NOUFERROUS METALLURGICAL EQUIPMENT

Abstract:Magnetic abrasive finishing is an advanced machining technology suitable for precision machining of surfaces of various geometric shapes of workpieces. It has the advantages of residual stress dispersion, good machining uniformity, and high degree of automation. After processing, the surface roughness of the workpiece can meet the requirements for the use of ultra precision parts. The article introduces the processing principle of magnetic abrasive finishing, and summarizes the research progress of magnetic abrasive finishing processing technology from five aspects, including abrasive preparation, shape and arrangement of magnetic poles, simulation, as well as material removal models and roughness models under different processing techniques and workpiece shapes.The mathematical model in magnetic abrasive finishing was emphasized, and the key steps for establishing a material removal model were summarized.The results show that selecting magnetic abrasives with different grinding phases according to materials of varying hardness can better achieve precision machining of workpieces. Simulation analysis of magnetic field, abrasive motion trajectory, and multi-field coupling can predict the force magnitude, thermo-mechanical coupling, wear condition, and temperature change of the workpiece during machining. The shape of the magnetic poles (tile shape, square shape, saddle shape, etc.), the arrangement of magnetic poles (N-N, N-S, N-S-N, Halbach array, etc.), and the dynamic magnetic field (alternating magnetic field, pulsed magnetic field, etc.) determine the force magnitude and motion of the abrasives. Material removal models and roughness models can accurately analyze the impact of process parameters on machining results, facilitating the setting of more appropriate experimental parameters.The advantages and disadvantages of the algorithm model and mathematical model in the roughness model are analyzed. Finally, the shortcomings and deficiencies in current research are summarized, and suggestions for future research directions of magnetic abrasive finishing technology are proposed.

Abstract:As one of the main equipment in intelligent manufacturing, welding robots have been widely used in many industries such as shipbuilding, automotive, and railways due to their high welding quality and low manufacturing costs. However, technical bottlenecks still exist in terms of efficiency optimization and energy consumption control in their motion planning. The paper systematically analyzes the key technologies of welding robots and adopts a multi-dimensional analytical framework to compare domestic and international research achievements across four dimensions: time optimization, energy consumption control, obstacle avoidance mechanisms, and multi-objective collaboration. A systematic classification model is constructed with the hope of providing valuable references for the future development of welding robots, promoting continuous progress and sustainable development in welding technology to meet increasingly complex and diversified industrial needs, and advancing the manufacturing industry toward higher levels of automation and intelligence.

Abstract:In recent years, with the development of digital and intelligent technologies, realizing unmanned operations in the non-ferrous metal smelting industry has become a future trend, and automatic zinc stripping machines are the key equipment for realizing unmanned operations in wet zinc smelting. In view of the problem that the poor peeling effect of the automatic zinc peeler directly leads to low zinc peeling operation efficiency and low output, based on the 32 large plate automatic zinc peeler peeler peeling equipment, this paper conducts in-depth analysis of various factors influencing the peeling effect during the peeling process, proposes the secondary orthogonal regression test analysis method, and selects the stripping tool stroke as the design parameter, the angle of the peeling tool, the width of the peeling tool, the thickness of the peeling zinc skin, and the bonding strength of the zinc skin bonding layer as the main influencing factors. The influence of each factor on the peeling effect was analyzed and studied, and the functional mapping relationship between the four factors and the stripping load and the stripping tool stroke was obtained, providing a theoretical basis for improving the peeling success rate of the zinc peeling machine, and has broad engineering application prospects and practical application value.

Abstract:Gas-liquid breaking hammer is a large and efficient mining impact crushing equipment, which is widely used in non-ferrous mining, marine engineering and construction fields. At present, in the mining process of magnesium ore, which affected by the geological and construction conditions, the gas-liquid breaking hammer has the problems of insufficient crushing impact force, low hammering frequency and low power utilization. This paper optimizes the design of the structure and hydraulic system, analyzes the relationship between the performance parameters of the hydraulic cylinder rise and the strike stage by the dynamic model of the hydraulic system, and the parameters of the various operating conditions have been simulated and analyzed by AMEsim on the gas-liquid breaking hammer. The results show that the model of the gas-liquid breaking hammer can solve the curves of velocity, displacement, impact energy, pressure of the hydraulic cylinder with time in the rise and strike stages, and the optimized hydraulic system can effectively improve the crushing impact force and hammering frequency. When the oil supply capacity and stroke length are unchanged, based on the single factor control variable method, it can be concluded that the velocity and impact force of the gas-liquid break increase with the increase of the initial pressure of the nitrogen chamber, and decrease with the increase of the initial volume; the hammering frequency increases with the increase of the initial volume of the nitrogen chamber, and decreases with the increase of the initial pressure.

Abstract:Driven by the rapid development of high-intensity smelting, flash smelting technology is trending towards higher feed rates, oxygen enrichment, volumetric heat intensity, and matte grades. To meet these demanding process requirements, the study details a structural upgrade of a flash furnace at a nickel smelter. To address severe operational conditions, such as high thermal loads and intense erosion in critical components like the reaction shaft and settling chamber, a variety of advanced water jacket designs were employed. Furthermore, side-blowing submerged combustion technology was introduced into the slag cleaning zone. This technology utilizes submerged lances to inject kinetic and thermal energy into the molten bath, thereby improving metallurgical conditions and enhancing slag reduction. Operational results demonstrate that the new cooling structures have effectively ensured the safe and stable operation of the furnace under high loads. The application of side-blowing technology has significantly improved the metallurgical environment in the slag cleaning zone, laying a solid foundation for increasing the recovery rate of valuable metals. The study provides a valuable practical reference for the technological upgrading of similar furnaces.

Abstract:To address the issues of high cost and significant pollution associated with traditional reducing agents (diesel oil and domestic low-sulfur coal) used in anode refining, this study investigates the feasibility of using local low-sulfur lignite in Zambia (with a total sulfur content of 0.5%~1.0%, dry ash-free volatile matter of 18.02%~21.03%, and fixed carbon content of 56%~58%) as an alternative reducing agent. 〖JP2〗By systematically analyzing the reduction principle of copper anode refining and the mechanism of sulfurs impact on anode plate quality, the study focuses on examining the behavior and role of key components in low-sulfur lignite (such as ash, fixed carbon, and volatile matter) during the reduction process, and optimizes the core control parameter of copper liquid oxygen content at 1300±200 ppm. The research results show that when low-sulfur lignite is used as the reducing agent for anode refining, the qualification rate of copper in anode plates can be stably controlled above 99.49%, and the unit cost of the reducing agent decreases by 83%. While reducing costs and improving efficiency, it also takes into account occupational health and environmental protection, thus possessing good promotion value.

Abstract:This paper addresses the implementation bottlenecks of engineering digital delivery faced by traditional industries during their digital transformation, particularly the challenges of standardization gaps and entrenched mindsets. Commencing with the fundamental concepts, it provides a systematic overview of digital delivery, covering its content, standards and basis, advantages, processes, management, platform and functional requirements, and associated challenges. The study then focuses on an analysis of its application within the non-ferrous metallurgy industry. The research concludes that digital delivery is a critical component in the construction of smart factories. It enables a forward-looking approach to digital factory construction that originates from the design phase, thereby enhancing the level of engineering digitalization, improving construction quality, and reducing costs. Furthermore, it establishes a solid digital foundation for factory operations and maintenance (O&M) and future smart factory initiatives, underscoring the profound significance of concurrently implementing digital delivery during the engineering construction phase.

Abstract:To address the issues of elevated failure rates and reduced equipment availability for underground Load-Haul-Dump (LHD) machines, stemming from the inherent limitations of manual lubrication in harsh mining environments, this study focuses on the ACY514 LHD lubrication system. An automatic centralized lubrication system was designed based on the grease consumption-supply balance equation. Practical application has demonstrated that the designed system is viable and effective, ensuring adequate lubrication, significantly reducing operator labor intensity during maintenance, and effectively mitigating equipment failures caused by poor lubrication. Furthermore, an optimization plan for this system was proposed to enhance lubrication effectiveness and simplify maintenance procedures. The results from the optimized system’s implementation show that it not only extends the service life of key components and improves overall operational efficiency and reliability but also provides a valuable reference for the lubrication technology upgrade of similar equipment.

Abstract:In the field of mining and metallurgical engineering, centrifugal slurry pumps are widely used as common conveying equipment. When conveying solid-liquid two-phase flow slurry through pipelines requires high conveying pressure, a single slurry pump often fails to meet the requirements. To effectively improve the conveying head, multiple slurry pumps can be combined into a series pump group for conveying. This article introduces the principle and type of centrifugal slurry pump series pump group, deeply analyzes the difficulties of series connection technology, and proposes targeted solutions, simultaneously elaborates on its application in engineering, and explores and proposes future technological development directions. The research results provide reference for the rational application and technological development of centrifugal slurry pump series pump sets, and are expected to further improve the conveying effect and efficiency of solid-liquid two-phase flow slurry in mining and metallurgical engineering.

Abstract:In mine backfilling engineering, the loop pipe experimental apparatus is a critical piece of equipment for studying the transport properties of backfill slurry, playing a significant role in ensuring the safe and efficient operation of the backfill system. The automation and intelligentization of the system equipment and experimental process for this apparatus represent a necessary trend. This paper focuses on the automation of a mobile backfill loop pipe experimental apparatus, which enables the centralized display of all measurement data, process flows, equipment status, and experimental parameters on a human-machine interface (HMI). Furthermore, equipment control and experimental parameter setting can be centrally operated via the HMI. The implementation of this system achieves the automated operation of the apparatus and the intelligentization of the experimental process, significantly enhancing the efficiency and data reliability of backfill slurry transport property research, and providing technological support for safeguarding the safe and efficient operation of the mine backfill system.

Abstract:Slag pot transportation in smelting plants, which involves moving hot molten slag from furnaces to cooling yards and subsequently transporting cooled slag to dumping stations, is traditionally plagued by harsh operating conditions such as poor lighting, high temperatures, and high dust concentrations. These conditions pose significant manual operational risks. The advent of intelligent and 5G technologies has created the technical prerequisites for remote slag pot transportation, presenting substantial market potential and critical safety significance. As teleoperation represents the future trend for hot slag handling, this paper presents the retrofitting of a slag pot carrier’s operational process based on machine learning. By leveraging remote driving technology, we achieve beyond-visual-line-of-sight (BVLOS) operation of the carrier, thereby mitigating operational risks and improving the working environment for personnel. The study lays a solid foundation for enhancing the automation and intelligence of the entire smelting production process and demonstrates significant engineering application value.

Abstract:This study conducts an in-depth analysis on the current operational status of the underground ventilation system in a high-altitude metal mine, identifying the characteristics of oxygen supply and temperature maintenance in high-altitude underground environments. Based on the demand-based ventilation theory, a ventilation system integrating remote fan control and demand-based ventilation functions was developed. This system enables remote and precise control of underground ventilation from the surface, along with demand-based ventilation adjustments, significantly improving ventilation efficiency and energy efficiency. Measured data from multiple workstations were analyzed using an extension model, and the evaluation results showed good consistency with the actual conditions, proving the feasibility of the proposed method. After the system was implemented, power consumption was reduced by 15%, and the effective ventilation rate was consistently maintained above 85%. The study provides a strong theoretical foundation and practical reference for the design and optimization of ventilation systems in similar mines.

Abstract:To address the bottleneck issues of delayed information exchange and low collaborative efficiency in the multi-process collaborative operations of PS converter copper smelting, which traditionally rely on paper-based records and manual communication, this paper proposes and designs a monitoring and management system for logistics and handling equipment in copper smelting workshops. The system employs Gray-coded bus and rotary encoders for the continuous positioning of overhead cranes in their long-travel and cross-travel directions, respectively. Load cells are installed on both the main and auxiliary hooks to achieve crane load weighing. Laser ranging is utilized for the precise positioning of electric transfer carts, and an image recognition method is implemented for the automatic identification of slag ladle numbers. Based on a workshop-wide, full-coverage wireless communication network, the automatic acquisition and transmission of various intelligent sensing data are achieved. Consequently, the system enables effective monitoring of the production processes of key equipment, such as smelting furnaces, overhead cranes, and slag ladles, presenting a comprehensive overview of the workshop’s production through 3D visualization technology. Furthermore, it facilitates the continuous and automatic tracking of the flow of primary metallic materials, including matte, blister copper, and cold charge, with tracking data being fed back to each smelting furnace in real-time. The automated acquisition and transmission of production information significantly enhance the collaborative efficiency between processes, serving as a valuable reference for the intelligent transformation of copper smelting workshops.

Abstract:For the application scenario where the automation level of traditional waste grab cranes in waste-to-energy power plants is not high, a set of intelligent scheduling and control system for waste crane operations has been developed. Absolute encoders are installed on the wheels of the crane‘s trolley and bridge to obtain real-time position coordinates of the trolley and bridge. An absolute encoder is also mounted on the axis of the hoisting cable drum to acquire the lifting height of the grab. Ultrasonic ranging sensors are employed to monitor the material level at the feeding port, providing accurate and reliable control basis for the scheduling software to generate feeding tasks. Two LiDAR sensors are installed on both sides of the long edge of the waste storage bunker to scan the material surface in real time, acquiring point cloud data within the bunker and generating a color model of the waste surface. Through algorithms, coordinates of suitable points for grabbing and stacking are calculated. Meanwhile, the scheduling software enables collaborative operations based on the status information of the two cranes. Finally, the relevant technologies were applied to the waste-to-energy plant, achieving the expected results.