More iron ore dressing plant because he did not mine, beneficiation process backward, outdated equipment rough, small-scale, low-grade ore, low sales prices, sales difficulties and other reasons, so that this type of concentrator at the edge of small profits and losses. How to make such enterprises develop, profitable and competitive is an important issue facing the leaders of such mineral processing plants.
Problems with raw material crushing and grinding systems
The particle size of the pre-grinding ore in a small-scale concentrator is about 25 mm, which greatly reduces the grinding efficiency of the mill. Since the mill is a fine grinding device, the grinding efficiency of the 25 mm (mm) ore is less than 80 micrometers (um) when the coarse crushing efficiency of the mill is low. At this time, 1 ton of medium hardness ore needs to consume about 25 KWH. The advanced crushing process has broken the ore to a particle size below 10mm. At this time, the power consumption of the mill grinding 1 ton of ore is only about 13KWH. The method is to add a fine crusher on the crude crushing system of the raw material, so that the particle size of the ore before the mill is reduced from 25 mm to 10 mm, and the crushing of 1 ton of ore by the fine crusher requires 5KWH. Instead of finely crushing the ore with fine crushing equipment before grinding, the power consumption of 1 ton of ore in the two systems of crushing and grinding can be reduced by 7KWH. Moreover, the cost of the hammer liner consumed by the fine crushing equipment before grinding is significantly lower than the cost of the ball mill and the liner. A concentrating plant that processes 100,000 tons of ore per year can use advanced technology in the crushing and grinding process to save electricity and materials consumption by 400,000 yuan.
Choose energy-saving, high-yield crushing equipment
There are many fine crushing equipments for ore, and the ideal equipment that users can choose is less. According to the main users, the consumption of the hammer and liner in the crusher is frequent, the replacement is frequent, the output is low, and the power consumption is high. Maintenance and maintenance are difficult, the time is long, and the equipment operation rate is low. For example, the hammer crusher , whether it is a vertical shaft hammer crusher or a horizontal hammer crusher, has a short service life of the hammer head. The shortest one is replaced once every three or five days, and the longest one is replaced once every two months. . The consumption of hammerheads and linings requires 1 yuan for 1 ton of ore and 7 KWH for electricity consumption of 1 ton of ore. Here, they recommend to the user an energy-saving bearing cone with low consumption of wear parts, long use time, high output, stable discharge size and low power consumption. The power consumption can be reduced from other crusher 7KWH/ton ore to 5KWH/ Tons of ore. The service life of the lining consumables can be increased from one week to half a year, and the wear-resistant steel such as liners and hammers consumed by crushing 1 ton of ore is about 0.2 kg/ton of ore, which drops to 0.01 kg/ton of ore, and drops nearly 20 times. More than double.
Choose energy-saving, high-yield grinding equipment
1, the general type grinding mill to use on the market today, the main bearings are pasteurized alloy pad bearing large running resistance, high fuel consumption, with a large mill bearings need lubrication station, maintenance difficulties, grinding 1 The electricity consumption per ton of ore is about 25 kWh (KWH); now the rolling bearing used in the main bearing of energy-saving ball mill, the electricity consumption of grinding 1 ton of ore is about 18KWH. It is lubricated with dry oil and saves more than 80% of lubricating oil annually. The large mill removes the lubrication station of the main bearing, and the maintenance is only required once a year, and the equipment operation rate can reach 100%.
2. The lining plate of the ordinary ball mill adopts strip shape, step shape and large wave type. The disadvantage of these lining boards is that when the lining plate is worn to a certain thickness, it will be bent and deformed, resulting in failure to use; The disadvantage is that the surface shape of the lining plate is simple, the contact area between the steel ball and the lining plate is small, the grinding ability is insufficient, and the grinding efficiency is low, so that the output of the mill is low. It is recommended here that the user adopts a double U-shaped liner which has the advantage of being corrugated in the circumferential direction of the mill barrel; there is a groove along the axis of the mill. When the mill is in operation, the grinding body is lifted to a high height, and the contact surface with the lining plate increases the grinding efficiency, and the lining plate has an output of more than 6% than the ordinary grinding machine.
Improve the classification performance of concentrate after grinding, reduce the phenomenon of over-grinding, and improve the grade of concentrate powder
Some concentrators have finely ground the ore powder and directly enter the magnetic separator for magnetic separation. For example, in a concentrating plant in Jiaocheng, Shanxi, the ball milled ore powder is directly subjected to magnetic separation without grading, and as a result, the particle size of the ore powder is uneven. The coarse-grained ore grade is low; the fine grade of ore fine is high, but the magnetic field strength is low and the adsorption capacity is poor. As the water flows into the tailings, the grade of the iron concentrate powder is low and the tail running phenomenon is serious. It is suggested that the manufacturer of this beneficiation process must be subjected to grading screening and magnetic separation. Because of the different ores, there is a monomer dissociation particle size at the highest grade. If the particle size is too coarse, the impurities in the ore will not separate, and the grade of the ore will be too low. If the particle size is too fine, the grinding ability and grinding time of the mill will be wasted. Because of the ore particle size below 10μm, for every 1% increase in ore powder, the grinding time will increase by 2%, and the power consumption and the wear of the steel ball lining will increase by 2%; therefore, do everything possible to reduce the overgrinding minerals. The content is the most effective way to increase mill output, reduce power consumption and increase iron fines recovery. After the group screening measures, the minerals with less than the required particle size are returned to the mill for re-grinding, and the minerals with the required particle size are sent to the selected points in time, which not only improves the concentrate grade, but also improves the grinding efficiency of the mill. .
There are many methods for mineral grading, and the spiral classifier is the most primitive grading device . The grouping method is simple, the classification accuracy is slightly poor, and it is generally applied to the classification of a section of grinding ore discharge products. When the final product size of the iron concentrate is required to be 100% under the sieve of minus 80μm, the first stage classification may adopt a spiral classifier; the second stage classification may adopt a high frequency fine sieve. If the final product particle size of the iron concentrate powder is required to be less than 100%, the proportion of the large particles of the ore particles is relatively small. Under the premise that the screen wear of the high frequency sieve is not serious, the high frequency vibrating screen can be used. The classification is carried out, and the middle ore under the sieve is magnetically selected; the coarse ore on the sieve is returned to the mill for re-grinding. Still another classification device is a hydrocyclone. There are now more large-scale concentrators, removing the spiral classifier equipment after the one-stage and two-stage grinding machines, and switching to hydrocyclones. This method not only plays a coarse subdivision of the ore powder, but also increases the concentration of the pulp before the magnetic separation and reduces the primary dewatering equipment . The equipment is also used for grading and concentrating the slurry before the non-magnetic mineral powder is selected, which has a good effect.
In summary, the low-level concentrating plant has improved the grade of the product by more than 66.5% by carrying out technological transformation, so that it has a good selling price. Through the technological transformation of the equipment, the power consumption of the production will be reduced by more than 25%, and the output will increase by about 30%. The consumption of steel such as lining board, hammer head and steel ball is reduced by more than 15%, which makes the comprehensive economic indicators reach the domestic advanced level, improves the economic benefits of enterprises, increases the competitiveness of enterprises, and creates for the future development and growth of enterprises. Good condition
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