基于竞争反应的锌直接浸出冶炼除铜过程建模与控制

Direct leaching technology is the most advanced green production process for zinc hydrometallurgy. The copper removal purification process is the first and most important process in purification section. Due to the complexity of competitive reaction mechanism and the uncertainty of returned underflow yields, it is difficult to realize the process optimization control, which leads to high consumption of energy and material, and large production fluctuation. It is very harmful to the stabilization of subsequent production process. Considering the problems mentioned above, we will investigate the randomness of the competitive reactions of copper removal purification process in continuous stirred tank reactor (CSTR) and the uncertainty of returned underflow yields with the closed-loop-chained characteristics. Based on the analysis of competitive reaction mechanism, we will establish the probabilistic dynamic model of competitive reaction system and the closed-loop-chained CSTR model based on reaction depth. Then, the efficiency coefficients of added zinc dust based on competitive discrimination factor will be studied and the feasible region of the control variables, i.e. the zinc power dosage of each reactor, will be defined. Finally, steady-production-oriented satisfactory optimization control method of copper removal purification process will be studied. The proposed methods will be applied to the practical copper removal purification process in direct leaching technology to validate the effectiveness. The research is important to stabilize the process production and to save energy, also promotes the interdisciplinary development of hydrometallurgy and control science, which is of great significance for both scientific research and industrial application.

直接浸出冶炼是最先进的湿法炼锌绿色生产工艺，除铜过程通过添加锌粉置换杂质铜，是该工艺净化工段首道关键工序，具有竞争反应机理复杂、晶种返回底流不确定等特征，使得除铜过程建模和优化控制困难，造成锌粉消耗高、工况波动大，严重影响后续生产流程的稳定。为此，本项目针对除铜过程连续搅拌反应槽（CSTR）内竞争反应的随机性和闭环链式结构底流返回晶种的不确定性，研究竞争反应体系概率动力学模型和基于反应深度的闭环链式CSTR模型；分析研究基于竞争判别因子的锌粉有效性，建立各反应槽锌粉添加量控制的可行域描述，提出面向工况稳定的满意优化控制方法，应用于锌直接浸出冶炼除铜生产过程以验证方法的有效性，形成竞争反应体系下除铜过程控制理论与方法。本项目研究对湿法冶炼流程的稳定和节能降耗具有重要意义，也将推动湿法冶金科学和控制科学的学科交叉发展，具有重要的科学意义和工业应用价值。

除铜过程作为锌直接浸出冶炼工艺净化工段首道关键工序，具有竞争反应机理复杂、多反应器关联以及入口矿源多变、晶种返回底流不确定等特征，导致除铜过程优化控制困难，造成生产能耗物耗高、出口铜离子浓度波动大。为此，本项目基于化学反应动力学原理和固液非催化反应模型，联立反应器物料衡算原理，建立了除铜过程竞争-连续反应体系机理模型，并研究了面向多工况的模型参数自适应辨识方法；建立基于趋势分布特征的锌粉有效性预测方法，提出了基于锌粉有效性预测的锌粉添加量多目标优化设定方法；提出了基于模糊评估的除铜过程可控域划分方法以及基于可控域的除铜过程锌粉模糊校正方法，实现了除铜过程锌粉添加量优化控制，并将成果应用于实际工业过程，提高了除铜过程出口溶液铜离子的合格率和稳定度，降低了锌粉的消耗。.项目执行过程中，发表论文12篇，其中SCI收录6篇，申请国家发明专利4项。