, maintenance and repair are only carried out during the major overhaul of the entire plant, mainly for the replacement of the leachate suction pipe, and the replacement cycle of the self-priming pump is greater than 2 years. The overall maintenance and repair frequency is reduced to once a year.

Abstract:制造业企业智能化进程参差不齐，最早建设的ERP系统已建成约30年，随着时间的推移，更多应用系统的建设，各系统交替使用给操作员的日常工作带来了巨大的压力。某铜箔公司目前已建成ERP、CRM、SCM、OA、PMS、SMS等诸多系统，且有AGV、WMS等在建智能化项目。为提升各系统协同性，提高日常工作效率、挖掘数据价值，彻底解决信息孤岛，铜箔公司建设智能管控系统，基于数据平台的数据处理、存储、共享能力，将企业现有系统进行整合，对其中冗余数据进行清理，为后续数字化建设打造良好数据基础。项目通过合理且有效的技术与策略对各现有系统进行集成，促进异构系统间信息交互及应用，有效提高数据资产准确性、及时性、完整性。实现了现场328台主生产设备、37台AGV、9台实验室检测设备、5套三方系统的数据集成。共采集20000余点实时数据、1000余点关系数据,减少现场手工记录单40余张，电子文档7套。