I-HPGR uma iqhathaniswa ne-Ball Mill: Yikuphi okonga amandla kakhulu?

Ama-circuit okugaya angase asebenzise ngaphezu kwengxenye yawo wonke amandla kagesi asetshenziswa yisikhungo sokucubungula amaminerali. Ngakho-ke, ukukhetha phakathi kwama-roller okugaya anengcindezi ephezulu (HPGR) nama-ball mill avamile akuvamile ukuba kube ukukhetha okusekelwe kubuchwepheshe kuphela — kuyisinqumo esithinta izindleko. Zombili lezi zindlela zehlisa usayizi wensimbi yamaminerali ukuze ifinyelele kusayizi ohlosiwe ofanayo, kodwa zisebenzisa izindlela ezihluke kakhulu zokuphula izinhlayiya. Lo mehluko ubonakala ngokuqondile enanini lama-kWh asetshenziswa ngethani ngalinye. Lokhu kuqhathanisa kuhlola ukuthi amandla asetshenziswa kuphi ngempela, amanani avamile okusetshenziswa kwamandla athile endleleni ngayinye, kanye nezimo lapho obunye ubuchwepheshe bunganciphisa khona ngempela izindleko zikagesi ze-circuit yakho.

Okwenza kube nzima ukunciphisa amandla asetshenziswa ekugayeni amaminerali

Ukuchoboza nokugaya amaminerali kuyizinqubo ezingasebenzisi amandla ngendlela ephumelelayo ngokwemithetho ye-thermodynamics. Izilinganiso ezivame ukutholakala ezincwadini zobuchwepheshe zibonisa ukuthi amandla asetshenziswa ngempela ekwakheni izindawo ezintsha zokuqhekeka angaphansi kakhulu kuka-5% wamandla esewonke adonswa yi-mill. Amanye amandla alahleka ngenxa yokugobeka nokubuyela esimweni kwempahla, ukungqubuzana phakathi kwezinhlayiya, ukushisa, umsindo nokudlidliza. Yilokhu okuchaza ukuthi kungani imboni iqhubeka nokufuna izindlela ezisebenza kangcono zokuphula amaminerali esikhundleni sokumane ifake ama-drive anamandla amakhulu.

Ukusetshenziswa kwamandla ngesikhathi sokuchoboza nokugaya kuncike esilinganisweni sokunciphisa usayizi nasekumelaneni kwensimbi yamaminerali nokuphuka. Lokhu kuvame ukukalwa nge-Bond Work Index (Wi) noma ngamanye amapharamitha amasha abonisa ukuqina kwensimbi yamaminerali. Ngakho-ke, kunezindlela ezimbili eziyinhloko zokuthuthukisa ukusebenza kahle: ukunciphisa umsebenzi odingekayo ukuze kufinyelelwe kusayizi ohlosiwe, noma ukushintsha indlela amandla asetshenziswa ngayo ukuze ingxenye enkulu yawo ifinyelele ezinhlayiyeni kunokuba ichithwe ekusebenzeni komshini. Umehluko omkhulu phakathi kwe-HPGR nama-ball mill ubonakala kule ndlela yesibili.

I-HPGR uma iqhathaniswa ne-ball mill: izindlela ezimbili ezihlukene zokuphula amaminerali

I-ball mill iwaphula kanjani amatshe

I-ball mill iyisilinda esijikelezayo esigcwaliswe ngamabhola ensimbi okugaya. Lapho igobolondo lomshini lizungeza, izinto ezingaphakathi ziyaphakanyiswa bese ziwela phansi ngokulandelana noma ngokuwa okunamandla, zisebenzisa inhlanganisela yokushayisana nokuhuzuka ukuze ziphule insimbi yamaminerali. Ukuphuka kuvame ukwenzeka ngendlela engahleliwe ezinhlayiyeni ngazinye: ibhola lokugaya lishaya inhlayiya, noma izinhlayiya zihuzuka phakathi kwezinto zokugaya. Ukulahleka kwamandla okungenakugwenywa kuhlanganisa ukuphakamisa wonke amabhola okugaya, ukuguga kwama-liner namabhola ngokwawo, kanye nokukhiqizwa kwezinhlayiya ezincane kakhulu esezikhululekile kakade. Ukuhanjiswa kwe-slurry nokuhlukaniswa kwezinhlayiya ngaphakathi kwe-mill nakho kudla amandla.

I-HPGR iwaphula kanjani amatshe

I-HPGR iphoqa ungqimba oluminyene lwezinhlayiya ukuba ludlule phakathi kwama-roller amabili azungeza ngezindlela eziphikisanayo ngaphansi kwengcindezi ephezulu kakhulu. Ukuphuka kwenzeka ngokucindezelana kwezinhlayiya: izinhlayiya zicindezelana, ngakho amandla asetshenziswayo asatshalaliswa ezindaweni eziningi zokuthintana kunokuba agxile ekushayeni okukodwa. Umphumela uba umkhiqizo onezinhlayiya ezincane eziningi futhi, okubaluleke kakhulu, onenethiwekhi yokuqhekeka okuncane emingceleni yezinhlamvu zamaminerali. Lokhu kuqhekeka okuncane kwenza impahla ibe buthaka ngaphambi kokugaywa okulandelayo, okuyisigaba lapho kuvela khona ingxenye enkulu yokonga amandla.

Ukuqhathanisa ukusetshenziswa kwamandla: zibukeka kanjani izinombolo

Amanani aqondile ancike kakhulu ekuqineni kwensimbi yamaminerali nakusayizi womkhiqizo ohlosiwe. Nokho, idatha eshicilelwe evela ezimbonini kanye nemiphumela yokuhlolwa kwabahlinzeki ivame ukuwela kulezi zigaba ezilandelayo:

• Isigaba se-HPGR (ukuchoboza kwesigaba sesithathu): ngokuvamile sisukela ku-1.5 kuya ku-3.5 kWh ngethani ngalinye lezinto ezintsha ezifakwa emshinini, kuye ngengcindezi yama-roller kanye nomthamo wezinto ezibuyiselwa ku-circuit.
• Isigaba se-ball mill (ukugaya kahle kuze kufike cishe kuma-micron angu-75 kuya ku-100): ngokuvamile sisebenzisa u-10 kuya ku-25 kWh ngethani ngalinye, kuye kakhulu nge-Bond Work Index kanye nesilinganiso sokunciphisa usayizi.
• I-circuit ehlanganisa i-HPGR ne-ball mill: ngokuvamile kubikwa ukuthi amandla esewonke asetshenziswa ekugayeni angaphansi ngo-15% kuya ku-30% kunalawo asetshenziswa yi-circuit evamile yokuchoboza nokugaya ngama-ball mill, uma kukhiqizwa umkhiqizo wosayizi ofanayo.
• Inzuzo yokuqhekeka okuncane: izinto ezifakwa ku-ball mill ngemva kokulungiswa yi-HPGR zivame ukukhombisa ukwehla okulinganisekayo kwe-effective work index, okuvame ukubikwa kuphakathi kuka-10% no-25%. Lokhu kwehlisa ngokuqondile amandla asetshenziswa yi-mill ngethani ngalinye.

Nokho, kubalulekile ukuqaphela ukuthi i-HPGR efakwe ukuze icubungule insimbi yamaminerali ethambile enobumba oluningi ingase inikeze inzuzo encane, kuyilapho ukonga kungaba kukhulu lapho kucutshungulwa insimbi yethusi yohlobo lwe-porphyry eqinile futhi ehuqayo. Ukuhlolwa kokucindezelwa kwamasampula amancane kanye nokuhlolwa kwe-pilot kuphela okungasiza ukubikezela ngokuthembekile umphumela wediphozithi ethile yamaminerali.

Ukuqhathanisa ngokuqondile: izinzuzo nemikhawulo

Lapho i-HPGR inenzuzo khona

• Ukusetshenziswa kwamandla okuphansi ngethani ngalinye lapho kugaywa izinhlayiya ezinkulu, ngoba ukucindezela ungqimba lwezinhlayiya kusebenza kangcono kunokuzishaya.
• Akudingeki amabhola okugaya asetshenziswa aphele, okuholela ekongeni izindleko zokusebenza namandla asetshenziswa ekukhiqizeni amabhola ensimbi.
• Ukwakheka kokuqhekeka okuncane okunamandla kakhulu emkhiqizweni, okusiza ukukhulula amaminerali ezigabeni ezilandelayo futhi kunciphise umthwalo we-ball mill.
• Ukwakheka komshini okuhlangene nomsindo ophansi uma kuqhathaniswa ne-tumbling mill enomthamo ofanayo, okungase kwenze kube lula ukuthola izimvume nokwenza umsebenzi wokwakha.
• Ukusebenza okungcono ensimbini yamaminerali eqinile lapho ama-circuit e-ball mill eba nobunzima ngenxa yomthamo omkhulu wezinto ezijikelezayo nezibuyiselwa ekugayweni.

Lapho i-ball mill isenenzuzo khona

• Usayizi wokugcina omncane kakhulu — uma usayizi ohlosiwe ungaphansi cishe kwama-micron angu-40 kuya ku-50, i-tumbling mill isalokhu iyindlela esebenzayo.
• Insimbi yamaminerali emanzi, enamathelayo noma enobumba oluningi, engavala izindawo zama-roller futhi ibangele ukuguga okungalingani noma ukushelela.
• Ukusebenza okulula nokwaziwayo, okunama-spare parts atholakala kalula kanye nezinqubo zokulungisa esezisunguliwe.
• Izindleko zokuqala zokuthenga eziphansi emisebenzini enomthamo omncane, lapho izinsiza ezengeziwe ze-HPGR, ezifana ne-feed chute, uhlelo lokubuyisela izinto ezisemaceleni kanye ne-hydraulic power unit, zingathetheleleki ngokwezomnotho.

Ukwakhiwa kwe-circuit kuvame ukunquma umphumela

Ukuqhathanisa imishini iyodwa kungadukisa, ngoba inzuzo ye-HPGR ekongeni amandla incike endleleni ehlanganiswa ngayo ohlelweni lokucubungula. Kunezinhlobo ezintathu eziyinhloko zama-flowsheet asetshenziswa ezimbonini zesimanje:

1. I-HPGR njengokugaya kwangaphambi kwe-ball mill. Lena enye yezindlela ezivame kakhulu zokuthuthukisa imishini ekhona ukuze kongiwe amandla. I-HPGR ilungisa izinto ezifakwa ku-mill zibe zincane futhi zibe nokuqhekeka okuncane. Ngemva kwalokho, i-ball mill ingakhethwa ibe ncane noma isetshenziswe ngamandla amancane ngethani ngalinye.
2. I-HPGR esebenza ku-closed circuit enohlelo lokubuyisela izinto ezisemaceleni. Ukubuyisela umkhiqizo ophuma emaphethelweni ama-roller kusiza ukuzinzisa ungqimba lwezinhlayiya futhi kuvimbele ukugaywa ngokweqile kwezinto eziphuma phakathi nendawo. Lokhu kuthuthukisa kokubili impilo yama-roller nokusebenza kahle kwamandla.
3. Ama-circuit okuphothula ukugaya nge-HPGR. Afanele imikhiqizo edinga ukugaywa ibe ncane ngokulingene futhi aya ngokuya esetshenziswa lapho amanzi etholakala ngobuncane, ngoba i-HPGR ingasebenza ngezinto ezifakwa emshinini ezomile kakhulu.

Njengomhlinzeki wemishini ye-HPGR nezinhlelo zama-ball mill, i-ZYmining ivame ukuncoma ukuthi kuqalwe ngokuhlaziya izici zensimbi yamaminerali kunokuba kukhethwe ubuchwepheshe ngenxa yokuthandwa kwabo. Ukuhlolwa kokucindezelwa kwamasampula athathwe emigodini yokumba, kulandelwe ukuhlolwa kwe-pilot, kunikeza inani elithembekile lokusetshenziswa kwamandla ngethani ngalinye elingafakwa ngokuqondile kumodeli yamandla esetshenziswa ekuhloleni ukuthi iphrojekthi izokwazi yini ukusebenza ngokwezomnotho.

Indlela yokukhetha i-circuit efanele insimbi yakho yamaminerali

Ukuqina kwensimbi yamaminerali ne-work index

Uma i-Bond Work Index ingaphezu cishe kuka-14 kuya ku-16 kWh ngethani ngalinye, ukukhetha i-HPGR kuba nenzuzo enkulu ngokushesha, ngoba ukulahleka kwamandla ekugayeni ngokushayisana kuyaqhubeka kukhula.

Usayizi womkhiqizo ohlosiwe

Uma usayizi odingekayo ukuze kukhululwe amaminerali ungaphezu kwama-micron angu-50, ama-circuit asebenzisa i-HPGR angancintisana kahle kakhulu. Uma kudingeka usayizi wama-micron angu-20, i-ball mill noma i-stirred mill cishe izohlala iyingxenye yesistimu.

Umswakama nokuqukethwe kobumba

Umswakama wezinto ezifakwa emshinini ongaphezu cishe kuka-8% kuya ku-10%, noma ukuba khona kobumba oluningi oluvuvukalayo, kuvame ukwenza ukugaya okuvamile kube yindlela ekhethwayo, ngaphandle uma ukomisa sekuvele kuhleliwe kuphrojekthi.

Izindleko zokuqala, izingxenye ezigugayo nokutholakala kwemishini

Impilo yendawo yokugaya yama-roller ingenye yezinto ezinkulu ezinquma izindleko zokulungisa i-HPGR. Izindawo ezinama-stud noma ezenziwe nge-tungsten carbide zibiza kakhulu ekuqaleni, kodwa zingashintsha kakhulu izindleko zokuguga lapho kucutshungulwa insimbi yamaminerali ehuqayo. Imodeli yezindleko eziphelele zobunikazi phakathi neminyaka eyishumi inikeza isithombe esinembile kakhulu kunokuqhathanisa ama-kWh kuphela.

Imibuzo evame ukubuzwa

Ingabe i-HPGR ihlala isebenzisa amandla amancane kune-ball mill?

Cha. I-HPGR isebenza kangcono ekugayeni izinhlayiya ezinkulu neziphakathi nendawo. Uma kudingeka ukugaya kube kuhle kakhulu, noma kucutshungulwa insimbi yamaminerali emanzi nenamathelayo, i-ball mill ingaba yindlela esebenzisa amandla amancane futhi enobungozi obuphansi.

Ingabe i-HPGR ingayithatha ngokuphelele indawo ye-ball mill?

Kwezinye izinhlelo ezingadingi ukugaya kube kuhle kakhulu, yebo, ikakhulukazi uma kusetshenziswa i-closed circuit. Kodwa kuma-flowsheet amaningi okulungiselela i-flotation noma i-leaching lapho kudingeka khona ukukhululwa kwamaminerali angaphansi kwama-micron angu-50, i-tumbling mill noma i-stirred mill isagcinwa njengesigaba sokugcina.

Kungakanani ukonga okuvame ukutholakala lapho kuthuthukiswa i-circuit ekhona?

Izimboni ezifaka i-HPGR ngaphambi kwe-ball mill ekhona zivame ukubika ukwehla kokusetshenziswa kwamandla okuphelele ekugayeni okuphakathi kuka-15% no-30%, kanye nokonga okwengeziwe ngenxa yokuncipha kokusetshenziswa kwezinto zokugaya. Inani eliqondile kufanele liqinisekiswe ngokuhlola insimbi yamaminerali ethile.

Imicabango yokugcina

Uma kubuzwa ukuthi yibuphi ubuchwepheshe obunciphisa kakhulu ukusetshenziswa kwamandla, impendulo enembile ithi i-HPGR inenzuzo engxenyeni yokugaya izinhlayiya ezinkulu, kuyilapho i-ball mill iqhubeka nokusebenza kahle engxenyeni yokugaya izinhlayiya ezincane kakhulu. Ukonga okukhulu kuvame ukutholakala ngokuhlanganisa le mishini ngobuhlakani kunokukhetha umshini owodwa kuphela: i-HPGR yenza umsebenzi omkhulu wokunciphisa usayizi ekuqaleni futhi yenze izinto ezifakwa kuyo zibe buthaka, bese i-ball mill ekhethwe ngosayizi ofanele ifinyelela ezingeni lokukhululwa kwamaminerali elidingekayo. Ukuhlolwa okuqondene nensimbi yamaminerali, i-circuit ehlelwe kahle kanye nemodeli enengqondo yokuguga kuzonquma ukuthi le nhlanganisela ingakwazi yini ukuletha ukuncipha kokusetshenziswa kwama-kWh okudingwa yiphrojekthi yakho.