大型半自磨机.ppt.ppt

国外大型半自磨机的设计理念和比例放大规则,选矿工艺：,碎磨,浮选，磁选，重选,碎矿,粗碎,中碎,细碎,球磨机,磨矿分级,磨矿分级,自磨机,返回料,排矿pi,新给矿fi,破碎过程,格子筛高比能 低比能矿浆,自磨机磨矿原理分级,HeightImpact ZoneToe Region,AttritionZone,半自磨机磨矿原理ShoulderRegionBallDrop,Rock,自磨，半自磨,SAG/Auto Mills,Conical ended mill,Flat ended mill,SAG/Auto MillsMill shapes,EGL 2 world class solutions,.au,Deliveringto the minerals industry,Low filling,EGL 1,SAG/Auto MillsEffective Grinding Length(EGL)High filling,SAG Mill and Discharge Trommels,SAG/Auto Mills,.au,Mill Dimensions 尺寸Mill Speed 转速Mill Load/Ball Load 充填率Mill Power 功率Ball Size 球径Lifters 衬板Delivering world class solutionsto the minerals industry,SAG/Auto Mills磨机参数,SAG/Auto MillsMill Aspect Ratio(D/L),High(1.5-3),Square(1/1),Low(1/1.5 1/3),瑞典AITIK 铜金银矿山,瑞典AITIK 铜金银矿山选矿流程,自磨+砾磨,澳大利亚世纪锌矿,PASMINCO,To Pipeline,PrefloatRougherTank Cells(7),Stockpile,PrimarySizer,ROMHopper,Zinc Rougher Zinc ScavengerTank Cells(7)Tank Cells(11),CENTURYMINE Pb Rougher Pb Scav.Tank Cells(4)Tank Cells(2),Tailings Dam,TailingsThick,ener,LeadThickener,SAG Mill36 x 16,Ball Mill20 x 32,(10”2 clusters x24),Lead StorageTanks(1),Zinc Regrind(6),Conditioner,Zinc Cleaner1,Tank Cells(6),Conditioner,Pb Cleaner 2Tank cells(2),Pb Cleaner 1Tank cells(3),Zinc,Thickener,Tanks(3),To Pipeline,Zinc Cleaner3 Tank Cells,(8),Zinc Cleaner4 Tank Cells(8),Zinc Cleaner 5Tank Cells(6),Zinc Cleaner 2Tank Cells(14),Cyclones(2”20 clusters x,16)Zinc Storage,Sand Grinders(15),Conditioners(2),Cyclones(6”2clusters x,20),Cyclones(6”2 clusters x,20),FlotationScreen(2.4m w*6.1m l),Oversize towastedump,澳大利亚世纪锌矿Cyclones,(S)AB 流程：,Ball mill,Flotation/leach,SAG mill,澳大利亚世纪锌矿,F80=80 mm,700 tph,P80=0.060 mm,球磨：6.7 MW,半自磨：12 MW,澳大利亚世纪锌矿,澳大利亚蒙特艾萨铜选厂,Process water12 l/s,Grinding Spillage,Flotation SpillageThickener U/F,Column Concentrate,Combined Scav.Conc.+Cleaner Tailings,REGRIND,REGRIND MILL,Regrind Mill Bypass,RETREATMENT,Retreatment Concentrate,Grinding and Flotation Flowsheet,From January 1998,Speed 13.99rpm 70%Allis-Chalmers,65mm Balls 0.65 kg/t,09 Ball Mill,05 Ball Mill,Size D=3.2m L=4.8mSpeed 17.9rpm 76%,50mm Balls 0.1kg/t,REGRIND CYCLONES7 D10B Krebs cyclonesin cyclopak arrangement6-7 operatingInlet diameter=55 mmVortex finder dia.=76 mmSpigot dia.=51 mm,BALL MILLSRated Power 2750 kW,Power Draw 2500 kWSize D=5m L=6m,MIBC 15 g/t,MIBC 15 g/t,SIBX,30 g/t,MIBC 15 g/t,30 g/t,SIBX,MIBC 15 g/t,Dextrin 60 g/t,6 g/t,NaCN,NaCN 4 g/t,09,05,LINE 2 SCAVENGERS,LINE 1 ROUGHERS,01,Rated Power 746 kWPower Draw 550 kW,Media and reagent usages given are,with respect to the total plant feed,N,AG,02,Line 1,SecondaryCyclones,Line 2,Line 1,PrimaryCyclones,Process water 10 l/s,AG01,PrimaryCyclones,NaCN 20 g/t,4 Krebs D26B cyclones incyclo-pak arrangement,Spigot dia=152mm,SECONDARY CYCLONES,Line 2,SecondaryCyclones,FULLY AUTOGENOUS MILLS,Rated Power=6600 KWPower Draw=6400 KW,Size D=9.75m L=4.42mSpeed 10.69 rpm 78%,PLANT FEED,Process water 10 l/sPLANT FEED,Scat returnWater jet 25 l/s,Process water15 l/s,Scat returnWater jet 25 l/sProcess water,15 l/s,Combined,RougherConcentrate,LINE 2 ROUGHERS,FLOTATION FEED,Line 2,Line 1,FLOTATION COLUMNSHeight=16mDiameter=2.5m,Minnovex spargersRain tray wash waterarrangement,NaCN 25 g/t,MOUNT ISA MINES LTDCOPPER CONCENTRATOR,COLUMNS,Wash,WaterColumn 3 Tailings,1,2,3,Cleaner,RECLEANERS,CLEANERS,Concentrate,RecleanerWater,RecleanerConcentrate,Concentrate,Cleaner,FLOTATION BANKS,Agitair model 120,4 cells per bank4 impellers per cell,Volume of bank=45.2 m 3Pipsa Impellers 115 rpm,FINAL CONCENTRATE,To Copper SmelterThickeners,Grade:,25.0%Copper28.0%Iron9.0%Silica,Recovery:94.8%Cu,Cone angle=20,o,PLANT FEEDTarget Milling Rate 680 tph3.4%Cu,8%Fe,65%SiO2Bond Work Index 19 KWh/tMoisture 2.5%,Inlet Diameter=133 mmCone angle=20oVortex Finder dia.=254 mm,SIBX 10 g/t,Final Tailings 0.20%Cu,5%Fe,76%SiO 2Silica Product 15 tph 78%SiO 2,LINE 1 SCAVENGERS,PREFLOAT,P/F to Final Tail,PREFLOATP/F to Final Tail,Final Concentrate,SIBX 50 g/t,SIBX 50 g/t,澳大利亚蒙特艾萨铜选厂,澳大利亚蒙特艾萨铜选厂SAB 磨矿回路,澳大利亚 Cadia 选矿厂，每天五万吨原矿处理量,head grades,-typical,Cu%Au g/tAg g/t,0.20.80.8,111,半自磨机,12 米 x 6.1米,20000 kW,CLEANER SCAVENGERS(6),FLASHFLOTATION(2),CYCLONE FEEDPUMPS(2),CYCLONEFEED HOPPER,AuCONCENTRATE,SCAVENGERS X 2 LINES,ROUGHERS X 2 LINES,RECYCLECRUSHERS,(2),SAGMILL,BALL MILL(2),COARSECLEANERS,GRAVITYCONCENTRATOR,SHIP TO SMELTER,TRAIN TO PORT,FILTER35 Km PIPELINE TO BLAYNEYFALCON,COPPERCONCENTRATE,PROCESS WATER,TAIL,THICKENER,CLEANERS(4),RECLEANERS,SCATS,STOCKPILE,RECYCLE CRUSHERSSTORAGE BIN,CYCLONES,BALLFEEDER,PRIMARYCRUSHER,COARSE ORESTOCKPILE,BELT,FEEDERS,Newcrest Mining LimitedLOWCADIA VALLEY OPERATIONS,CV003 WEIGHTOMETER,DESLIME,CIRCUIT,REGRIND,CIRCUIT,CV005 WEIGHTOMETER,Final TailSampler,Final ConcentrateSampler,BALLFEEDER,LIME SILO,CV002WEIGHTOMETER,STOCKPILE08-APR-2008JD,Conc.,1 DESLIMECOF TORECLEANER,破落破碎有效粒级：研磨破碎有效粒级：,50-200 mm 20 mm,顽石累计粒级：,20-50 mm,自磨半自磨机能耗高于球磨机 20%,Shoulder,HeightImpact ZoneToe Region,AttritionZone,RegionBallDrop,Rock,feed,Ball mill,SAG mill,Primary crushed(S)ABC 流程Recycle crusher,T80(mm),破碎机影响,kWh/t,Ball mill,SAG,millT80(mm),Recyclecrusher,开停,8.3511.07,0.930.44,澳大利亚凯迪选矿厂SABC 破磨流程，每天,五万吨原矿处理量,球磨：17.5 MW,半自磨：20 MW,澳大利亚比和比拓 Cannington 银铅矿,澳大利亚比和比拓 Cannington 银铅矿选矿流程,Flotation/Leach,SAG mill,澳大利亚Cannington 半自磨回路,2011.4.16,2011.7.6,自磨，半自磨机优点,流程简单Line 1flotation,Line 2flotation,Rod mill,Ball Mill,Rod mill,Ball Mill,Ball Mill,Ball Mill,ROM,Total installed power:13.7 MWLine 1flotation,01 AG,05 Ball mill,ROMLine 2flotation09 Ball mill02 SAGROM,每天五万吨选矿厂,1台10台80台,2万千瓦半自磨(12.2 米 直径）2千千瓦 球磨机(4.5 米 直径)250千瓦球磨机(2.7 米 直径),Percentage Passing,Particle Size,mm,0.001,0.01,0.1,1,10,100,1000,80,高破碎比100,5660 kW at 503 tphSAG feed,SAG discharge6040200,Mount Isa SAG Circuit,自磨，半自磨机缺点,磨机处理量与产品粒度极易受给矿粒度变化的影响,400 t/h,350 t/h,350 t/h,Mill Throughput Rate,tph,Minutes,0,100,200,300,400,500,600,700,300200,600,AG mill,SAG mill500400,ROM,Con,Tail,产品粒度变化对处理量影响,半自磨给矿粒度配比,给矿粒度配比,Percentage Passing,Particle Size,mm,0.1,1,10,100,1000,给矿粒度监测100806040200,衬板结构,Hi-Low vs Hi-Hi:,Liner shapesFace Angle,A,B,RailA=3xRock siz;B=3xball size,Top Hat,20-25o,衬板结构,Port size:25 mm,50 mm,70 mm,Port shape:Taped,顽石排矿,功率小时给矿量磨机重量磨机转速,加球量噪音转矩返砂量给矿粒度加水量矿浆浓度,半自磨参数优化,半自磨机系统设计优化,排矿口尺寸,混料,顽石返回量,参数优化传感器配置球直径,衬板设计顽石排料磨机变速,顽石破碎机,分级效率,圆筒筛设计放大设计,Cum%Passing,Percentage Passing,P t/h Wi,半自磨比例放大数学模型,Particle Size,mm,0.01,0.1,1,10,100,1000,00.001,4020,60,10080,10 F 80,10 P805660 kW at 503 tphSAG feedSAG discharge,3020100,5040,60,邦德功指数不再适用！100908070,0.01,0.1,1,10,100,Size(mm),Rod Mill DischSAG Mill Discharge,给矿，吨/小时,产品，吨/小时,固体量，吨,自磨机进出质量平衡模型,a,总体平衡模型,ij=1,ij,rj s j,i 粒级的给矿量,fi,i粒级的排矿量pi di si,ri si,大于i粒级的各个颗粒（i 到 最粗粒级1）在磨机内经破碎后进入i,粒级的固体量(吨）,i粒级的颗粒在磨机内经破碎后进入小于i粒级的固体量（吨,）,aij 为表观函数，rj为j粒级的破碎速率，Sj为j 粒级在磨机中的固体量。,ri为i粒级的磨矿速率，Si为i 粒级在磨机中的固体量。,a,总体平衡模型,ij=1,ij,rj s j,i 粒级的给矿量,fi,i 粒级的排矿量,pi,ri s iij=1p,.au,总体平衡模型ij=1,pid i,si=,or,pi=di si,磨矿速率：磨机尺寸和磨矿条件的函数,表观函数：矿石性质的函数,排矿函数：磨机尺寸和磨矿条件的函数Delivering world class solutionsto the minerals industry,f i-ri.s i+a ij rj s j-d i si=0,Drop,Height,Shoulder,Impact ZoneToe Region,AttritionZone,Ball,Rock,RegionDropweight,Guide Rod,Winch,Perspexenclosure,An vilConcreteplatform,Rockspecimen,总体平衡比能模型,ij=1,pi,s=,or,p=di si,矿石比能参数：A&b,JK 半自磨落锤测试机,f i-ri.s i+a ij rj s j-d i si=0,ij=1,pi,s=,or,p=di si,磨矿速率模拟：,Ball,Rock,总体平衡比能模型转速，,球直径，装球量，磨机直径，磨机长度，,JKSimMet 模拟SABC磨矿回路,Ball mill,mill,SABC 流程JKSIMMET模拟粒度分布RecyclecrusherSAG,截至2005年已经投产的大型半自磨机,中国大型半自磨机的应用,德兴铜矿乌山铜钼矿大洪山铁矿铜陵东瓜山铜矿贵溪冶炼厂,10.5米 at 12000 kW8.8米 at 6000 kW8.8米 at 6000 kW5.5米 at 2600 kW5.5米 at 2600 kW,结论,结论,半自磨机是现代选矿厂首选破碎磨矿技术,半自磨机的选型和设计由矿石性质决定,半自磨机的运作成功依赖于可靠的比例放大方法,中国在未来十年将是大型半自磨机应用的主要市场,