高压辊磨机新型应用工艺流程

高压辊磨机在金属矿山上的应用日益广泛,高压辊磨机的最大效用并没有完全显现出来。分析了目前高压辊磨机在金属矿破碎工艺中的3种典型应用工艺流程的利弊。为了发挥高压辊磨机的最大作用,对国内外金属矿山应用高压辊磨机的典型工艺流程作了分析、对比后,提出了一种新的工艺流程,并论述了该工艺流程在金属矿山上应用的可行性,为今后金属矿山应用高压辊磨机工艺流程的设计提供参考。     

高压辊磨机新型应用工艺流程

高压辊磨机在金属矿山上的应用日益广泛,高压辊磨机的最大效用并没有完全显现出来。分析了目前高压辊磨机在金属矿破碎工艺中的3种典型应用工艺流程的利弊。为了发挥高压辊磨机的最大作用,对国内外金属矿山应用高压辊磨机的典型工艺流程作了分析、对比后,提出了一种新的工艺流程,并论述了该工艺流程在金属矿山上应用的可行性,为今后金属矿山应用高压辊磨机工艺流程的设计提供参考。     

高压辊磨机在金属矿山的应用与设备选型

分析了当前高压辊磨机在金属矿山应用现状,归纳了高压辊磨机在金属矿山应用的选型要领和方法,并展望了高压辊磨机在金属矿山应用前景。     

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。     

高压辊磨机在金属矿山领域的应用前景

随着世界金属矿山企业生产规模的不断壮大及对高效能设备的不断重视,同时,伴随着资源的贫化或难碎难磨等问题,高压辊磨机因其特点越来越受到金属矿山开发企业的青睐,不断出现在主要碎磨工艺方案比较中。文中阐述了高压辊磨机的工作原理、选型依据、流程方案、以及高压辊磨机近些年在国、内外工程中的应用情况,并展望了其在金属矿山领域的应用前景。为高压辊磨机在今后金属矿山企业的碎磨工艺的设计及应用方面开阔思路。     

高压辊磨机在我国金属矿山的应用与前景展望(二)

介绍了高压辊磨机的结构构造、工作原理、破碎作用机理及其突出的特点,以及高压辊磨机在马钢凹山选厂的应用情况。对国内外金属矿山应用高压辊磨机的典型工艺流程,在提高选别指标、简化工艺流程、扩能降耗等方面作了重点分析、对比,为新建金属矿山优化工艺、老金属矿山进行扩能降耗改造,提供参考思路和原则流程。     

高压辊磨机在我国金属矿山的应用与前景展望(二)

介绍了高压辊磨机的结构构造、工作原理、破碎作用机理及其突出的特点,以及高压辊磨机在马钢凹山选厂的应用情况。对国内外金属矿山应用高压辊磨机的典型工艺流程,在提高选别指标、简化工艺流程、扩能降耗等方面作了重点分析、对比,为新建金属矿山优化工艺、老金属矿山进行扩能降耗改造,提供参考思路和原则流程。     

高压辊磨机在我国金属矿山的应用与前景展望(一)

介绍了高压辊磨机的结构构造、工作原理、破碎作用机理及其突出的特点,以及高压辊磨机在马钢凹山选厂的应用情况。对国内外金属矿山应用高压辊磨机的典型工艺流程,在提高选别指标、简化工艺流程、扩能降耗等方面作了重点分析、对比,为新建金属矿山优化工艺、老金属矿山进行扩能降耗改造,提供参考思路和原则流程。     

高压辊磨机在我国金属矿山的应用与前景展望（一）

介绍了高压辊磨机的结构构造、工作原理、破碎作用机理及其突出的特点,以及高压辊磨机在马钢凹山选厂的应用情况。对国内外金属矿山应用高压辊磨机的典型工艺流程,在提高选别指标、简化工艺流程、扩能降耗等方面作了重点分析、对比,为新建金属矿山优化工艺、老金属矿山进行扩能降耗改造,提供参考思路和原则流程。     

金属矿用高压辊磨机及其工艺系统发展概况

简要介绍了高压辊磨机的结构特点、发展概况及其在金属矿的应用实践;重点介绍了应用于低品位铁矿的高压辊磨机与磁力预选设备所组成的粉末预选系统的工艺概况;分析了在金属矿(尤其是铁矿)细碎作业中选用高压辊磨机应该重点考虑的设备参数和工矿条件。     

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。     

高压辊磨机选型试验的研究现状

结合高压辊磨机中物料粉碎机理,介绍了影响高压辊磨机粉碎效果的关键因素,评述了高压辊磨机设备选型试验的研究现状。高压辊磨机粉碎物料的效果主要受物料性质、辊压机工作参数及粉碎工艺等的影响。通过小型及半工业型高压辊磨机粉碎试验能够为高压辊磨机的设备选型和流程设计提供依据,但试验过程相对复杂。颗粒床活塞压载试验和数学建模尽管能够对矿石料层粉碎的工作压力、比能耗、产品粒度分布等进行有效预测,但和高压辊磨机设备选型的经验公式一样均需要对其适用性进行验证。指出高压辊磨机未来的研究方向为粉碎过程中能量传递模型、矿石碎磨特性及对分选工艺影响等的理论基础研究,以及高压辊磨机在选矿流程中的数值模拟研究。     

A novel approach for the modelling of high-pressure grinding rolls

The HPGR technology has become more attractive to the copper industry because of its high throughput capacities and its low specific energy consumptions. A HPGR model, able to give enough information based on pilot plant testing, in order to back up HPGR engineering studies, was developed. The model was based on the physical phenomena of the grinding operation. The model parameters were fitted with pilot scale test results, corresponding to a Chilean copper ore, classified in two lithologies (andesitic and porphyrytic ores). Some sets of data were not used in the fitting stage, to test the predictive capability of the model. The pilot scale tests were performed at the facilities of two HPGR manufacturers, changing operating pressure and rolls peripheral velocity (only one of the manufacturers). The simulated specific energy consumptions and particle size distributions, compared with the experimental data, were considered good enough. The model was able to predict adequately throughput capacity, specific energy consumption and particle size distributions of the edge, centre and total products.     

Robust HPGR model calibration using genetic algorithms

Mathematical modeling and simulation techniques are widely used to design and optimize comminution circuits in mineral processing plants. However, circuit performance predictions are prone to errors due to inaccurate calibration of models used in simulations. To address this problem, the authors applied a method based on genetic algorithms (GA) for estimation of HPGR (high pressure grinding rolls) model parameters. In this research, a simulation algorithm was developed and implemented in MATLAB™ based on published HPGR models to test and demonstrate GA application for model calibration. The GA toolbox of MATLAB was used to obtain the optimal values of HPGR model parameters. The authors successfully validated simulator predictions against HPGR data sets at laboratory and industrial scales. The results indicate that GA is a robust and powerful search method to find the best values of HPGR model parameters that lead to more reliable simulation predictions.     

Some benefits of using studded surfaces in high pressure grinding rolls

High pressure grinding rolls (HPGR) with studded or profiled surfaces are being promoted as new advancements to address the wear problem apparent with the grinding of harder materials. This study examines the performance of studded rolls in comparison with smooth rolls in terms of energy consumption, throughput, product size and slip between the compressed particles and particle bed. The experiments were performed on the CSIRO HPGR with studded roll tyres. The results indicate that the use of studs will increase throughput while wear is expected to be reduced, however, it is at the cost of higher energy consumption and grinding forces.     

Investigation of the breakage of hard and soft components under high compression: HPGR application

In the cement industry, high pressure grinding rolls (HPGR) has been used since 1985. At the first applications, this equipment has been installed in the existing cement grinding circuits as an open circuit precrusher in order to crush clinker especially. The cement factories produce different type of cement by using basically clinker, gypsum and additives like limestone and trass. The additives generally are not precrushed before ball mill circuits.In this study, three different mixed feeds were prepared with clinker, gypsum, limestone and trass to evaluate the performance of an industrial scale open circuit HPGR. The results of the tests show that due to the stress concentrates on soft and fractured material, the performance of HPGR becomes worse when the relatively hard material (clinker) is fed together with soft and weak materials (i.e. gypsum, limestone, trass). In addition to the industrial tests, the piston die tests have been also performed with narrow size fractions of the mixed and unmixed materials.     

Predicting the specific energy required for size reduction of relatively coarse feeds in conventional crushers and high pressure grinding rolls

In a previous paper (Morrell, 2009. Predicting the overall specific energy requirement of crushing, high pressure grinding roll and tumbling mill circuits. Minerals Engineering 22 (6), 544–549), an approach was described to predict the specific energy of a range of tumbling mill and crushing/high pressure grinding rolls (HPGR) circuits. In the case of crushing and HPGR circuits, recently acquired data have enabled this approach to be extended to coarser particle size reduction situations. This is achieved through the use of a size-dependent hardness parameter. Crushing and HPGR conditions are described where the use of this parameter should improve the accuracy of specific energy predictions. A worked example is also given.     

破碎方式对邦铺钼铜矿石可磨性及钼浮选的影响

分别采用高压辊磨工艺和传统破碎工艺将西藏墨竹工卡县邦铺钼铜矿石破碎到-3.2 mm,分析了两种破碎产品的粒度特性,测定了两种破碎方式下矿石的 Bond球磨功指数,考察了两种破碎方式对后续球磨-钼浮选的影响。结果表明：高压辊磨产品比传统破碎产品细粒级含量多且粒度分布更均匀;高压辊磨产品在不同目标粒度下的Bond 球磨功指数比传统破碎产品至少降低9.05%;高压辊磨产品和传统破碎产品浮选钼的最佳磨矿细度分别为-0.074 mm占65%和75%,相应地,前者的Bond球磨功指数比后者降低10.87%,但浮钼回收率减少2.32个百分点。