Intelligent ball feeding system and method for ball mill

Abstract

The application provides a ball mill intelligent ball adding system and method, which comprises an automatic material taking device (2), a screening machine (3), an ore impact crushing property on-line detector (4), mill power consumption intelligent operation and maintenance software and an upper computer (5), a ball mill (6), a power monitoring device (8) and an automatic ball adding device (9). The technical scheme can be used to select a process flow with the most reasonable operation cost in real time, so that the goal of energy saving, consumption reduction and production increase is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metal mineral processing, in particular to a ball mill intelligent ball feeding system and method. BACKGROUND

[0002] Before valuable metal minerals are recovered from raw ore in a metal mine, the raw ore must be crushed and ground to reduce the particle size of the feed material and to fully dissociate the metal minerals. Ball mill is a kind of grinding equipment commonly used in metal mines. According to the grinding power consumption theory, in order to make the particle size of the ore reach the required degree of reduction, the energy corresponding to the grindability of the ore must be consumed. That is, when the grindability of the ore, the particle size of the feed material and the particle size of the grinding product are determined, the operating power of the mill should reach the corresponding value.

[0003] Under the condition that the specifications of the mill are determined, the power of the ball mill mainly depends on the ball loading rate. As the grinding operation proceeds, the amount of steel balls in the mill will decrease due to wear and tear, and steel balls need to be added in time to maintain the power of the mill. Currently, the steel ball feeding system mainly used in production sites assumes a fixed proportional relationship between the amount of steel ball wear and the amount of ore processed, and the amount of steel ball wear is calculated according to the amount of ore processed. However, due to the significant fluctuations in the nature of the feed ore in the production site over time, this method has two problems: first, the proportional relationship between the amount of steel ball wear and the amount of ore processed is not fixed, which can cause the actual amount of steel balls in the mill and the power of the mill to deviate from the target value; second, changes in the grindability of the ore can cause the target value of the required mill power itself to change. Due to the above reasons, the crushing and grinding characteristics of the ore feed, the processing capacity and the target fineness of the final product cannot always be maintained at the best state, resulting in substandard processing capacity or product fineness, or reducing energy efficiency. SUMMARY

[0004] Therefore, the purpose of the present application is to provide a ball mill intelligent ball feeding system and method, which can select the most reasonable process flow in real time to achieve the goal of energy saving, consumption reduction and production increase.

[0005] To achieve the above purpose, the present application adopts the following technical solution: a ball mill intelligent ball feeding system, comprising an automatic material taking device (2), a screen mill (3), an ore impact crushing property online detector (4), a mill power intelligent operation and maintenance software and an upper computer (5), a ball mill (6), a power monitoring device (8) and an automatic ball feeding device (9).

[0006] The application further provides a ball mill intelligent ball feeding method, which adopts the ball mill intelligent ball feeding system; when the feed ore (1) is fed to the ball mill 6 through a belt, the automatic material taking device (2) is first used to automatically take samples at intervals, the screen (3) and the ore impact crushing property online detector (4) are linked with the automatic material taking device (2) and are automatically started at intervals; the automatic material taking device (2) obtains part of the feed ore and provides the ore to the screen (3) for screening; the ore sample of a qualified particle size level obtained after screening by the screen (3) is provided to the ore impact crushing property online detector (4), and the ore impact crushing property online detector (4) obtains the hardness index of the ore and provides the hardness index of the ore to the mill power intelligent operation and maintenance software and the upper computer (5) for analysis.

[0007] In a preferred embodiment, the sampled feed ore (1) is fed to the ball mill (6) for grinding operation; when the ball mill is running, the power monitoring device (8) installed in the ball mill circuit system measures the running power of the ball mill and transmits the power information of the ball mill (6) to the mill power intelligent operation and maintenance software and the upper computer (5) for analysis; after the mill power intelligent operation and maintenance software and the upper computer (5) obtain the hardness index of the ore and the power information of the ball mill (6), comprehensive analysis is performed.

[0008] In a preferred embodiment, the mill power intelligent operation and maintenance software in the mill power intelligent operation and maintenance software and the upper computer (5) includes an ore crushing and grinding characteristic representation module, a mill grinding process unit energy consumption prediction module, a ball mill ball loading rate online prediction module, and a mill intelligent ball feeding amount calculation module; the real-time ball feeding amount of the ball mill (6) is obtained through step-by-step analysis of the ore crushing and grinding characteristic representation module, the mill grinding process unit energy consumption prediction module, the ball mill ball loading rate online prediction module, and the mill intelligent ball feeding amount calculation module.

[0009] In a preferred embodiment, the ore crushing and grinding characteristic index C1, …, C n ;

[0010] For conventional crushing + ball milling and high-pressure roller milling + ball milling grinding process, there is a quantitative corresponding relationship between the ore crushing and grinding characteristic index, the ball mill feed particle size F80, the ball mill product particle size P80, and the unit energy consumption W required by the ball mill, that is:

[0011] W = f(C1、…、C n 、F80、P80) (1)

[0012] F80 and P80 respectively refer to the sieve hole size through which 80% of the particles in the feed and product can pass; the ball mill product refers to the fine product of the classification device as the final product under closed-circuit classification;

[0013] For the ore grinding process of autogenous mill / semi-autogenous mill+ball mill, the total unit energy consumption of the autogenous mill / semi-autogenous mill+ball mill ore grinding process is calculated according to the ore crushing grinding characteristic index, the semi-autogenous mill feed size F80 and the ball mill product size P80, then the unit energy consumption of the autogenous mill / semi-autogenous mill is subtracted from the total unit energy consumption, and the difference is taken as the unit energy consumption of the ball mill, and the product of the unit energy consumption of the ball mill and the target processing capacity is the power requirement of the ball mill.

[0014] In a preferred embodiment, in the ball mill ball loading rate online prediction module, there is a one-to-one mapping relationship between the ball mill power and the ball loading rate; the actual ball loading rate R1 is calculated by detecting the overall power of the ball mill; when the actual unit energy consumption of the ball mill cannot meet the production requirement, the ball loading rate is adjusted so that the ball mill can reach the operating power required by the crushing grinding power consumption theory, that is, the ball loading rate reaches the target ball loading rate R2; the difference between the actual ball loading rate R1 and the target ball loading rate R2 is the ball loading amount that can meet the actual requirement in the daily production management of the ball mill.

[0015] After the mill power intelligent operation software and the upper computer (5) calculate the ball loading amount, the ball loading device is controlled to add steel balls; the adjustment of the steel ball filling rate of the ball mill is completed; through the monitoring, operation and adjustment of the system, the ball loading rate and the feeding amount of the ball mill can be kept around the rated power of the ball mill.

[0016] Compared with the prior art, the present application has the following beneficial effects: the target setting value of the mill power is adjusted in real time through online detection of the ore properties; the actual steel ball amount in the mill and the steel ball amount required to reach the mill power target value are estimated according to the mill power curve, and the steel ball supplement amount is determined according to the difference between the two, thereby establishing an intelligent steel ball supplement system for the mill. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 The figure is a structural schematic diagram of a preferred embodiment of the present application;

[0018] Figure 2 The figure is a schematic diagram of the operating power curve of a ball mill of a preferred embodiment of the present application;

[0019] The figure is a structural schematic diagram of a preferred embodiment of the present application; DETAILED DESCRIPTION

[0020] The present application will be further described below in combination with the drawings and embodiments.

[0021] It should be noted that the following detailed description is illustrative only, and is intended to provide further description in order to provide a fuller enabling and comprehensive disclosure of exemplary embodiments according to the present application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the application pertains. In the description of the exemplary embodiments of the application, terms of similarity and / or comparison such as, without limitation, "substantially", "approximately", "about", "generally", and "comparable" are used to describe and account for minor deviations from theoretical norms or idealizations of the systems, structures, methods, devices, and materials described in the present disclosure. Such terms of similarity and / or comparison are not to be interpreted as a requirement for exact matching of the described features, but rather are intended to account for minor variations from the described norms and idealizations.

[0022] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application; as used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, devices, components and / or combinations thereof, but do not preclude the presence or addition of one or more other features, steps, operations, devices, components and / or combinations thereof.

[0023] The present application provides an intelligent ball feeding system and method for a ball mill, which is described with reference to Figures 1-2 The intelligent ball feeding system and method for a ball mill can be used in combination with online detection of ore crushing and grinding characteristics, online detection of mill filling rate, and intelligent mill power consumption operation software to precisely control the ball filling rate of the mill, so that the mill power is matched with the processing capacity and the ore crushing and grinding characteristics in real time, the online selection and parameter adjustment of the ore grinding equipment are achieved, the most reasonable process flow is selected in real time, and the goal of energy saving, consumption reduction and yield increase is achieved. The differences in the crushing and grinding characteristics of the feed ore do not have adverse effects on the ore grinding operation. The present application is suitable for the intelligent operation of the ball mill in the ore grinding process flow, including semi-autogenous grinding / autogenous grinding-ball milling, conventional crushing + ball milling, high-pressure roller milling + ball milling, etc. Figure 1 The structure of the intelligent ball feeding system and method for a ball mill is shown in the figure, which includes an automatic material taking device 2, a screening machine 3, an ore impact crushing property online detector 4, intelligent mill power consumption operation software and an upper computer 5, a ball mill 6, a power monitoring device 8, and an automatic ball feeding device 9. In the figure, 1 represents the feed ore, and 7 represents the ground ore.

[0024] When the feed ore 1 is fed to the mill 6 through a belt feeder or other feeding device, it is first taken by the automatic material taking device 2. The automatic material taking device 2 automatically takes samples at intervals, and the screening machine 3 and the ore impact crushing property online detector 4 are linked with the automatic material taking device 2 and automatically turned on at regular intervals. The automatic material taking device 2 obtains part of the feed ore and provides it to the screening machine 3 for screening. The ore samples of qualified particle size are obtained after screening by the screening machine 3 and are fed to the ore impact crushing property online detector 4. The working process and principle of the ore impact crushing property online detector 4 are described in the associated patent "A method and device for online rapid characterization of ore impact crushing properties". After the ore impact crushing property online detector 4 obtains the crushing characteristics (hardness index) of the ore, the hardness index of the ore is provided to the intelligent ball feeding software and the upper computer 5 for analysis.

[0025] The sampled feed ore 1 is fed into the ball mill 6 for grinding operation. When the ball mill is running, the power monitoring device 8 installed in the ball mill circuit system measures the running power of the ball mill and transmits the power information of the ball mill 6 to the ball mill intelligent operation and maintenance software and the upper computer 5 for analysis.

[0026] After obtaining the ore hardness index and the power information of the ball mill 6, the ball mill intelligent operation and maintenance software and the upper computer 5 perform comprehensive analysis. The mill power consumption intelligent operation and maintenance software includes four modules: ore crushing and grinding characteristic representation module, grinding process unit energy consumption prediction module, ball mill ball loading rate online prediction module, and mill intelligent ball loading amount calculation module. The real-time ball loading amount of the ball mill 6 is obtained through the step-by-step analysis of the four modules. The specific analysis process of each module is as follows:

[0027] (1) The ore crushing and grinding characteristic index C1, …, Cn is calculated through the ore crushing and grinding characteristic representation module. The specific calculation method is referred to the associated patent "A method and device for online rapid representation of ore impact crushing property".

[0028] (2) For conventional crushing + ball milling, high-pressure roller milling + ball milling and other ore grinding process, there is a quantitative corresponding relationship between the ore crushing and grinding characteristic index, the ball mill feed size F80, the ball mill product size P80 and the unit energy consumption W required by the ball mill, that is:

[0029] W = f(C1, …, Cn, F80, P80) (1)

[0030] F80 and P80 respectively refer to the sieve hole size through which 80% of the particles in the feed and product can pass. The ball mill product refers to the fine product of the classification device as the final product under closed-circuit classification.

[0031] In particular, for the ore grinding process of a semi-autogenous mill / semi-autogenous mill + ball mill, the total unit energy consumption of the semi-autogenous mill / semi-autogenous mill + ball mill grinding process is calculated according to the ore crushing and grinding characteristic index, the semi-autogenous mill feed size F80, the ball mill product size P80, and then the unit energy consumption of the semi-autogenous mill / semi-autogenous mill is subtracted from it, and the difference is taken as the unit energy consumption of the ball mill.

[0032] The product of the unit energy consumption of the ball mill calculated by the above method and the target processing capacity is the power requirement of the ball mill.

[0033] (3) Ball mill ball loading rate online prediction module: for a given size of ball mill, the ball loading rate is the dominant factor affecting the power consumption of the ball mill. As shown in Figure 2 , there is a one-to-one mapping relationship between the ball mill power and the ball loading rate. Therefore, the actual ball loading rate R1 can be calculated by detecting the overall power of the ball mill.

[0034] (4) Intelligent ball mill ball adding calculation module: The overall principle of ball mill ball adding is to ensure that the total amount of steel ball medium in the ball mill can make the ball mill "take" the power that can meet the demand. When the actual unit energy consumption of the ball mill cannot meet the production demand, it is necessary to adjust the ball filling rate to make the ball mill reach the operating power required by the grinding power theory, that is, the ball filling rate reaches the target ball filling rate R2. According to the mapping relationship reflected by the formula, the target power can be obtained The target ball filling rate R2 corresponding to it. The difference between the actual ball filling rate R1 and the target ball filling rate R2 is the ball adding amount that can meet the actual demand in the daily production management of the ball mill. Figure 2 The mapping relationship reflected by the formula can be obtained by the target power. The target ball filling rate R2 corresponding to it. The difference between the actual ball filling rate R1 and the target ball filling rate R2 is the ball adding amount that can meet the actual demand in the daily production management of the ball mill.

[0035] After the intelligent operation and maintenance software of the mill power consumption and the host computer 5 calculate the ball adding amount, the ball adding device is controlled to add steel balls. Complete the adjustment of the steel ball filling rate of the ball mill. Through continuous monitoring, operation and adjustment of the system, the ball mill ball filling rate and the feed amount can be kept near the rated power of the ball mill.

[0036] The screen machine adopts double-layer three-product vibrating screening equipment.

[0037] The present application uses sensors and signal processing systems to make the target setting and implementation of the ball mill power more "transparent" and digital, to achieve the goal of matching the mill power with the processing capacity and the ore grinding characteristics, to realize the intelligent and accurate operation and maintenance of the grinding process, and to achieve the goal of energy saving, consumption reduction and production increase.

[0038] The system automatically takes, analyzes and adds materials in the whole process without manual operation, avoiding the training cost and manual maintenance cost of on-site operators.

Claims

1. A method for intelligent ball feeding of a ball mill, characterized in that, The application discloses an intelligent ball feeding system of a ball mill, which comprises an automatic material taking device (2), a screening machine (3), an ore impact crushing property on-line detector (4), a mill power intelligent operation and maintenance software and an upper computer (5), a ball mill (6), a power monitoring device (8) and an automatic ball feeding device (9). When the feeding ore (1) is fed to the ball mill (6) through a belt, the feeding ore (1) is firstly taken by the automatic material taking device (2), the automatic material taking device (2) takes samples at intervals, the screening machine (3) and the ore impact crushing property on-line detector (4) are linked with the automatic material taking device (2) and are automatically started at intervals, the automatic material taking device (2) obtains part of the feeding ore and provides the ore to the screening machine (3) for screening, the ore sample with a qualified particle size is obtained after the screening of the screening machine (3) and is fed to the ore impact crushing property on-line detector (4), the ore impact crushing property on-line detector (4) obtains the hardness index of the ore and provides the hardness index of the ore to the mill power intelligent operation and maintenance software and the upper computer (5) for analysis. The sampling feeding ore (1) is fed to the ball mill (6) for ore grinding, the power monitoring device (8) installed in the circuit system of the ball mill measures the running power of the ball mill and transmits the power information of the ball mill (6) to the mill power intelligent operation and maintenance software and the upper computer (5) for analysis, the mill power intelligent operation and maintenance software and the upper computer (5) obtain the hardness index of the ore and the power information of the ball mill (6) and perform comprehensive analysis. The mill power intelligent operation and maintenance software in the mill power intelligent operation and maintenance software and the upper computer (5) comprises an ore crushing and grinding characteristic representation module, a mill grinding process unit energy consumption prediction module, a ball mill ball loading rate on-line prediction module and a mill intelligent ball feeding amount calculation module. The real-time ball feeding amount of the ball mill (6) is obtained through the step-by-step analysis of the ore crushing and grinding characteristic representation module, the mill grinding process unit energy consumption prediction module, the ball mill ball loading rate on-line prediction module and the mill intelligent ball feeding amount calculation module. The ore crushing property index C1, …, C is calculated by the ore crushing property characterization module. n ; For the conventional crushing + ball milling and high-pressure roller milling + ball milling ore grinding process, there is a quantitative corresponding relationship between the ore crushing and grinding characteristic index, the ball mill feeding particle size F80, the ball mill product particle size P80 and the unit energy consumption W required by the ball mill, namely: W = f(C1,..., C n , F80, P80) (1) F80 refers to the sieve hole size through which 80% of particles in the feeding can pass; P80 refers to the sieve hole size through which 80% of particles in the product can pass; the ball mill product refers to the fine product of the classification equipment as the final product under the closed circuit classification; For the ore grinding process of the autogenous mill / semi-autogenous mill + ball mill, the total unit energy consumption of the autogenous mill / semi-autogenous mill + ball mill ore grinding process is calculated according to the ore crushing and grinding characteristic index, the ball mill feeding particle size F80 and the ball mill product particle size P80, then the unit energy consumption of the autogenous mill / semi-autogenous mill is subtracted from the total unit energy consumption, the difference is taken as the unit energy consumption of the ball mill, and the product of the unit energy consumption of the ball mill and the target processing capacity is the power requirement of the ball mill.

2. The method as claimed in claim 1, wherein, In the ball mill ball loading rate online prediction module, there is a one-to-one mapping relationship between the ball mill power and the ball loading rate; the actual ball loading rate R1 is calculated by detecting the overall power of the ball mill; when the actual unit energy consumption of the ball mill cannot meet the production demand, the ball loading rate is adjusted to make the ball mill reach the required operating power of the grinding power consumption theory, that is, the ball loading rate reaches the target ball loading rate R2; the difference between the actual ball loading rate R1 and the target ball loading rate R2 is the ball loading amount that can meet the actual demand in the daily production management of the ball mill; After the intelligent operation and maintenance software of the mill power consumption and the upper computer (5) calculate the ball loading amount, the ball loading device is controlled to add steel balls; the adjustment of the steel ball filling rate of the ball mill is completed; through the monitoring, operation and adjustment of the system, the ball loading rate and the feeding amount of the ball mill can be kept near the rated power of the ball mill.

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