司家营研山铁矿高压辊磨流程的优化

司家营研山铁矿破碎系统引入高压辊磨工艺后,存在高压辊磨机排料粒度粗、处理量低等问题。为改善工艺指标,对其进行了增设检查筛与高压辊组成闭路的流程改造。改造后高压辊磨机排料-12 mm粒级含量由63.55%提高到98.96%,-8 mm粒级含量达80.02%,处理量由700~800 t/h提高到1 000 t/h,完善了高压辊磨工艺流程,提高了矿石入磨粒度的稳定性。     

高压辊磨工艺在有色选矿厂的应用实践及前景分析

原处理能力14 400 t/d的钼、钨矿选矿厂,增加高压辊磨机超细碎作业后,球磨机给矿粒度由-12 mm变为-6 mm,选矿厂碎、磨系统得到合理匹配,整体处理能力得到有效提升,达到24 000 t/d。论述了选矿厂原三段一闭路破碎工艺(3C-B)改造为高压辊磨粉碎工艺(3C-HPGR-B)的过程,总结了高压辊磨机破碎产品对下游磨矿、浮选作业的节能增效作用,对有色矿山碎、磨工艺的升级改造以及选矿厂节能降耗、扩建增产有一定的借鉴作用。     

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%。     

高压辊磨机在某钼选厂破碎系统改造中的应用

分析高压辊磨机工作原理和技术特性,并将高压辊磨—微分筛应用在某钼选矿厂破碎系统检查筛分筛下进行超细碎。应用实践表明,改造后,选矿厂原矿处理量提高到2万t/d以上,钼精矿品位由50.08%提高到52.20%,提高了2.12个百分点;回收率由81.95%提高到83.50%,提高了1.55个百分点,并大大降低了选矿能耗,综合经济效益显著。     

新疆某选铁厂破碎系统工艺流程优化改造

新疆某超贫钒钛磁铁矿选矿厂原设计采用两段开路破碎、高压辊磨机闭路破碎（直线振动筛湿式筛分）、筛下湿式粗粒预选抛尾的磨前碎选工艺，由于矿石硬度大、中碎和高压辊磨作业能力不足，导致选矿厂无法达产。为实现达产，在中碎和高压辊磨作业间增设了闭路细碎系统。改造后，不仅选矿厂顺利达产，而且辊压产品的粒度组成得到了优化，入磨物料的品质得到了改善，为企业带来了良好的经济效益。     

内蒙古大千博选矿厂改扩建实践

介绍了高压辊磨试验结果、干选试验结果和选矿厂生产现状,对破碎系统、磨选系统的流程及改扩建内容进行了详细论述.改扩建后达到了设计要求的规模.     

高压辊磨—球磨工艺的改造

对某选厂碎磨工艺采用高压辊磨机进行了工艺改造,结果表明：采用高压辊磨工艺代替常规的三段一闭路破碎流程,简化了破碎流程,精简了设备配置,提高了破碎系统处理能力,生产铁精粉的单位耗电量比改造前降低了40.58%,节能效果显著。     

CLM2000×1600型高压辊磨机及其配套系统在马坑铁矿的应用

马坑铁矿为了扩大产能,在原三段一闭路破碎与阶段磨矿弱磁选工序间增设了高压辊磨机及其配套系统。应用实践表明,新工艺系统的增设,通过放粗中、细碎产品粒度,提高了碎矿设备处理能力,选矿厂处理能力提高1.4倍;通过井下多出矿,多级预选,不仅每年可生产建筑砂、石料达200万t,而且保证了入磨矿石品位,大大提高了矿岩资源的综合利用率;磨前高效预选抛废,大大减少了进入磨选系统的矿量,单系列球磨系统的精矿产能由原53.52 t/h提高到100.47 t/h;高压辊磨机的选择性破碎,磨前粗粒湿式预先抛尾,改善了磁选效果,使铁精矿品位由改造前的63.68%提高到目前的65.42%;高压辊磨机在密闭空间内的层压粉碎不仅噪音低,而且扬尘少,改善了作业环境,减少了职业危害;铁精矿生产电耗下降4.6 kWh/t,钢球消耗下降246 g/t,节能减排成果突出。     

某大型钼矿碎磨工艺研究

根据新建40 000t/d选矿厂的建设规模、入选矿石性质、选矿工艺的需要,研究以多缸液压圆锥破碎机为代表的"三段一闭路"常规碎磨工艺、高压辊磨机为核心设备且节能效果最好的"圆锥中碎+高压辊磨机细碎+球磨闭路磨矿"的高压辊磨工艺和以半自磨为核心设备,流程最短的"半自磨+顽石破碎+球磨"的SABC工艺,并对3种工艺进行基建投资和生产成本的综合比较,从中优选出工艺技术先进、能源和材料消耗综合成本低、运行安全可靠、符合矿石特性和建厂条件的碎磨工艺方案。     

破碎方式对贫磁铁矿预选效率和磨矿特性的影响

对贫磁铁矿进行高压辊磨破碎和传统颚式破碎, 对比研究了不同破碎工艺对破碎产物预选分离指标和磨矿特性的影响。结果表明, 与传统颚式破碎相比, 高压辊磨的破碎比(F₈₀/P₈₀)高31.52%, 产物中-0.074 mm粒级含量高8.46个百分点;干式抛尾精矿全铁品位高2.66个百分点, 全铁回收率和磁性铁回收率分别高4.54和4.47个百分点。在-0.074 mm粒级占85%的磨矿细度下, 高压辊磨产物与传统破碎产物的相对可磨度为1.24, 高压辊磨产物在磨矿过程中细粒级的生成速率比传统破碎快;高压辊磨破碎产物表面产生的微裂纹比传统破碎多, 这是高压辊磨能提高破碎产物预选分离指标和可磨性的主要因素。     

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。     

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.     

高压辊磨超细碎在贫磁铁矿石预选中的应用

从高压辊磨机的工作原理及粉碎产品特性出发,分析了高压辊磨超细碎在贫磁铁矿石预选工艺中的作用。高压辊磨机特有的层压粉碎方式使其粉碎产品具有细粒级含量高、微裂纹发育充分、解离特性好等特点。高压辊磨超细碎—预选工艺能够在贫磁铁矿石入磨前抛除大量合格尾矿,减少入磨量,提高入磨品位,降低矿石的Bond球磨功指数,提高选别效率,有利于实现节能降耗。指出今后应加强高压辊磨设备与矿石性质及生产工艺的适应性研究,发展高效、低耗的新型辊磨设备,高压辊磨机与先进的预选设备配合使用时效果更好,因此针对高压辊磨产品的特性,研发配套的先进预选设备,对提高高压辊磨超细碎—预选指标具有重要意义。     

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。     

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。     

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.     

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。     

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.     

大山选矿厂碎矿工艺和设备的改进

介绍了大山选矿厂为完善碎矿工艺和设备所进行的技术改造。通过技术改造,碎矿系统工艺设备日趋完善,生产能力、系统台效、系统运转率分别提高到6.2万t、1503t/h和85.5%,2002年实现了6万t/d达产。