Manufacturing method of continuous authigenic magnetic ceramic coating of light-weight energy-saving ball mill

Abstract

The invention discloses a manufacturing method of a continuous authigenic magnetic ceramic coating of a light-weight energy-saving ball mill, and belongs to the technical field of ore grinding. The manufacturing method of the continuous authigenic magnetic ceramic coating of the light-weight energy-saving ball mill comprises the following steps: paving a layer of magnetic lining plate on the inner wall of the ball mill to form a magnetic lining ball mill; iron, ceramic balls and steel balls are added into the magnetic lining ball mill to form a magnetic ceramic ball mill for initial ball loading, the magnetic ceramic ball mill is connected to a production process, and the waveform grid magnetic ceramic coating is naturally formed after an adsorption period of 3-6 months. The problems that an existing ball mill lining plate is short in service life and low in ball mill operation rate and ore grinding efficiency are solved, the wave-shaped grid magnetic ceramic coating is naturally formed through the adsorption effect of the magnetic lining plate, good abrasion resistance and corrosion resistance are achieved, no complex technology exists in the process, operation steps are simplified, and the production cost is reduced. And the plating layer can be continuously self-generated to counteract abrasion consumption, and the ultra-long service life is achieved

Description

Technical Field

[0001] The invention relates to the technical field of ore grinding, and in particular to a method for manufacturing a continuous self-generated magnetic ceramic coating of a lightweight and energy-saving ball mill. Background Art

[0002] In the production and operation process of the ore dressing plant, the ball mill, as the core equipment of the production process, operates continuously 24 hours a day. Its operating rate is the operating rate of the ore dressing plant, which directly corresponds to the production efficiency of the enterprise. The shutdown and maintenance of the ball mill is the top priority of the ore dressing plant maintenance task, and the replacement of the ball mill liner is the largest maintenance content, and it is also the maintenance project that takes the longest time and requires the most manpower. Extending the service life of the ball mill liner, improving the ball mill operating rate and grinding efficiency, can improve the production efficiency and economic benefits of the ore dressing plant.

[0003] Nowadays, wear-resistant technologies such as manganese steel, magnets, and rubber are mostly used to extend the service life of ball mill liners. For example, the Chinese patent with the announcement number CN114260068B discloses a mining ball mill liner with a wear-resistant structure. The liner is enhanced in practicality through the combined effect of high-temperature resistant coating, waterproof coating, anti-corrosion coating and adhesive reinforcement layer, so that it can be used in high temperature environments. The liner has a wear-resistant function through the combined effect of rubber strips, PE anti-friction layer, lubricating coating, flocking anti-friction layer and fixed card strips. The special properties of PE anti-friction layer and flocking anti-friction layer are used to reduce the friction force when the liner collides with the ball mill to avoid wear. However, this structure greatly increases the thickness of the overall wear-resistant layer. After being installed in the original cylinder structure, it will reduce the effective volume of the ball mill, affect its table-hour capacity, and reduce the production efficiency of the ball mill.

[0004] The Chinese patent with announcement number CN115740462A discloses a ball mill liner with high wear resistance and its preparation process. By setting a wear-resistant coating on the alloy surface, the use of rare metals is reduced. The wear-resistant coating forms a unique toughening structure between boron nitride, ferrochrome powder and tungsten disulfide, so that the coating has dual wear resistance. At the same time, tungsten disulfide reacts chemically with iron to produce a FeS film with a low melting point, which effectively reduces the contact between metal friction and thus reduces the wear on the metal surface. The wear-resistant coating of the invention can well avoid the wear of the liner body, but the manufacturing process of this liner is very complicated, and the installation accuracy of the liner at the maintenance site is very high, otherwise the wear-resistant coating will be damaged, or the wear-resistant coating will be ineffective due to insufficient installation accuracy.

[0005] Therefore, it is of great significance to study how to extend the service life of the ball mill lining while ensuring the grinding effect and stability. Summary of the invention

[0006] The purpose of the present invention is to provide a method for producing a lightweight and energy-saving ball mill continuous self-generated magnetic ceramic coating, which can reduce the total weight of the ball mill during stable production while ensuring the grinding effect and stability, thereby achieving the purpose of extending the service life of the ball mill lining while saving energy, and solving the problems raised in the above-mentioned background technology.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A method for preparing a lightweight and energy-saving ball mill continuous self-generated magnetic ceramic coating comprises the following steps:

[0009] Step 1: Lay a layer of magnetic lining on the inner wall of the ball mill to form a magnetic lined ball mill;

[0010] Step 2, adding iron into the magnetic lined ball mill described in step 1;

[0011] Step 3, adding ceramic balls into the magnetic lined ball mill described in step 1;

[0012] Step 4, adding steel balls into the magnetic lined ball mill described in step 1 to form a magnetic ceramic ball mill with initial balls;

[0013] Step 5. Connect the magnetic ceramic ball mill with the initial balls obtained in step 4 to the production process and carry out conventional grinding production operations. After an adsorption period of 3 to 6 months, a corrugated grid magnetic ceramic coating is naturally formed, and the iron is continuously adsorbed to automatically generate a coating to offset the wear and tear in the production process, thereby maintaining a stable corrugated grid magnetic ceramic coating for a long time.

[0014] Preferably, as described in step five, during the initial adsorption period of one week, the iron is adsorbed by the magnetic lining, and the points with higher magnetic field strength around the magnetic lining adsorb more iron, and the ceramic balls are filled into the gaps and recessed parts between the magnetic linings in the form of being stuck, embedded, and adhered to form an initial corrugated grid magnetic ceramic coating;

[0015] Continue to add ceramic balls and steel balls, and connect the magnetic lined ball mill to the actual production process, officially entering the adsorption period. During this period, add balls according to the steel consumption of steel balls and ceramic balls to maintain the filling rate at 40% to 42% and the grinding concentration at 63% to 67%.

[0016] Preferably, with respect to step 2, the maximum geometric dimension of the iron monomer is ≤20 mm.

[0017] Preferably, with respect to step three, the diameter of the ceramic balls is 20 cm to 30 mm, and the specification ratio of the ceramic balls during initial loading is: the ratio of 20 cm diameter ceramic balls, 25 cm diameter ceramic balls, and 30 cm diameter ceramic balls is 4:3:3.

[0018] Preferably, with respect to step 4, the specification of the steel ball is φ30mm~φ35mm.

[0019] Preferably, with respect to step five, the specification of the steel balls added during the adsorption period is φ35 mm, and the specification of the ceramic balls added is φ30 mm.

[0020] Preferably, as described in step one, the front side of the magnetic lining is provided with a semi-ellipsoidal protrusion and an outer ring edge, and the back side of the magnetic lining is provided with an inwardly embedded magnet; the magnetic field strength on the front side of the magnetic lining gradually weakens from the outer edge to the inside, and the gradient of the change of the magnetic field strength is 3000Gs, 2000Gs, 1400Gs, 1000Gs and 800Gs respectively.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. The present invention adds iron and ceramic balls in the ball mill and utilizes the adsorption effect of the magnetic liner to naturally form a corrugated grid magnetic ceramic coating, which has good wear resistance and corrosion resistance. This process does not require additional chemical treatment or complex processes, thus simplifying the operation steps. After the adsorption period expires, the coating can continue to self-generate to offset wear and tear, thus achieving ultra-long life wear resistance.

[0023] 2. The present invention provides a semi-ellipsoidal protrusion and an outer ring edge 1 cm higher than the plane on the front side of the magnetic lining plate, and inlays magnets on the back side, so as to form a magnetic field intensity distribution that decreases from the outside to the inside. This design not only enhances the adsorption capacity of the magnetic lining plate, but also provides physical structural support for the formation of a corrugated grid magnetic ceramic coating. The formed magnetic ceramic coating exists on the inner wall surface of the ball mill in the shape of a corrugated grid, which can meet the needs of improving the grinding medium for a long time.

[0024] 3. The present invention increases the effective volume of the ball mill by making the coating thickness lower than that of conventional corrugated linings made of manganese steel or other materials, thereby increasing the hourly capacity; and the density is much lower than that of manganese steel linings, reducing the total weight of the ball mill in production state, thereby reducing the energy consumption of the ball mill system. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the front structure of the magnetic lining plate of the present invention;

[0026] Figure 2 It is a schematic diagram of the back structure of the magnetic liner of the present invention;

[0027] Figure 3 It is the magnetic field strength arrangement diagram of the magnetic liner of the present invention;

[0028] Figure 4 This is a flow chart of the adsorption of self-generated magnetic ceramic coating of the present invention;

[0029] Figure 5 This is a schematic diagram of laying a magnetic lining plate on the inner wall of a mill according to the present invention;

[0030] Figure 6 It is a schematic diagram of the produced magnetic ceramic coating of the present invention.

[0031] In the figure: 1. magnetic lining; 2. semi-ellipsoidal protrusion; 3. outer ring edge; 4. magnet; 5. corrugated grid magnetic ceramic coating; 6. ceramic ball; 7. iron. DETAILED DESCRIPTION

[0032] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0033] In order to solve the problems of short service life of existing ball mill liner, low ball mill operation rate and grinding efficiency, the following technical solutions are provided:

[0034] Embodiment 1:

[0035] In this example, the MQY4060 ball mill is selected as the production object. The main parameters are: cylinder inner diameter 4000mm, cylinder length 6000mm, effective volume 69.85m 3 , the cylinder working speed is 16.8r / min, the hourly capacity is about 170t / h, and the conventional matching motor power is 1500kW.

[0036] like Figure 1-2 As shown, a semi-ellipsoidal protrusion 2 is provided in the center of the front side of the magnetic lining 1, an outer ring edge 3 1 cm higher than the plane is provided on the outer ring of the front side of the magnetic lining 1, and an inwardly embedded magnet 4 is provided in the middle of the back side of the magnetic lining 1, and the geometric dimensions of the magnet 4 are: 16 cm in length, 8 cm in width, and 2 cm in height.

[0037] like Figure 3 As shown, the magnetic field strength on the front side of the magnetic lining plate 1 gradually weakens from the outer edge to the inside, and the gradient of the change of the magnetic field strength is 3000Gs, 2000Gs, 1400Gs, 1000Gs, and 800Gs respectively.

[0038] like Figure 5 As shown, the magnetic lining 1 is laid on the inner wall of the MQY4060 ball mill, and all inner wall surfaces except the ball mill feed port and discharge port are fully laid flat to complete the installation of the magnetic lining 1.

[0039] like Figure 4As shown, iron 7 is added to the ball mill with the magnetic liner 1 installed, and the added amount is the volume required to cover the inner wall of the MQY4060 ball mill. In this embodiment, waste steel balls with a single maximum geometric size of ≤20mm are selected as iron 7 for addition, and the added amount is 20t at a time; ceramic balls 6 are added to the ball mill, 34t is added for the first time, and the specifications are 10t of φ30mm ceramic balls 6, 14t of φ25mm ceramic balls 6 and 10t of φ20mm ceramic balls 6.

[0040] After the first addition of ceramic balls 6, the system is connected to the production system and operated for one week for initial adsorption. During the one-week initial adsorption, the iron 7 will be adsorbed by the magnetic lining 1. The points with higher magnetic field strength around the magnetic lining 1 will adsorb more iron 7, and the points with lower magnetic field strength around the magnetic lining 1 will adsorb less iron 7.

[0041] During the process of the magnetic lining 1 adsorbing the iron 7, the ceramic balls 6 will be filled into the gaps, grooves, depressions and other parts between the magnetic linings 1 in the form of carding, embedding, adhesion and the like; after a week of initial adsorption, the iron 7 and the ceramic balls 6 are continuously adsorbed to the surface of the magnetic lining 1 on the inner wall of the ball mill, and the adsorption layer in the area with high magnetic field intensity gradually thickens, and the adsorption layer in the area with low magnetic field intensity gradually stabilizes, and an initial corrugated grid magnetic ceramic coating 5 will be formed.

[0042] After the initial corrugated grid magnetic ceramic coating 5 is formed, ceramic balls 6 are added for the second time, with an addition amount of 20t and a specification of φ30mm; steel balls are added for the first time, with an addition amount of 32t and a specification of φ30mm; at this time, it can be used as a normal ball mill and connected to the actual production process, and officially enters the adsorption period. During this period, additional balls are added according to the steel consumption of steel balls and ceramic balls 6, maintaining a filling rate of 38% to 40%, and the grinding concentration is controlled within the range of 63% to 67%.

[0043] After the present embodiment is put into actual production, it formally enters the adsorption period, during which 61t / month of ceramic balls with a specification of φ30mm and 1t / week of steel balls with a specification of φ30mm are added.

[0044] like Figure 6 As shown, a shaped coating is formed, which contains iron 7 and ceramics of different sizes. The coating is measured to be in a grid shape, with a thickness of 2.8 cm at the highest point of the grid and 0.1 cm at the lowest point of the grid, which is basically level with the semi-ellipsoidal protrusion 2. The height difference is greater than the peak height of the conventional corrugated manganese steel liner, and the shape of the grid bars is similar to the upper protrusion of a sine wave. The above determines that a stable corrugated grid magnetic ceramic coating 5 is formed, and will not affect the effect of the ball mill in improving the grinding value.

[0045] According to the property that the magnetic field intensity attenuation cycle of the magnet 4 reaches more than 15 years, the ceramic balls 6 and steel balls are supplemented in the production process according to the ball adding system formulated by the ore dressing process. In this stable cycle, the corrugated grid magnetic ceramic coating 5 will continuously absorb iron 7 and ceramic balls 6 to offset the grinding and selection consumption in the production process, so that the continuous self-generation of the corrugated grid magnetic ceramic coating 5 can be achieved. Because there is no liner wear, the ability of the ball mill to enhance the grinding medium will not be weakened due to the wear of the liner waveform, so that the ball mill is in a state of efficient operation for a long period of time.

[0046] Embodiment 2:

[0047] like Figure 1 to Figure 4 As shown, the present invention includes the magnetic liner 1 and the manufacturing method as described in Example 1. This example selects the MQY2736 ball mill as the production object, and the main parameters are: cylinder inner diameter 2700mm, cylinder length 3600mm, effective volume 18.5m 3 , the cylinder working speed is 22r / min, the hourly capacity is about 12t / h~145t / h, and the conventional matching motor power is 400kW. Figure 5 As shown, the magnetic lining 1 is laid on the inner wall of the MQY2736 ball mill, and all inner wall surfaces except the ball mill feed port and discharge port are fully laid flat to complete the installation of the magnetic lining 1.

[0048] like Figure 4 As shown, iron 7 is added to the ball mill with the magnetic liner 1 installed, and the added amount is the volume required to cover the inner wall of the MQY2736 ball mill. In this embodiment, waste steel balls with a single maximum geometric size of ≤20mm are selected as iron 7 for addition, and the added amount is 5t at a time; ceramic balls 6 are added to the ball mill, 10t is added for the first time, and the specifications are 63t of φ30mm ceramic balls, 64t of φ25mm ceramic balls, and 63t of φ20mm ceramic balls.

[0049] After the first addition of ceramic balls 6, the system is connected to the production system and operated for one week for initial adsorption. During the one-week initial adsorption, the iron 7 will be adsorbed by the magnetic lining 1. The points with higher magnetic field strength around the magnetic lining 1 will adsorb more iron 7, and the points with lower magnetic field strength around the magnetic lining 1 will adsorb less iron 7.

[0050] During the process of the magnetic lining 1 adsorbing the iron 7, the ceramic balls 6 will be filled into the gaps, grooves, depressions and other parts between the magnetic linings 1 in the form of carding, embedding, adhesion and the like; after a week of initial adsorption, the iron 7 and the ceramic balls 6 are continuously adsorbed to the surface of the magnetic lining on the inner wall of the ball mill, and the adsorption layer in the area with high magnetic field intensity gradually thickens, and the adsorption layer in the area with low magnetic field intensity gradually stabilizes, forming an initial corrugated grid magnetic ceramic coating 5.

[0051] After the initial corrugated grid magnetic ceramic coating 5 is formed, ceramic balls 6 are added for the second time, the amount added is 12t, and the specification of ceramic balls 6 is φ30mm; steel balls are added for the first time, the amount added is 10t, and the specification of steel balls is φ30mm; at this time, it can be used as a normal ball mill, connected to the actual production process, and officially enters the adsorption period. During this period, additional balls are added according to the steel consumption of steel balls and ceramic balls 6, maintaining the filling rate at 40% to 42%, and the grinding concentration is controlled in the range of 63% to 67%.

[0052] After the present embodiment is put into actual production, it formally enters the adsorption period, during which 60.5t / month of ceramic balls with a specification of φ30mm and 0.5t / week of steel balls with a specification of φ30mm are added.

[0053] like Figure 6 As shown, a formed coating is formed, which contains iron 7 and ceramics of different sizes. The coating is measured to be in the shape of a grid, with a thickness of 2.7 cm at the highest point of the grid and a thickness of 0.1 cm at the lowest point of the grid, which is basically level with the semi-ellipsoidal protrusion 2. The height difference is greater than the peak height of a conventional corrugated manganese steel liner, and the shape of the grid bars is similar to the upper protrusion of a sine wave. The above determines that a stable corrugated grid magnetic ceramic coating 5 is formed, and the corrugated grid magnetic ceramic coating 5 can be continuously self-generated.

[0054] Working principle: One or more layers of magnetic lining plates 1 are laid on the inner wall of the ball mill. The front of each magnetic lining plate is provided with a semi-ellipsoidal protrusion 2 and an outer ring edge 3 that is 1 cm higher than the plane, and a magnet 4 is embedded on the back, forming a magnetic field intensity distribution that decreases from the outside to the inside. Iron 7 with a maximum geometric size of ≤20 mm and ceramic balls 6 of different specifications are added to the ball mill. These materials interact with the magnetic lining plate 1 during the grinding process. At the beginning of the ball mill startup, the iron 7 is adsorbed by the magnetic lining plate 1 to form a preliminary magnetic layer. The ceramic balls 6 are filled into the gaps, grooves and depressions of the magnetic lining plate 1 by means of snapping, embedding, adhesion, etc., to form a corrugated grid-shaped ceramic layer 5. As the grinding process proceeds, the magnetic lining plate 1 continuously adsorbs new iron 7 and ceramic balls 6 to form and maintain a stable corrugated grid magnetic ceramic coating 5. The coating has good wear resistance and corrosion resistance, which can effectively reduce the wear of the ball mill liner, extend its service life, and improve work efficiency and energy utilization. During the adsorption period, according to the consumption of grinding media, regular addition of appropriate amount of ceramic balls 6 and steel balls is performed to keep the filling rate of the ball mill within a reasonable range and ensure that the grinding indicators are qualified.

[0055] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0056] While the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that many changes, modifications, substitutions and variations can be made to the embodiments without departing from the principles and spirit of the invention.

Claims

1. A method for preparing a lightweight and energy-saving ball mill continuous self-generated magnetic ceramic coating, characterized in that: The following steps are involved: Step 1: Laying a layer of magnetic lining plate (1) on the inner wall of the ball mill to form a magnetic lined ball mill; Step 2, adding iron (7) into the magnetic lined ball mill described in step 1; Step 3, adding ceramic balls (6) into the magnetic lined ball mill described in step 1; Step 4, adding steel balls into the magnetic lined ball mill described in step 1 to form a magnetic ceramic ball mill with initial balls; Step 5: Connect the magnetic ceramic ball mill with the initial balls obtained in step 4 to the production process and carry out conventional grinding production operations. After an adsorption period of 3 to 6 months, a corrugated grid magnetic ceramic coating (5) is naturally formed, and the iron (7) is continuously adsorbed to automatically generate a coating to offset the wear and tear during the production process, thereby maintaining a stable corrugated grid magnetic ceramic coating (5) for a long time.

2. The method for manufacturing a lightweight energy-saving ball mill continuous self-generated magnetic ceramic coating according to claim 1, characterized in that: With respect to step 5, during the initial adsorption period of one week, the iron (7) is adsorbed by the magnetic lining, and the points with higher magnetic field strength around the magnetic lining adsorb more iron (7), and the ceramic balls (6) are filled into the gaps and recessed parts between the magnetic linings in the form of being stuck, embedded, or adhered, forming an initial corrugated grid magnetic ceramic coating (5); Continue to add ceramic balls (6) and steel balls, and connect the magnetic lined ball mill to the actual production process, officially entering the adsorption period. During this period, additional balls are added according to the steel consumption of steel balls and ceramic balls (6), maintaining the filling rate at 40% to 42% and the grinding concentration at 63% to 67%.

3. The method for manufacturing a lightweight energy-saving ball mill continuous self-generated magnetic ceramic coating according to claim 2, characterized in that: With respect to step 2, the maximum geometric dimension of the iron (7) is ≤ 20 mm.

4. The method for producing a lightweight energy-saving ball mill continuous self-generated magnetic ceramic coating according to claim 3, characterized in that: With respect to step three, the diameter of the ceramic balls (6) is 20 cm to 30 mm, and the specification ratio of the ceramic balls (6) during the initial loading is: the ratio of the ceramic balls (6) with a diameter of 20 cm, the ceramic balls (6) with a diameter of 25 cm, and the ceramic balls (6) with a diameter of 30 cm is 4:3:

3.

5. The method for manufacturing a lightweight energy-saving ball mill continuous self-generated magnetic ceramic coating according to claim 4, characterized in that: For step 4, the specification of the steel ball is φ30mm~φ35mm.

6. The method for manufacturing a lightweight energy-saving ball mill continuous self-generated magnetic ceramic coating according to claim 5, characterized in that: As described in step 5, the specification of the steel balls added during the adsorption period is φ35 mm, and the specification of the ceramic balls (6) added is φ30 mm.

7. The method for manufacturing a lightweight energy-saving ball mill continuous self-generated magnetic ceramic coating according to claim 6, characterized in that: With respect to step one, the front side of the magnetic lining (1) is provided with a semi-ellipsoidal protrusion (2) and an outer ring edge (3), and the back side of the magnetic lining (1) is provided with an inwardly embedded magnet (4); the magnetic field strength of the front side of the magnetic lining gradually decreases from the outer edge to the inside, and the gradient of the change of the magnetic field strength is 3000Gs, 2000Gs, 1400Gs, 1000Gs and 800Gs respectively.

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