有色金属(冶炼部分)

针对铜侧吹熔炼工艺参数优化控制难题，基于MetCal软件平台，利用已开发的铜侧吹熔炼多相平衡热力学数学模型和仿真系统，采用L₄₉(7⁸)正交试验设计，系统探究了氧料比、燃煤率、熔剂配比等7个关键工艺参数对熔炼过程的影响规律。通过方差分析(SPSS)结合效应量评估，揭示了各参数对铜锍品位、渣相组分及烟气成分的显著性作用机制。结果表明：氧料比和燃煤率对铜锍品位、渣含铜等6项指标具有全局性显著影响；石英熔剂率通过调节硅酸度显著改变渣中Fe_3O₄含量和铁硅比；富氧浓度与烟气SO₂浓度呈强正相关，而熔炼温度和烟灰率对工艺指标无统计学显著影响。在此基础上，采用热力学模型进一步探讨了Cu-Fe-S-O-Si-Ca多元体系的相平衡机制。本研究建立的参数显著性分级结果为铜侧吹熔炼工艺优化提供了理论依据，该方法可推广至复杂冶金系统的多目标优化研究。

The copper side-blown smelting process faces persistent challenges in industrial optimization due to the complex coupling mechanisms among multiple operational parameters and insufficient theoretical understanding of their synergistic effects. To systematically address these limitations, this study develops an integrated computationalexperimental framework combining multi-phase equilibrium thermodynamics with advanced statistical analysis. Using the MetCal numerical simulation platform as the foundational tool, a comprehensive thermodynamic model for the Cu-Fe-S-O-Si-Ca six-component system was established, explicitly accounting for phase equilibria interactions between matte, slag, and gaseous phases under dynamic smelting conditions. A mixed-level orthogonal experimental design(L₄₉(7⁸) matrix) was implemented to decouple the intertwined effects of seven critical parameters: oxygento-feed ratio, coal consumption rate, quartz flux rate, smelting temperature, oxygen enrichment level, ash content, and iron-to-silicon ratio. This design strategy enables efficient exploration of experimental combinations while maintaining statistical validity through balanced factor-level distribution. Process responses were quantified through six key performance indicators: copper matte grade, copper loss in slag, Fe_3O₄ content in slag, operational iron-tosilicon ratio, slag viscosity, and flue gas SO₂ concentration. Three-factor analysis of variance(ANOVA) performed through SPSS 26.0 quantitatively assesses parameter contributions to six critical process indicators: matte grade, copper content in slag, Fe_3O₄ content, operational iron-to-silicon ratio, slag viscosity, and flue gas SO₂ concentration. The ANOVA results demonstrate that oxygen-to-feed ratio and coal consumption rate exhibit statistically significant impacts(p<0.01) on global performance metrics including matte grade and copper loss in slag. Quartz flux rate primarily regulates magnetite content and iron-to-silicon ratio through silicate degree modulation. Oxygen enrichment concentration shows strong positive correlation with flue gas SO₂ levels. Notably, smelting temperature and ash content display no statistically significant influences(p>0.05), suggesting potential overspecification in current temperature control practices. Complementary thermodynamic modeling further elucidates parameter effects on product phase composition. The elevation of oxygen potential facilitates the preferential oxidation of FeS, thereby promoting matte enrichment in copper smelting. The quartz flux rate demonstrates a significant reduction effect on Fe_3O₄ content within slag through adjustment of the SiO₂/Fe ratio, with a notable reduction amplitude reaching 30%. Conversely, the lime flux rate induces a linear increase in CaO concentration within slag, elevating from 3% to 14%. Regarding oxygen enrichment, each 10% increment in concentration correlates with an average 3% enhancement of SO₂ concentration in flue gas. However, stringent control of coal rate is imperative to suppress CO₂ generation, as exceeding 5% coal rate results in CO₂ proportion surpassing 18% in flue gas composition. The developed parameter significance classification model provides theoretical guidance for optimizing copper side-blown smelting processes, while the methodology demonstrates generalizability for multi-objective optimization in complex metallurgical systems. This integrated approach effectively bridges the knowledge gap between multi-parameter interactions and process outcomes, offering a systematic framework for data-driven decision-making in industrial smelting operations.