高压辊磨机挤满给料控制系统开发与应用

为了提高高压辊磨机的设备利用效率,减少空转率,本文提出了一套完整的高压辊磨机给矿控制策略。该控制策略以挤满给料专家控制算法为核心,加之对整个高压辊磨机作业回路进行故障监测与诊断,保证了高压辊磨机给料的持续和稳定性,提高了作业回路的生产效率和安全性。     

研山铁矿高压辊磨机工艺参数优化试验

司家营研山铁矿引进高压辊磨机后,其产品指标一直未达到设计要求,为此,对高压辊磨机进行了工业试验,结果表明：在高压辊磨机工作压力为12.5 MPa、边料返回量为70%、辊面线速度为1.78 m/s、给料粒度为+12-40 mm时高压辊磨机破碎效果最佳。     

高压辊磨机给料系统的改造与应用

重钢西昌矿业有限公司选矿厂的GM150/80型金属矿用高压辊磨机已运行了2000多h。筛下矿物经辊磨机辊压破碎,以矿饼形式排出,打散后6mm以下的矿物达70%左右,磨碎效果良好。笔者对该高压辊磨机的给料系统做一介绍和探讨。     

高压辊磨机工艺因素的研究

高压辊磨机自问世以来,引起粉碎界的高度关注,它不仅有助于实现多碎少磨,而且随着产品细度的降低,很可能成为以碎代磨的新型粉碎设备。笔者利用φ200mm×50mm实验室型高压辊磨机,对其工艺因素进行了较系统的研究,分析了高压辊磨机的压力、转速、给料粒度和组成、含水率等工艺因素与粉碎能耗、粉碎概率等粉碎指标的关系,对于研制和设计高压辊磨机,生产运用高压辊磨机有着理论的和实践的意义。     

高压辊磨机用于顽石破碎作业的工艺研究

在自磨/半自磨工艺流程中,圆锥破碎机作为自磨机顽石处理设备,在作业率和处理量上难以与大型自磨机相匹配,造成自磨机回路系统难以达到稳定平衡,并限制了产能提升。针对自磨机和顽石破碎机的工艺特点,结合SINO铁矿自磨生产实践及实验室试验,重点研究了自磨机回路中,使用高压辊磨机进行顽石破碎作业的工艺可行性。     

高压辊磨机粉碎数学建模和计算机模拟研究进展

介绍高压辊磨机粉碎数学模型的研究进展,以及应用粉碎数学模型通过计算机模拟计算进行工业型高压辊磨机粉碎效果预测、粉碎回路流程设计和工艺条件优化的研究进展。     

高压辊磨机在金堆城钼矿的应用试验

介绍了高压辊磨机的工作原理、国内外的发展状况以及高压辊磨机在金堆城钼矿的半工业试验情况。结果表明应用高压辊磨机对金堆城钼矿石进行超细碎处理,作业效果很好,高压辊磨机的引进将给选厂的节能降耗带来巨大的发展潜力。     

高压辊磨机在金堆城钼矿的应用试验

介绍了高压辊磨机的工作原理、国内外的发展状况以及高压辊磨机在金堆城钼矿的半工业试验情况。结果表明应用高压辊磨机对金堆城钼矿石进行超细碎处理,作业效果很好,高压辊磨机的引进将给选厂的节能降耗带来巨大的发展潜力。     

高压辊磨机在金堆城钼矿的应用试验高压辊磨机在金堆城钼矿的应用试验

介绍了高压辊磨机的工作原理、国内外的发展状况以及高压辊磨机在金堆城钼矿的半工业试验情况。结果表明应用高压辊磨机对金堆城钼矿石进行超细碎处理,作业效果很好,高压辊磨机的引进将给选厂的节能降耗带来巨大的发展潜力。     

某钒钛磁铁矿高压辊磨碎矿试验

利用中钢集团安徽天源科技股份有限公司自主研发的1 000 mm×260 mm型高压辊磨机,对某钒钛磁铁矿进行了高压辊磨试验研究。试验结果表明:高压辊磨机能大幅度降低产品粒度,显著提高磨矿效率,并为高压辊磨机在大型铁矿石选矿厂应用提供了可行性依据。     

高压辊磨机粉碎工艺国外应用进展与发展趋势

基于层压粉碎原理,高压辊磨机具有处理量大、能量利用率高、粉碎产品粒度细等特性,已经广泛应用 于冶金矿山领域,且节能降耗效果显著。 文章总结了开路粉碎、边料返回半闭路粉碎和筛分(包括干法筛分和湿法筛 分)全闭路粉碎三种粉碎工艺的选择依据。 结合高压辊磨机在金刚石解离、铁矿球团原料预处理、(半)自磨顽石破碎 和金属矿磨前粉碎领域的典型应用案例,重点阐述了高压辊磨机的粉碎工艺流程、设备型号、操作参数及应用效果。 不断提高粉碎效率、降低粉碎成本仍是高压辊磨机粉碎工艺的发展方向。 虽然多台高压辊磨机串联配置、高压辊磨 机与风力分级设备配置、高压辊磨机与搅拌磨机直接配置等新工艺发展不够成熟,但节能降耗优势明显,有望为冶金 矿山物料高效粉碎提供新的解决方案。     

The effect of feed moisture on the comminution efficiency of HPGR circuits

The comminution efficiency of high-pressure-grinding-rolls (HPGRs) is a well described function of a number of feed parameters including grindability, abrasion index, granulometric composition, top size and particle size distribution. Far less studied is the effect of feed moisture. This paper investigates both the overall and the specific comminution efficiency of a circuit consisting of a pilot HPGR unit followed by a batch ball mill as a function of the moisture level in the HPGR feed. Forsterite olivine sand (−7 mm) supplied by Sibelco Nordic was used as feed material. The results showed that the relationship between moisture and crushing efficiency for both the HPGR and the circuit can be described successfully by means of a parabolic function. Dry material, as well as that with the highest moisture content, showed the lowest particle size reduction ratios irrespective of the specific grinding force level. The paper also analyses the phenomenon of flake generation and shows that the feed moisture influences the flake content in the coarser size fractions of the HPGR product.     

Comparison of open and closed circuit HPGR application on dry grinding circuit performance

A conventional cement grinding circuit is composed of a two compartment tube mill, a mill filter which collects the fine material inside the mill and a dynamic air separator where final product with required fineness is collected. In general the material fed to the circuit has a top size of 50 mm which is very coarse for the ball mill. For this purpose, later in 1980s, high pressure grinding rolls (HPGR) has found applications as a pregrinder which increased throughput of the grinding circuit at the same fineness.In early applications, HPGR was operated in open circuit. But later as the operating principle of the equipment based on the compression, some portion of the HPGR discharge recycled back to improve efficiency of the mill or operated closed circuit with classifiers. Within this study effect of open and closed circuit HPGR applications on dry grinding circuit performance was examined. For this purpose sampling studies around three different cement grinding circuit were completed. In the first study, a circuit including open circuit HPGR, ball mill and air separator was sampled and chosen as the basic condition. As the final product size distribution is important for grinding circuit, model structure of each equipment was developed. The second and third surveys were carried out around closed circuit HPGR operation with V and VSK separator to develop models for the separators. Finally the separator models were used in basic condition to simulate closed circuit HPGR application.It was understood from the studies that closed circuit HPGR operation improved the overall circuit efficiency at the same final product fineness by reducing the specific energy consumption.     

高压辊磨机粉碎行为研究进展

高压辊磨机粉碎原理为层压粉碎，具有处理量大、节能高效等特点。与传统破碎方式相比，高压辊磨机粉碎产品细粒级含量高、微裂纹发育、矿物解离度高、邦德球磨功指数低，还有助于下游选别或浸出作业。随着辊面抗压强度和抗磨蚀性能不断增强，高压辊磨机已经广泛应用于冶金矿山领域，如金刚石与围岩解离、球团原料铁精矿预处理、金属矿磨前（超）细碎，（半）自磨工艺顽石破碎等。高压辊磨机的成功应用与其粉碎行为密切相关。文章依次从高压辊磨机的研发背景、工作原理、辊面压力分布、宏观粉碎过程、料床应力响应、粉碎产品特性等方面系统评述了高压辊磨机的粉碎行为，并分析了边缘效应和辊面磨损的产生机理、负面影响及其应对措施，旨在全面地阐述高压辊磨机粉碎行为。     

Flowsheet considerations for optimal use of high pressure grinding rolls

High pressure grinding roll (“HPGR”) technology is very rapidly gaining a wide acceptance within the mineral processing industry. Benefits, including a superior energy efficiency and a lower overall operating cost of an HPGR based circuit compared to alternative technologies have been demonstrated at a number of operations throughout the world. Increasing numbers of units are presently being installed in the minerals industry world-wide. This trend is an excellent reflection of the confidence now placed in the technology by new and existing users.This paper summarizes basic principles of the equipment and of various options how to include an HPRG in the grinding circuit for most efficient use. Case studies demonstrate the application of HPGR’s in different grinding circuit set-ups and for the comminution of different ore types. Benefits of the options of open circuit grinding, closed circuit grinding incorporating wet and dry screening as well as the option of achieving a finer grind by recirculating part of the HPGR product using a mechanical splitter are discussed.From a processing point of view the effects of partial product recycle are detailed and some guidance for selection of cut size between HPGR and ball mill is provided.     

不同破碎方式对鞍山式赤铁矿石磨矿特性的影响

高压辊磨破碎是基于料层粉碎的一种新型破碎方式,不仅本作业破碎效率高、能耗低、粉矿量大,而且破碎产品颗粒内部丰富的微裂纹也有利于后续磨矿作业节能。为了定量评价高压辊磨破碎对后续磨矿的影响,以鞍山式某赤铁矿石为试样,进行了磨矿技术效率和Bond球磨功指数试验。结果表明：由于高压辊磨产品中小于指定粒度（-0.074 mm）的物料产率明显较高,因而在较粗磨矿细度下,高压辊磨产品的磨矿技术效率均略低于颚式破碎产品,但随着磨矿细度的提高,二者的差距越来越小,当-0.074 mm占85%时,二者的磨矿技术效率相当,超过该磨矿细度,则磨矿效率开始小幅反超;目标粒度为280、150、105、74 μm时,高压辊磨产品的Bond球磨功指数比颚式破碎产品分别低9.41%、7.70%、4.97%和4.28%,降低的幅度随目标粒度的降低而减小,表明高压辊磨破碎对一段磨矿有显著的节能效果。     

罗河铁矿复合铁矿石高压辊磨工艺应用研究

为了解高压辊磨破碎对罗河铁矿选矿厂细碎产品可磨性的影响,对现场细碎产品进行了开路辊压破碎、边料返回闭路辊压破碎试验,边料返回闭路辊压破碎产品与现场细碎产品相对可磨度测定试验,样品和高压辊磨机边料返回闭路破碎产品球磨功指数测定试验,以及增设高压辊磨工艺后一段球磨扩能效果分析。结果表明：①高压辊磨作业可大幅度提高产品中细粒级含量,边料返回闭路破碎试验产品-3 mm粒级含量由辊磨前的56.73%提高至85.30%,提高28.57个百分点;-5 mm粒级含量由辊磨前的67.79%提高至92.65%,提高24.86个百分点;单位处理量为252 ts/（hm3）。②高压辊磨作业可显著改善入磨矿石的磨矿性能,当磨矿细度为-0.075 mm占60%时,与样品相比,高压辊磨机边料返回闭路破碎产品的相对可磨度为1.294;样品经高压辊磨破碎后,其球磨邦德功指数由16.15 kWh/t降至13.75 kWh/t,降幅为14.86%。③选矿厂增设高压辊磨边料返回超细碎作业后,由于入磨矿石可磨性的改善,一段球磨的产能可提高35.41%。     

Improvement of energy efficiency of rock comminution through reduction of thermal losses

The principal objective of this work was to develop a thermal imaging technique to measure the radiant heat coming from rock particles during or immediately after crushing, with the purpose of minimising energy losses while maintaining the efficiency of rock crushing. The main goal of the work was energy optimization of crushing in High Pressure Grinding Rolls (HPGR). We were able to perform reproducible measurements of the temperature increase that occurs during transient events such as dynamic rock breakage and HPGR crushing. Results obtained show that with an increase of energy introduced, there is an increase in the maximum temperature along the fractured surface as well as increases in the overall amount of thermal energy.Results obtained during HPGR testing clearly indicate that there is an optimum intensity of pressure to which rock needs to be exposed. Any further increase in pressure, results in only a marginal increase in fragmentation and a significant increase in unproductive heating of rock. We were also concerned about the effect of the size of particles coming into the HPGR. The fraction of new fine material (fines) produced during HPGR crushing is much higher in the case of feed with a narrow size distribution, i.e. without pre-existing fines. Significantly, improved performance is achieved with a reduced amount of net comminution energy.Observed relative crushing inefficiency of feed with a wide fragment size distribution (containing fines and coarse particles), is due to a large amount of pre-exiting fines, which clog the pore space between coarser fragments. In the compressed zone of the HPGR this creates approximately hydrostatic compressive loading conditions, which require much higher pressure (i.e. energy) to cause breakage of coarser particles. Experimental results indicate that up to 40% of energy can be saved through optimization of the applied pressure and modification of feed fragments size distribution.     

The effect of using different comminution procedures on the flotation of sphalerite

High Pressure Grinding Rollers (HPGR) are known to reduce energy consumption and wear costs and improve the throughput in the circuit. It has been suggested that they can also modify the liberation characteristics of the ore. In the present study the effect of using conventional crushing as opposed to HPGR in combination with either dry or wet milling was investigated using a base metal sulphide, viz. sphalerite, in order to determine whether there may be an improvement in flotation performance following the use of different comminution procedures. It was found that, irrespective of the crushing procedure (HPGR or conventional), dry milling resulted in the highest grades and recoveries of zinc. These were typically 94% recovery at 40% grade. In order to gain an insight into the effect which these comminution procedures had on the ore, samples of feed and product were investigated using surface analytical techniques. Mineralogical analyses showed no differences in the liberation characteristics of sphalerite irrespective of the comminution procedures used. However, dry milling produced a lower d50. The paper proposes possible reasons to explain these observations.