A repair material and a repair method for a mineral processing plant

Abstract

The application discloses a kind of ore dressing equipment's repair material and repair method, belong to ore dressing equipment maintenance technical field.The repair material of the application is composed of the following components by weight ratio: cement: fine sand: combination agent=0.5-1.5:2.5-3.5:3.5-4.5;The combination agent is composed of the following components by weight ratio: tailing backwater: water: hydrochloric acid: water glass=2-5:2-5:0.3-0.8:0.5-1.5.The application carries out repair to ore dressing equipment by self-made repair material, can solve the problem of wear and tear of flotation machine, stirring barrel and other ore dressing equipment under the premise of not needing to purchase and replace ore dressing equipment, ensure that it can maintain normal safe production, prolong the service life of equipment, promote the improvement of company economic benefit.

Description

Technical Field

[0001] This invention relates to the field of mineral processing equipment maintenance technology, specifically to a repair material and repair method for mineral processing equipment. Background Technology

[0002] In the mining industry, numerous mineral processing equipment are used. These equipment are complex, operate for extended periods, and work in challenging environments. Under these conditions, wear and corrosion can occur, severely impacting the equipment's lifespan and the safety of the operation. For example, in lead-zinc mines, flotation operations primarily utilize numerous flotation machines and stirred tanks. The ore is complex, containing up to 60% dolomite, calcite, and other light gangue minerals. The valuable minerals are finely distributed with complex intergrowth characteristics and symbiotic relationships. Furthermore, after use, flotation machines and stirred tanks are subjected to repeated contact and fusion with froth, acidic water, and flotation reagents, including lime, copper sulfate, xanthate, and ethyl thiocyanate. The bottom of the machines is also prone to wear due to contact wear with the impeller and impeller cover. Currently, mining companies lack effective repair methods for worn-out mineral processing equipment. Most often, they simply replace worn-out equipment like flotation machines and mixing tanks with new ones after leaks appear at the bottom, resulting in excessive costs. The economic benefits of replacing worn-out equipment are disproportionate to the investment, which is detrimental to business development. Summary of the Invention

[0003] The purpose of this invention is to address the aforementioned problems in the existing technology by providing a repair material and method for mineral processing equipment. This invention repairs mineral processing equipment using self-made repair materials, solving the wear and tear problems of flotation machines, mixing tanks, and other mineral processing equipment without requiring the purchase or replacement of the equipment. This ensures normal and safe production, extends equipment lifespan, and promotes improved company economic benefits.

[0004] To achieve the above objectives, the technical solution of the present invention is as follows:

[0005] A repair material for mineral processing equipment, comprising the following components by weight:

[0006] Cement: Fine sand: Admixture = 0.5-1.5: 2.5-3.5: 3.5-4.5;

[0007] The combined agent is composed of the following components in the following weight ratio:

[0008] Tailings return water: clean water: hydrochloric acid: water glass = 2-5: 2-5: 0.3-0.8: 0.5-1.5.

[0009] Furthermore, the tailings return water is tailings return water from the lead-zinc ore beneficiation process, with a pH of 5.5-6.5, a zinc content of 0.1-0.2%, and a lead content of 0.6-1%. The tailings return water has a suitable pH value and contains heavy metal ions such as Pb and Zn, which can interact with hydrochloric acid and water glass, shortening the solidification time and improving the wear resistance of repair materials.

[0010] This invention also provides a method for preparing repair materials for the mineral processing equipment, comprising the following steps:

[0011] (1) Preparation of the combined agent: Mix the tailings return water and clean water evenly, then titrate with hydrochloric acid to control the pH in the range of 5-6, then add water glass and mix evenly to prepare the combined agent. The ambient temperature during the preparation process is controlled at 15-30℃.

[0012] (2) Preparation of repair materials: Take cement and fine sand according to the proportion, mix them evenly, and then add the combined agent obtained in step (1) to mix into a paste to make repair materials for mineral processing equipment.

[0013] The present invention also provides a method for repairing mineral processing equipment, comprising the following steps:

[0014] S1. Place the mineral processing equipment in the tank, transfer the internal slurry, remove the internal parts, and then clean it with clean water. Treat the surface of the structural layer that needs to be repaired until there are no impurities.

[0015] S2. Apply a layer of the repair material prepared in step (2) above to the surface of the structural layer of the mineral processing equipment that needs to be repaired;

[0016] S3. After standing for 3-5 minutes until the surface solidifies, brush the repair material prepared in step (2) above onto the surface.

[0017] S4. After standing for 20-40 minutes until the repair materials have completely solidified, reassemble the internal components.

[0018] Furthermore, in step S2, the thickness of the repair material coating is 0.5-1cm.

[0019] Furthermore, in step S3, the thickness of the repair material coating is 4-6 cm.

[0020] Furthermore, the mineral processing equipment includes a flotation machine and a mixing tank.

[0021] The beneficial effects of this invention are as follows:

[0022] (1) This invention addresses the characteristics of mineral processing equipment and its operating environment by developing a self-made repair material for such equipment. During repair, workers simply need to apply the repair material to the worn area with a certain thickness, resulting in a simple repair method and low repair cost. The components of this repair material work together to enhance service life, accelerate hardening, improve wear resistance, and resist corrosion, thereby reducing costs, increasing efficiency, and extending equipment life. It effectively solves leakage problems in mineral processing equipment such as flotation machines and mixing tanks, and offers good repair results with low overall cost.

[0023] (2) This invention greatly prevents leakage accidents of mineral processing equipment such as flotation machines and mixing tanks during normal operation, and can significantly reduce the workload and maintenance cost of flotation machines; without the need to purchase or replace equipment, it ensures that mineral processing equipment such as flotation machines and mixing tanks can maintain normal production and promote the improvement of enterprise economic benefits.

[0024] (3) After trial use, the results show that the technology of the present invention can repair the structural layers of mineral processing equipment such as flotation machines and mixing tanks on schedule. The wear is almost zero, which reduces the frequency and cost of maintenance and promotes the improvement of enterprise economic benefits. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments.

[0026] Example 1

[0027] (a) Preparation of repair materials for mineral processing equipment:

[0028] Raw material preparation:

[0029] Raw materials for the compounding agent: Prepare the components according to the following weight ratio: tailings return water: clean water: hydrochloric acid: water glass = 4:4:0.5:1.

[0030] Repair materials: Prepare the components according to the following weight ratio: cement: fine sand: binder = 1:3:4;

[0031] The tailings return water is tailings return water from the lead-zinc ore beneficiation process, with a pH of 6.13, a zinc content of 0.12%, and a lead content of 0.75%.

[0032] The preparation steps for repair materials are as follows:

[0033] (1) Preparation of the combined agent: Mix the tailings return water and clean water evenly according to the ratio, then titrate with hydrochloric acid to adjust the pH to 5-6, then add water glass and mix evenly to prepare the combined agent. The ambient temperature during the preparation process is 20℃.

[0034] (2) Preparation of repair materials: Take cement and fine sand according to the proportion, mix them evenly, and then add the combined agent obtained in step (1) to mix into a paste to make repair materials for mineral processing equipment.

[0035] (II) Repair methods for mineral processing equipment, including the following steps:

[0036] S1. Place the flotation machine of the mineral processing equipment into the tank, transfer the internal slurry to the emergency pool, remove the machine shaft, impeller and impeller cover plate with a crane, and clean them with clean water. Treat the surface of the bottom structural layer that needs to be repaired to ensure that there are no foreign objects.

[0037] S2. Lightly brush a layer of the repair material prepared in step (2) onto the surface of the structural layer to be repaired in the flotation machine of the mineral processing equipment. The thickness of the repair material is 0.5-1cm.

[0038] S3. After standing for 4 minutes and waiting for the surface to solidify, brush the repair material prepared in step (2) above onto the surface, with a thickness of 5cm.

[0039] S4. After standing for 30 minutes until the repair material has completely solidified, reinstall the internal components, including the shaft, impeller, and impeller cover.

[0040] Example 2

[0041] (a) Preparation of repair materials for mineral processing equipment:

[0042] Raw material preparation:

[0043] Raw materials for the compounding agent: Prepare the following components in the following weight ratio: tailings return water: clean water: hydrochloric acid: water glass = 2:2:0.3:0.5.

[0044] Repair materials: Prepare the following components according to the following weight ratio: cement: fine sand: binder = 1.5: 3.5: 4.5;

[0045] The tailings return water is tailings return water from the lead-zinc ore beneficiation process, with a pH of 6.48, a zinc content of 0.16%, and a lead content of 0.64%.

[0046] The preparation steps for repair materials are as follows:

[0047] (1) Preparation of the combined agent: Mix the tailings return water and clean water evenly, then titrate with hydrochloric acid to adjust the pH to 5-6, then add water glass and mix evenly to prepare the combined agent. The ambient temperature during the preparation process is controlled at 20℃.

[0048] (2) Preparation of repair materials: Take cement and fine sand according to the proportion, mix them evenly, and then add the combined agent obtained in step (1) to mix into a paste to make repair materials for mineral processing equipment.

[0049] (II) Repair methods for mineral processing equipment, including the following steps:

[0050] S1. Place the mixing tank of the mineral processing equipment into the tank, transfer the internal slurry, remove the internal parts, and then clean it with clean water. Treat the surface of the structural layer that needs to be repaired until there are no impurities.

[0051] S2. Apply a layer of the repair material prepared in step (2) above to the surface of the structural layer of the mineral processing equipment that needs to be repaired, with a thickness of 0.5-1cm.

[0052] S3. After standing for 5 minutes and waiting for the surface to solidify, brush the repair material prepared in step (2) above onto the surface, with a thickness of 4cm.

[0053] S4. After standing for 20 minutes until the repair materials have completely solidified, reassemble the internal components.

[0054] Example 3

[0055] (a) Preparation of repair materials for mineral processing equipment:

[0056] Raw material preparation:

[0057] Raw materials for the compounding agent: Prepare the following components in the following weight ratio: tailings return water: clean water: hydrochloric acid: water glass = 5:5:0.8:1.5.

[0058] Repair materials: Prepare the following components according to the following weight ratio: cement: fine sand: binder = 0.5: 2.5: 3.5;

[0059] The tailings return water is tailings return water from the lead-zinc ore beneficiation process, with a pH of 5.89, a zinc content of 0.14%, and a lead content of 0.65%.

[0060] The preparation steps for repair materials are as follows:

[0061] (1) Preparation of the combined agent: Mix the tailings return water and clean water evenly, then titrate with hydrochloric acid to adjust the pH to 5-6, then add water glass and mix evenly to prepare the combined agent. The ambient temperature during the preparation process is 25℃.

[0062] (2) Preparation of repair materials: Take cement and fine sand according to the proportion, mix them evenly, and then add the combined agent obtained in step (1) to mix into a paste to make repair materials for mineral processing equipment.

[0063] (II) Repair methods for mineral processing equipment, including the following steps:

[0064] S1. Discharge the flotation machine of the mineral processing equipment, transfer the internal slurry, remove the internal parts, and then clean it with clean water to treat the surface of the structural layer to be repaired until there are no impurities.

[0065] S2. Apply a layer of the repair material prepared in step (2) above to the surface of the structural layer of the flotation machine of the mineral processing equipment that needs to be repaired, with a thickness of 0.5-1cm.

[0066] S3. After standing for 3 minutes and waiting for the surface to solidify, brush the repair material prepared in step (2) above onto the surface, with a thickness of 6cm.

[0067] S4. After standing for 40 minutes until the repair materials have completely solidified, reassemble the internal components.

[0068] Specific practical applications of this invention:

[0069] Test conditions:

[0070] (1) A lead-zinc mine in Guangxi has a daily processing capacity of 114t and operates for 330 days a year. Currently, it uses a large number of flotation machines and mixing tanks for flotation operations. The ore has complex properties and contains light gangue minerals such as dolomite and calcite, which account for up to 60% of the mineral content. The useful minerals are distributed in fine particles with complex intergrowth characteristics and symbiotic relationships. The useful minerals are lead-zinc minerals with uneven fineness and 90% of the ore is -700 mesh after regrinding of the middlings.

[0071] (2) The lead-zinc flotation process adopts a process of prioritizing lead flotation and then zinc flotation. The lead flotation process consists of one roughing, two scavenging, and five cleaning processes; the zinc flotation process consists of two roughing, two scavenging, and four cleaning processes. Various mineral processing reagents such as lime, copper sulfate, xanthate, and ethyl thiocyanate are added for separation, and groundwater (pH 5, acidic) is used for flotation. The flotation machine and mixing tank are in long-term repeated contact and fusion with foam, water, and mineral processing reagents, and the bottom is prone to wear due to contact wear of the impeller and impeller cover plate.

[0072] (3) In this experiment, the No. 1 flotation machine for rough zinc in the zinc flotation process was selected. The model was SF-16, and the flotation cell was made of cast iron with a thickness of 8cm. After 5 years of use, due to the wear of the flotation machine impeller, impeller cover plate and slurry, only 3cm of the 8cm thick iron plate at the bottom of the flotation cell remained, with 5cm of wear.

[0073] The specific construction method is as follows:

[0074] S1. The temperature at the construction site is 20 degrees Celsius.

[0075] S2. Preparation of the combined agent: Take 8 kg of tailings return water (same as in Example 1), 8 kg of clean water, 1 kg of hydrochloric acid, and 2 kg of water glass, mix and stir evenly. The hydrochloric acid is titrated to control the pH of the mixture within the range of 5-6, and prepare the combined agent.

[0076] S3. Preparation of repair materials: Take 2kg of cement and 6kg of fine sand, mix them evenly, then add 8kg of binder and mix into a paste to prepare the repair materials.

[0077] S4. Remove the No. 1 flotation machine for zinc roughing and transfer the internal slurry to the emergency tank. Take out the machine shaft, impeller and impeller cover plate and clean them with clean water. Treat the surface of the bottom structural layer until there are no impurities.

[0078] S5. Lightly brush a layer of repair material onto the surface of the bottom structural layer of the flotation machine, with a thickness of 0.5-1cm;

[0079] S6. After standing for 4 minutes and waiting for the surface to solidify, apply repair material to it, with a thickness of 5cm.

[0080] S7. After standing for 30 minutes until the repair materials have completely solidified, install the shaft, impeller, and impeller cover of the No. 1 zinc roughing flotation machine.

[0081] Experimental results:

[0082] (1) The flotation machine was repaired using this repair method. After repair, it was run under the same test conditions for 5 years. The bottom of the flotation cell of the original flotation machine was only worn by 4 cm, while the bottom of the flotation cell of the original flotation machine was worn by 5 cm after 5 years of operation. It can be seen that the repair method of the present invention can effectively improve the wear resistance of the flotation machine.

[0083] (2) The purchase and labor cost of an SF-16 flotation machine is 370,000 yuan, with a service life of 5 years. The material and labor cost for repairing it once using the method of this invention is 2,000 yuan, with a service life of 5 years. It can be seen that this invention can greatly reduce production costs.

[0084] To further verify the technical effects of the present invention, a comparative test was conducted, as follows:

[0085] (1) Test equipment: 1 new SF-4 flotation machine with cast iron flotation cell thickness of 8cm; 1 SF-4 flotation machine that has been used for 5 years with 2cm remaining flotation cell thickness.

[0086] (2) Test method: The bottom of the flotation cell of the old SF-4 flotation machine, which had been in use for 5 years, was repaired using the repair material and repair method prepared in Example 1. Under the condition that other conditions remain unchanged, the new SF-4 flotation machine was used as the No. 2 flotation machine of zinc refining No. 4, and the repaired old SF-4 flotation machine was used as the No. 3 flotation machine of zinc refining No. 4 (the two positions are basically equally likely to be worn). They were operated for 100 days with a daily processing capacity of 114t, and their wear conditions were compared.

[0087] (3) Test results: The bottom of the flotation cell of the No. 2 flotation machine was worn by 2.6 mm, and the bottom of the flotation cell of the No. 3 flotation machine was worn by 2.3 mm. It can be seen that the present invention can improve the wear resistance of the flotation machine, and its wear resistance effect has reached or even exceeded that of new equipment.

[0088] To confirm the role of tailings return water in the repair material of this invention, a comparative test method was used for verification, as follows:

[0089] (1) Test equipment: Two SF-4 flotation machines that have been in use for 5 years, with the remaining thickness of the flotation cells being 1cm (original thickness 8cm).

[0090] (2) Repair materials: including Group A and Group B. Group A repair materials are the repair materials prepared in Example 3; Group B repair materials are based on Example 3, with tailings return water replaced with clean water.

[0091] (3) Test method: The bottom of the flotation cell of one SF-4 flotation machine was repaired using repair materials from group A, and the bottom of the flotation cell of the other SF-4 flotation machine was repaired using repair materials from group B. Both SF-4 flotation machines were treated using the repair method of Example 3 (only the repair materials were different). Under the condition that other conditions remained unchanged, the SF-4 flotation machine repaired with repair materials from group A was used as the No. 2 flotation machine of zinc refining grade 3, and the SF-4 flotation machine repaired with repair materials from group B was used as the No. 3 flotation machine of zinc refining grade 3 (the two positions had basically the same probability of wear). They were operated for 100 days with a daily processing capacity of 114t, and their wear conditions were compared.

[0092] (4) Test results: The bottom of the flotation cell of flotation machine #2 showed wear of 2.1 mm, and the bottom of the flotation cell of flotation machine #3 showed wear of 3.8 mm. It can be seen that using tailings recycled water to treat the repair materials can improve the wear resistance of the flotation machines. In addition, during the repair process, the repair materials of group A can be completely solidified after standing for 31 minutes in step S4; while the repair materials of group B need to be standing for 59 minutes in step S4 to be completely solidified. It can be seen that the tailings recycled water can interact with hydrochloric acid and water glass, which can greatly shorten the solidification time.

[0093] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications and improvements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be defined by the claims.

Claims

1. A repair material for mineral processing equipment, characterized in that, The following components are in the following weight ratio composition: Cement: Fine sand: Admixture = 0.5-1.5: 2.5-3.5: 3.5-4.5; The combined agent is composed of the following components in the following weight ratio: Tailings return water: Clean water: Hydrochloric acid: Water glass = 2-5: 2-5: 0.3-0.8: 0.5-1.5; The tailings return water is tailings return water from the lead-zinc ore beneficiation process, with a pH of 5.5-6.5, a zinc content of 0.1-0.2%, and a lead content of 0.6-1%.

2. The method for preparing the repair material for the mineral processing equipment according to claim 1, characterized in that, Includes the following steps: (1) Preparation of the combined agent: Mix the tailings return water and clean water evenly, then titrate with hydrochloric acid to control the pH in the range of 5-6, then add water glass and mix evenly to prepare the combined agent. The ambient temperature during the preparation process is controlled at 15-30℃. (2) Preparation of repair materials: Take cement and fine sand according to the ratio, mix them evenly, and then add the combined agent obtained in step (1) to mix into a paste to make repair materials for mineral processing equipment.

3. A method for repairing mineral processing equipment, characterized in that, Includes the following steps: S1. Place the mineral processing equipment in the tank, transfer the internal slurry, remove the internal parts, and then clean it with clean water. Treat the surface of the structural layer that needs to be repaired until there are no impurities. S2. Apply a layer of the repair material prepared according to claim 2 to the surface of the structural layer of the mineral processing equipment that needs to be repaired; S3. After standing for 3-5 minutes until the surface solidifies, brush the repair material made according to claim 2 onto the surface. S4. After standing for 20-40 minutes until the repair materials have completely solidified, reassemble the internal components.

4. The method for repairing mineral processing equipment as described in claim 3, characterized in that: In step S2, the thickness of the repair material coating is 0.5-1 cm.

5. The method for repairing mineral processing equipment as described in claim 3, characterized in that: In step S3, the thickness of the repair material coating is 4-6 cm.

6. The method for repairing mineral processing equipment as described in claim 3, characterized in that: The mineral processing equipment includes a flotation machine and a mixing tank.