Intelligent ball adding system and method for a semi-autogenous mill

Abstract

The application provides a kind of intelligent ball adding system of semi-autogenous mill, including automatic material taking device (2), screening machine (3), ore impact crushing property on-line detector (4), mill intelligent ball adding software and host computer (5), mill (6), mill filling rate on-line detection sensor (8), sensor data acquisition instrument (9) and power monitoring device (10). The application can realize intelligent operation and maintenance of semi-autogenous mill, and achieve the goal of reducing cost, increasing benefit and increasing production.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metal mineral processing, in particular to a semi-autogenous mill intelligent ball adding 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. A semi-autogenous mill is a kind of grinding equipment commonly used in large metal mines. In order to ensure the processing capacity of the beneficiation process, the power of the semi-autogenous mill should ideally be maintained in a stable range. Given the specifications of the mill, the power of the semi-autogenous mill mainly depends on the total filling rate and the ball filling rate of the semi-autogenous mill. However, as the grinding operation progresses, the amount of steel balls in the mill will decrease due to wear. Therefore, in order to maintain the power of the semi-autogenous mill, steel balls are regularly added to the semi-autogenous mill at the production site.

[0003] Currently, the main steel ball adding system used at the production site assumes a fixed proportional relationship between the amount of steel ball wear and the amount of ore processed, and the amount of steel ball addition is calculated based on the amount of ore processed. However, due to significant fluctuations in the nature of the incoming ore at 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, and adding steel balls according to the existing system cannot maintain the stability of the mill ball filling rate; second, when the nature of the ore changes, the target ball filling rate of the mill should also be adjusted accordingly. The above problems result in significant fluctuations in the power of the semi-autogenous mill under the existing steel ball addition system, resulting in power waste or insufficient production capacity. SUMMARY

[0004] Therefore, the purpose of the present application is to provide a semi-autogenous mill intelligent ball adding system and method, which realizes intelligent operation and maintenance of the semi-autogenous mill, and achieves the goal of reducing costs, increasing efficiency and increasing production.

[0005] To achieve the above-mentioned purpose, the present application adopts the following technical solution: a semi-autogenous mill intelligent ball adding system, comprising an automatic material taking device (2), a screen mill (3), an ore impact crushing property online detector (4), a mill intelligent ball adding software and an upper computer (5), a mill (6), a mill filling rate online detection sensor (8), a sensor data acquisition instrument (9), and a power monitoring device (10).

[0006] The present application provides a semi-autogenous mill intelligent ball adding method, which adopts the above-mentioned semi-autogenous mill intelligent ball adding system. The automatic material taking device (2) takes samples of the incoming ore (1) before it enters the semi-autogenous mill; the belt conveyor end part regularly takes part of the incoming ore sample;

[0007] The screening machine (3) classifies the ore sample, so that the fine particle level meets the feeding size requirement of the ore impact crushing property on-line detector (4);

[0008] The ore impact crushing property on-line detector (4) automatically detects the ore crushing and grinding characteristics index; the mill filling rate on-line detection sensor (8) and the sensor data acquisition instrument (9) monitor and collect the signal of the total filling rate of the semi-autogenous mill (6); the total filling rate of the mill (6) refers to the percentage of the volume of the ore and the steel ball in the mill to the internal volume of the mill after the mill stops running and simultaneously stops feeding ore and water;

[0009] The power monitoring device (10) obtains the actual power of the semi-autogenous mill.

[0010] In a preferred embodiment, the mill intelligent ball adding software and the mill power consumption intelligent operation and maintenance software of the upper computer (5) include: an ore crushing and grinding characteristics representation module, a mill grinding process unit energy consumption prediction module, a semi-autogenous mill actual ball loading rate on-line prediction module, and a mill intelligent ball loading amount calculation module.

[0011] In a preferred embodiment, the ore crushing and grinding characteristics index C1, C2, …, C n is calculated by the ore crushing and grinding characteristics representation module.

[0012] In a preferred embodiment, the ball loading rate of the semi-autogenous mill is defined as: the percentage of the volume of the steel ball in the mill to the internal volume of the mill after the semi-autogenous mill stops feeding ore and water and continues to run for a short time to grind all the ore load and then stops; the running power of the semi-autogenous mill is obtained by the power monitoring device (10), and the total filling rate is obtained by the mill filling rate on-line detection sensor (8); the running power and the total filling rate of the semi-autogenous mill are obtained.

[0013] In a preferred embodiment, the unit energy consumption W of the semi-autogenous mill is the result of the comprehensive action of multiple factors:

[0014] W=K×f (F 80 , C1、…、C n , ball loading rate, mill speed, length-diameter ratio)

[0015] According to the above relationship, the mill grinding process unit energy consumption prediction module calculates the theoretical unit energy consumption of the semi-autogenous mill process by the correction coefficient K, the feeding size F 80 , the ore crushing and grinding characteristics index C1, …, C n , the ball loading rate, the mill speed, and the length-diameter ratio;

[0016] Wherein F 80 specifically refers to the screen aperture size through which 80% of the material in the feeding size can pass in the crushing and grinding process.

[0017] In a preferred embodiment, in the intelligent ball adding calculation module of the mill, when steel balls need to be added to make up for the wear of the steel balls in the semi-autogenous mill, the difference between the original ball rate R0 and the actual ball rate R1 is the required amount of added balls.

[0018] When the ore crushing and grinding properties change and the ball filling rate of the semi-autogenous mill needs to be adjusted, first, the ore crushing and grinding property indicators are input, the target ball filling rate R2 and the target total filling rate are set, the unit energy consumption and the mill operating power are calculated, and then the processing capacity is calculated according to the mill operating power and the unit energy consumption. When the processing capacity can meet the demand and the mill operating power is less than the installed power × k, the difference between the actual ball filling rate R1 and the target ball filling rate R2 is the required amount of added balls. If the actual ball filling rate R1 is greater than or equal to the target ball filling rate R2, the required amount of added balls is considered to be 0, and the natural wear of the steel balls is waited. If the processing capacity cannot meet the demand or the mill operating power is greater than the installed power × k, the above operation is repeated until the target is reached. K is a self-defined safety factor.

[0019] In a preferred embodiment, after the intelligent ball adding software and the upper computer (5) calculate the amount of added balls, the automatic ball adding device (11) is controlled to add the steel balls.

[0020] In a preferred embodiment, the mill filling rate online detection sensor (8) monitors the total filling rate of the material and the steel balls in the mill (6) through a vibration signal.

[0021] In a preferred embodiment, the mill filling rate online detection sensor (8) transmits the total filling rate information in the mill (6) to the intelligent ball adding software and the upper computer (5) for analysis through a wireless signal transmission method.

[0022] Compared with the prior art, the present application has the following beneficial effects: the present application combines online detection of ore crushing and grinding properties, online detection of mill filling rate, and intelligent ball adding software calculation to intelligently and accurately control the ball filling rate of the mill, so that the mill power, processing capacity, and ore crushing and grinding properties are matched in real time, the intelligent operation and maintenance of the semi-autogenous mill are realized, and the goal of reducing costs, increasing efficiency, and increasing production is achieved. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 The structure schematic diagram of the preferred embodiment of the present application;

[0024] Figure 2 The mapping relationship diagram of the semi-autogenous mill operating power, ball filling rate, and total filling rate of the preferred embodiment of the present application;

[0025] Figure 3 The iteration operation flowchart of the preferred embodiment of the present application;

[0026] The figure shows: 1 - feed ore; 2 - automatic ore taking device; 3 - screening machine; 4 - ore impact crushing property on-line detector; 5 - intelligent ball adding software of the mill and upper computer; 6 - mill; 7 - milled ore; 8 - mill filling rate on-line detection sensor; 9 - sensor data acquisition instrument; 10 - power monitoring device; 11 - automatic ball adding device. DETAILED DESCRIPTION

[0027] The application will be further described below in conjunction with the drawings and examples.

[0028] It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the 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 this application belongs.

[0029] It should be noted that the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application; as used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise, and furthermore, it should be understood that when the terms "comprise" and / or "include" are used in the specification, there is a presence of the features, steps, operations, devices, components and / or combinations thereof.

[0030] A semi-autogenous mill intelligent ball adding system and method, referring to Figures 1-3 , the system comprises an automatic ore taking device 2, a screening machine 3, an ore impact crushing property on-line detector 4, intelligent ball adding software of the mill and an upper computer 5, a mill 6, a mill filling rate on-line detection sensor 8, a sensor data acquisition instrument 9, and a power monitoring device 10. In the figure, 1 represents the feed ore, and 7 represents the milled ore.

[0031] The automatic ore taking device 2 can take samples of the feed ore 1 before it enters the semi-autogenous mill, preferably at the end of the belt conveyor to take a portion of the feed ore sample at a fixed time.

[0032] The screening machine 3 can classify the ore sample, so that the fine particle level meets the feed size requirement of the ore impact crushing property on-line detector 4.

[0033] The ore impact crushing property on-line detector 4 can realize rapid automatic detection of the ore crushing and grinding characteristics index, and the specific operation method refers to the associated patent "a method and device for on-line rapid characterization of ore impact crushing properties"

[0034] The mill filling rate online detection sensor 8 and the sensor data acquisition instrument 9 can realize signal monitoring and acquisition of the total filling rate of the semi-autogenous mill 6. The total filling rate of the semi-autogenous mill refers to the percentage of the volume of the ore and the steel balls (including the internal pores thereof) in the internal volume of the mill after the semi-autogenous mill in operation is stopped synchronously with the stop of ore feeding and water feeding.

[0035] The power monitoring device 10 can obtain the actual power of the semi-autogenous mill.

[0036] The mill power consumption intelligent operation and maintenance software and the upper computer 5 include four functional modules: an ore crushing and grinding characteristic representation module, a mill ore grinding process unit energy consumption prediction module, a semi-autogenous mill actual ball loading rate online prediction module, and a mill intelligent ball loading amount calculation module. According to the ore crushing and grinding characteristic indexes collected in the above process, the total filling rate of the semi-autogenous mill 6, and the actual power of the semi-autogenous mill, the real-time ball loading amount of the semi-autogenous mill 6 is obtained through the step-by-step analysis of the four modules. The specific calculation process and principle are as follows:

[0037] (1) The ore crushing and grinding characteristic indexes C1, C2, …, Cn are 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 properties”.

[0038] (2) Semi-autogenous mill actual ball loading rate online prediction module:

[0039] The ball loading rate of the semi-autogenous mill is defined as: the percentage of the volume of the ore and the steel balls (including the internal pores thereof) in the internal volume of the mill after the semi-autogenous mill in operation is stopped with ore feeding and water feeding, and then continues to run for a short time to discharge all the ore load and stops again.

[0040] Figure 2 The semi-autogenous mill power curve shown reflects the relationship between the semi-autogenous mill power and the ball loading rate and the total filling rate. The semi-autogenous mill running power can be obtained through the power monitoring device 10, and the total filling rate can be obtained through the mill filling rate online detection sensor 8. After obtaining the running power and the total filling rate of the semi-autogenous mill, the semi-autogenous mill actual ball loading rate R1 online prediction module can find the unique solution by Figure 2 the mapping relationship shown.

[0041] (3) The unit energy consumption W of the semi-autogenous mill is the result of the comprehensive action of multiple factors:

[0042] W=K×f (F80, C1, …, Cn, ball loading rate, mill speed, length-diameter ratio, etc.)

[0043] Based on the above relationship, the grinding process unit energy consumption prediction module can calculate the theoretical unit energy consumption of the semi-autogenous grinding process through the correction coefficient K, feed particle size F80, ore crushing and grinding characteristic indicators C1, ..., Cn, ball filling rate, mill speed and aspect ratio.

[0044] The specific meaning of F80 is the sieve aperture through which 80% of the feed in the crushing and grinding process can pass.

[0045] (4) Intelligent ball adding calculation module for grinding mill: When steel balls need to be added to compensate for the wear of steel balls in the semi-autogenous grinding mill, the difference between the original ball rate R0 and the actual ball rate R1 is the required ball adding amount.

[0046] When the ore crushing and grinding properties change and the ball loading rate of the semi-autogenous grinding mill needs to be adjusted, the following method is used to calculate the amount of balls to be added. Figure 3 The iterative process shown here adjusts the feed rate and ball loading rate: First, input the ore crushing properties, set the target ball loading rate R2 and the target total filling rate, calculate the specific energy consumption and mill operating power, and then calculate the throughput based on the mill operating power and specific energy consumption. When the throughput meets the requirements and the mill operating power is less than the installed power × k, the difference between the actual ball loading rate R1 and the target ball loading rate R2 is the required ball loading rate. If the actual ball loading rate R1 is greater than or equal to the target ball loading rate R2, the required ball loading rate is considered to be zero, and the balls are allowed to wear naturally. If the throughput does not meet the requirements or the mill operating power is greater than the installed power × k, the above process is repeated until the target is reached.

[0047] k is a user-defined safety factor, which defaults to 0.9.

[0048] After the intelligent operation and maintenance software of the mill power consumption and the host computer 5 calculate the amount of balls to be added, the automatic ball adding device 11 is controlled to add the steel balls.

[0049] The mill filling rate online detection sensor 8 monitors the total filling rate of the material and steel balls in the mill 6 through the vibration signal.

[0050] The mill filling rate online detection sensor 8 transmits the total filling rate information in the mill 6 to the mill power consumption intelligent operation and maintenance software and the host computer 5 through wireless signal transmission for analysis.

[0051] The screening machine adopts double-layer three-product vibrating screening equipment.

[0052] This invention utilizes sensors and a signal processing system to make the grinding process more transparent and digital, matching mill power with throughput and ore crushing characteristics. This allows for precise control of the mill's ball loading rate, fully utilizing the mill's installed power and production capacity. This enables intelligent and precise operation and maintenance of the grinding process, achieving the goals of energy conservation, consumption reduction, and increased production.

[0053] The system has automatic material taking, automatic analysis and automatic feeding, and does not need manual operation, thereby avoiding training cost and manual maintenance cost of on-site operators.

Claims

1. A method for intelligent balling of a semi-autogenous mill, characterized by, An intelligent ball adding system for a semi-autogenous mill is adopted, which comprises an automatic material taking device (2), a screening machine (3), an ore impact crushing property on-line detector (4), a mill intelligent ball adding software and an upper computer (5), a mill (6), a mill filling rate on-line detection sensor (8), a sensor data acquisition instrument (9), and a power monitoring device (10); the automatic material taking device (2) takes samples from the feed ore (1) before the feed ore enters the semi-autogenous mill; the screening machine (3) classifies the ore samples so that the fine particle level meets the feed size requirement of the ore impact crushing property on-line detector (4); The ore impact crushing property on-line detector (4) automatically detects the ore crushing and grinding characteristics; the mill filling rate on-line detection sensor (8) and the sensor data acquisition instrument (9) monitor and acquire the signal of the total filling rate of the mill (6); the total filling rate of the mill (6) refers to the percentage of the volume of the ore and steel balls in the mill to the internal volume of the mill after the mill stops running and simultaneously stops feeding ore and water; The power monitoring device (10) obtains the actual power of the semi-autogenous mill; The mill power consumption intelligent operation and maintenance software of the mill intelligent ball adding 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 semi-autogenous mill actual ball loading rate on-line prediction module, and a mill intelligent ball adding amount calculation module; The ball loading rate of the semi-autogenous mill is defined as the percentage of the volume of the steel balls in the mill to the internal volume of the mill after the mill stops feeding ore and water and continues to run for a short time to grind and discharge all the ore load and then stops; the running power of the semi-autogenous mill is obtained by the power monitoring device (10), and the total filling rate is obtained by the mill filling rate on-line detection sensor (8); The ore crushing property index C1, C2, …, C is calculated by the ore crushing property characterization module. n ; The unit energy consumption W of the semi-autogenous mill is the result of the comprehensive action of multiple factors: In the mill intelligent ball adding amount calculation module, when steel balls need to be added to compensate for the wear of the steel balls in the semi-autogenous mill, the difference between the original ball loading rate R0 and the actual ball loading rate R1 is the required ball adding amount; W = K x f (F 80 , C1, …, C n , ball loading, mill speed, length-diameter ratio) According to the above relationship, the grinding process unit energy consumption prediction module calculates the theoretical unit energy consumption of the semi-autogenous grinding process through the correction coefficient K, the feed size F 80 , ore crushing and grinding characteristics indicators C1, …, C n , ball loading rate, mill speed and length-diameter ratio. wherein F 80 The specific value is the aperture size of the screen through which 80% of the feed material passes during the grinding process.

2. The method according to claim 1, wherein, When the ore crushing and grinding properties change and the ball loading rate of the semi-autogenous mill needs to be adjusted, first, input the ore crushing and grinding property index, set the target ball loading rate R2 and the target total filling rate, calculate the unit energy consumption and the mill running power, and then calculate the processing capacity according to the mill running power and the unit energy consumption; when the processing capacity can meet the demand and the mill running power is less than the installed power × k, the difference between the actual ball loading rate R1 and the target ball loading rate R2 is the required ball adding amount; if the actual ball loading rate R1 is greater than or equal to the target ball loading rate R2, the required ball adding amount is considered as 0, and the steel ball is naturally worn; if the processing capacity cannot meet the demand or the mill running power is greater than the installed power × k, repeat the above operation until the target is reached; k is a self-defined safety factor. After the mill intelligent ball adding software and the upper computer (5) calculate the ball adding amount, the automatic ball adding device (11) is controlled to add steel balls.

3. The method according to claim 2, wherein, ​ 4. The method according to claim 3, wherein, The mill filling rate online detection sensor (8) monitors the total filling rate of the material and the steel ball of the mill (6) through a vibration signal.

5. A method of intelligent ball charging for a semi-autogenous mill as claimed in claim 4 wherein, The mill filling rate online detection sensor (8) transmits the total filling rate information in the mill (6) to the intelligent ball adding software of the mill and the upper computer (5) through a wireless signal transmission mode for analysis.

Images