Calculation method for mass and consumption of grinding medium in ball mill

Abstract

The invention discloses a method for calculating the mass and consumption of an ore grinding medium in a ball mill. The method comprises the steps that running currents of the ball mill under different ore grinding medium loading masses are obtained; fitting the current for driving the ore grinding medium in the operation current and the corresponding data of the loading quality of the ore grinding medium to obtain a fitting curve; when the ball mill runs, real-time running current of the ball mill is obtained, current for driving the ore grinding medium is obtained according to the real-time running current, and then the current mass of the ore grinding medium in the ball mill is calculated through the fitted curve; and obtaining the ball consumption of the ore grinding medium based on the mass of the ore grinding medium and the previous adding mass. According to the method, more accurate data guidance is provided for the state of the internal ore grinding medium in the running process of the ball mill, so that the mass ratio and the filling rate of the internal ore grinding medium of the ball mill can be stabilized at a certain specific optimal value, the production process is kept stable, the energy utilization efficiency is improved, and the production cost is reduced. And a new method and thought are provided for energy conservation and consumption reduction in the field production process.

Description

Technical Field

[0001] The invention relates to the technical field of grinding, and in particular to a method for calculating the mass and consumption of grinding media inside a ball mill. Background Art

[0002] In the application practice of ball mills, the strategy of using steel balls and ceramic balls as mixed grinding media is becoming increasingly popular. Compared with the traditional method of using steel balls as grinding media, this mixed grinding media method has shown unique advantages. However, it also brings with it higher requirements for precise control of the mass ratio of the two grinding media. Due to the differences in hardness, density and wear resistance between ceramic balls and steel balls, their action mechanisms in the grinding process are different, which is directly related to multiple key production indicators such as grinding efficiency, product particle size distribution and energy consumption.

[0003] Therefore, how to scientifically adjust and monitor the mixed grinding media mass ratio parameter to ensure that it can not only give full play to the advantages of high wear resistance and reduced iron pollution of ceramic balls, but also combine with the good crushing ability of steel balls has become a new challenge.

[0004] In view of this, the applicant considers providing a method for calculating the amount and consumption of media inside a ball mill, which can be used to adjust and monitor the mass ratio of mixed grinding media. Summary of the invention

[0005] In order to overcome the shortcomings of the above-mentioned technology, the purpose of the present invention is to provide a method for calculating the mass and consumption of grinding media inside a ball mill, aiming to achieve precise control of the mass ratio of mixed grinding media so that it can achieve the optimal ratio under specific working conditions, thereby maximizing the grinding efficiency, reducing energy consumption, and ensuring the quality and stability of the final product.

[0006] To achieve the above purpose, the technical solution adopted by the present invention is as follows:

[0007] A method for calculating the mass and consumption of grinding media inside a ball mill comprises the following steps:

[0008] 1) Obtain the operating current of the ball mill under different grinding medium loading masses;

[0009] 2) Calculate the current I driving the grinding medium based on the operating current 球 , and the current I that drives the grinding media 球 Data corresponding to the grinding media loading mass M 球 Perform fitting to obtain a fitting curve;

[0010] 3) When the ball mill is running, obtain the real-time operating current of the ball mill, and obtain the current I that drives the grinding medium based on the real-time operating current 球, and then calculate the mass of the grinding medium in the current ball mill through the fitting curve;

[0011] 4) Based on the current mass of grinding media in the ball mill and the mass of grinding media previously added, the ball consumption of grinding media can be obtained.

[0012] Preferably, the grinding medium is a mixed grinding medium consisting of steel balls and ceramic balls.

[0013] Preferably, the step 1) comprises:

[0014] Obtain the grinding medium mass M1 when there are only steel balls inside the ball mill, and read the meter to record the operating current I1;

[0015] Ball mill empty machine running test: the internal grinding medium mass M 球 is 0, the meter reads the running current I2;

[0016] Load the mixed grinding medium with a grinding medium mass of M3 to conduct an operation test: record the operating current value I3;

[0017] After the operation is stable, the ball adding operation test is carried out. At this time, the internal grinding medium mass M4=M3+M 添加 , record the operating current value I4.

[0018] Preferably, the fitting process in step 2) uses at least four sets of currents I driving the grinding media. 球 Data corresponding to the grinding media loading mass M 球 .

[0019] Preferably, in step 2), the current driving the grinding medium is calculated by the following formula:

[0020] I 球 =I 运 -(I 其他 +I 矿 +I 衬损 );

[0021] In the formula, I 运 is the operating current; I 球 I is the current driving the grinding medium; 其他 I is the current driving the equipment and lining; 矿 is the current driving the slurry; I 衬损 It is the current change value caused by lining wear during long-term operation of the equipment.

[0022] Preferably, various current measurement methods are as follows:

[0023] The current I driving the slurry 矿 : When the machine is just started, the slurry flow has not yet entered the ball mill. 运 =I球 +I 其他 +I 衬损 ; The slurry flows into the ball mill, causing the operating current to increase. At this time, the change in the operating current is the current I that drives the slurry. 矿 ;

[0024] Current I of driving equipment and lining 其他 :The current value when the ball mill is idling is I 其他 ;

[0025] The current change value I caused by lining wear during long-term operation of the equipment 衬损 :I 衬损 =t×△I 运 / △t, where t is the working time of the liner after replacement, △I 运 is the current change before and after the liner is replaced, △t is the usage time of the liner before replacement; or, I 衬损 The current I merged into the drive equipment and lining 其他 Calculated value.

[0026] Preferably, the step 4) comprises:

[0027] 4.1) obtaining the current filling rate in the ball mill, and calculating the current average bulk density of the mixed grinding media based on the filling rate;

[0028] 4.2) Based on the average bulk density, the mass of various grinding media in the mixed grinding medium in the current ball mill is calculated, and the ball consumption of various grinding media in the mixed grinding medium can be obtained based on the mass of the mixed grinding medium added in the past.

[0029] Preferably, the current average bulk density of the mixed grinding medium in step 4.1) is calculated by the following formula:

[0030]

[0031] In the formula, ρ 现 V is the current average bulk density of the mixed grinding media; 现 is the current filling rate in the ball mill, which is obtained by manual measurement when the mill is stopped; M 球 is the mass of the grinding medium in the current ball mill obtained by calculating the fitting curve in step 3).

[0032] Preferably, in step 4.2), the mass of the grinding medium in the current ball mill is calculated by the following formula:

[0033]

[0034] M 球 =M T +M G ;

[0035] In the formula, ρ 现 M is the current average bulk density of the mixed grinding media; 球 M is the mass of the grinding medium in the current ball mill obtained by calculating the fitting curve in step 3); T is the weight of ceramic balls in the current ball mill, M G is the current weight of the steel balls inside the ball mill, ρ T is the bulk density of ceramic balls, ρ G is the bulk density of steel balls.

[0036] Preferably, in step 4.2), the ball loss calculation method of various grinding media in the mixed grinding medium is: based on the current mass of different grinding media, in connection with past data, the loss values ​​of ceramic balls and steel balls over a period of time are calculated by the following formulas:

[0037] M T(耗) =M T(i-1) +M T(加) -M T(i) ;

[0038] M G(耗) =M G(i-1) +M G(加) -M G(i) ;

[0039] Where M T(耗) M is the loss value of grinding medium quality over a period of time, T(i-1) is the initial weight of the ceramic ball during the calculation period, M T(加) is the amount of ceramic balls added during this period, M T(i) is the weight of the ceramic ball at the current moment; M G(耗) M is the loss value of grinding medium quality over a period of time, G(i-1) is the initial weight of the steel ball during the calculation period, M G(加) is the amount of steel balls added during this period, M G(i) is the weight of the steel ball at the current moment.

[0040] Compared with the prior art, the present invention has the following beneficial effects:

[0041] The present invention provides a method for calculating the mass and consumption of grinding media inside a ball mill using ceramic balls + steel balls as mixed grinding media. By decomposing the operating current of the ball mill into several types of currents, different types of current values ​​are measured based on the ball mill replacement and transformation process, revealing the relationship between the current used for grinding media in the ball mill operating current and the total amount of grinding media in the ball mill, and further providing a method for calculating the mass ratio of mixed grinding media inside the ball mill and the ball consumption. The method of the present invention provides more accurate data guidance for on-site production technicians based on the state of the internal grinding media during the operation of the ball mill, so that the mass ratio and filling rate of the grinding media inside the ball mill can be stabilized at a specific optimal value, which helps to maintain the stability of the production process, improve energy utilization efficiency, and provide a new method and idea for energy saving and consumption reduction in on-site production processes. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 A flow chart of a method for calculating the quality and consumption of grinding media inside a ball mill according to the present invention;

[0043] Figure 2 The present invention is a curve diagram showing the relationship between the operating current and the grinding medium loading mass corresponding data fitting;

[0044] Figure 3 It is a schematic diagram of the current change during the start-up operation of the ball mill in the present invention;

[0045] Figure 4 It is a schematic diagram of the comparison of the power changes before and after the liner is replaced under a long span in the present invention;

[0046] Figure 5 is the mass M of the mixed grinding medium in Example 1 球 The current I that drives the grinding media 球 Corresponding data fitting relationship curve diagram;

[0047] Figure 6 is the mass M of the mixed grinding medium in Example 2 球 The current I that drives the grinding media 球 Corresponding data fitting relationship curve diagram;

[0048] Figure 7 is the mass M of the mixed grinding medium in Example 3 球 The current I that drives the grinding media 球 Corresponding data fitting relationship curve. DETAILED DESCRIPTION

[0049] In order to better explain the present invention, the main contents of the present invention are further explained below in conjunction with the drawings and specific embodiments, but the contents of the present invention are not limited to the following embodiments.

[0050] The calculation method in the present invention is implemented based on a transformation process of replacing the grinding medium in a ball mill, in which the full steel ball grinding medium inside the ball mill is replaced with a mixed grinding medium of steel balls and ceramic balls.

[0051] like Figure 1 As shown, a method for calculating the mass and consumption of grinding media inside a ball mill of the present invention comprises the following steps:

[0052] Step 1) for a single model of ball mill, obtain the operating current of the ball mill under different grinding medium loading masses; the specific operation is as follows:

[0053] 1.1) Before the ball mill is shut down for unloading, the grinding medium inside the ball mill is full of steel balls. Obtain the filling rate of the grinding medium inside the ball mill, calculate the total ball mass (M1) at this time, and read the meter to record the operating current (I1).

[0054] 1.2) After the ball mill is emptied of all the grinding media inside, the ball mill is tested for empty operation: At this time, the amount of grinding media inside the ball mill M 球 =0, the meter reads the running current (I 运 ) value is I2.

[0055] 1.3) After the transformation is completed, a certain amount of mixed grinding media (M3) is loaded and an operation test is carried out: the operating current value (I3) is recorded.

[0056] 1.4) After the operation is stable, add balls and run the test immediately. At this time, the total ball mass inside (M4 = M3 + M 添加 ), record the operating current value (I4).

[0057] Step 2) The current I of the operating current driving the grinding medium is 球 Data corresponding to the grinding media loading mass M 球 Perform fitting to obtain a fitting curve;

[0058] Among them, the corresponding data of operating current and grinding medium loading mass can also be fitted, and the fitting relationship curve is as follows: Figure 2 As shown;

[0059] From the perspective of making the material move and do work, the operating current can be decomposed into the current that drives the grinding medium (I 球 ), the current driving the slurry (I 矿 ), the current of the driving equipment and lining (I 其他 ) and the current change value caused by the wear of components during long-term operation of the equipment (I 衬损 The operating current of the ball mill has a relationship according to its composition as shown in formula (1); the current driving the grinding medium has a corresponding relationship with the total mass of the balls inside the ball mill as shown in formula (2).

[0060] I 运 =I 球 +I 其他 +I 矿 +I 衬损 ; (1)

[0061] I 球 =f(M 球 ); (2)

[0062] During the ball mill replacement and grinding media transformation process, various current measurement methods include:

[0063] The current driving the slurry (I 矿 ): When the machine is just started, the slurry flow has not yet entered the ball mill. 运 =I 球 +I 其他 +I 衬损 ; After running for a period of time, the slurry flows into the ball mill, causing the operating current to increase, such as Figure 3 As shown in Figure 2, the change in operating current is the current driving the slurry (I 矿 ).

[0064] Current of driving equipment and lining (I 其他 ): During the process of replacing the ball milling media, pour out all the ball milling media in the ball mill, and measure the current value when the ball mill is idling, which is I 其他 .

[0065] The current change value (I 衬损 ): Component wear mainly refers to liner wear, I 衬损 It is only necessary to calculate the current change caused by the wear of the liner. The liner wears with the operation of the ball mill. Under long-term span, the current change before and after the replacement of the liner can be calculated as follows: Figure 4 As shown, the current before and after the liner is replaced is compared and calculated: I 衬损 =t×△I 运 / △t, where t is the working time of the liner after replacement, △I 运 is the current change value before and after the liner is replaced, △t is the usage time of the liner before replacement; I 衬损 Can be merged into I in a short time 其他 Calculated value.

[0066] The current driving the grinding media (I 球 ): Under known operating current (I 运 ) and then, according to the different grinding media loading mass, the operating current can be decomposed and subtracted from other values ​​to calculate I 球 The corresponding value of I 球The I can be obtained by fitting the corresponding data of the grinding medium loading mass. 球 Relationship curve with the quality of mixed grinding media.

[0067] Step 3) During the ball mill operation, the current I driving the grinding medium is obtained based on the real-time operating current. 球 , and the current I driving the grinding medium in step 2) 球 Data corresponding to the grinding media loading mass M 球 The fitting curve is used to obtain the grinding medium quality (M 球 ).

[0068] Step 4) Based on the mass of the grinding media in step 3) and the mass previously added, the ball consumption of various grinding media can be obtained.

[0069] 4.1) Combined with the current filling rate (V 现 ), the current average bulk density ρ of the mixed grinding medium can be calculated by formula (3): 现 The current filling rate of the ball mill is obtained by manual measurement when the mill is stopped.

[0070]

[0071] 4.2) Calculate the mass and ball consumption of the ceramic balls and steel balls in the current mill based on the mass of the grinding media in the current ball mill and the current average bulk density of the mixed grinding media;

[0072] a. The mass calculation method of the ceramic balls and steel balls in the ball mill is: the bulk density of the ceramic balls and steel balls is known, combined with the average bulk density (ρ 现 ) and step 3) the current amount of grinding media in the ball mill (M 球 ), the current masses of the ceramic ball and the steel ball can be calculated by equation (4) and equation (5); where M T is the weight of ceramic balls in the current ball mill, M G is the current weight of the steel balls inside the ball mill, ρ T is the bulk density of ceramic balls, ρ G is the bulk density of steel balls.

[0073]

[0074] M 球 =M T +M G ; (5)

[0075] b. According to the respective masses of ceramic balls and steel balls in the current mill, combined with the previous values ​​and working conditions, the ball consumption of ceramic balls and steel balls per unit time and unit processing volume under different ball loading systems and mass ratios and different filling rates can be obtained.

[0076] The specific method for calculating the ball consumption of ceramic balls and steel balls under certain conditions is to obtain the loss values ​​of ceramic balls and steel balls in the past period of time based on the current mass of different grinding media and the past data, respectively, as follows:

[0077] M T(耗) =M T(i-1) +M T(加) -M T(i) ; (6)

[0078] M G(耗) =M G(i-1) +M G(加) -M G(i) ; (7)

[0079] Where M T(耗) M is the loss value of grinding medium quality over a period of time, T(i-1) is the initial weight of the ceramic ball during the calculation period, M T(加) is the amount of ceramic balls added during this period, M T(i) is the weight of the ceramic ball at the current moment; M G(耗) M is the loss value of grinding medium quality over a period of time, G(i-1) is the initial weight of the steel ball during the calculation period, M G(加) is the amount of steel balls added during this period, M G(i) is the weight of the steel ball at the current moment.

[0080] The technical solution of the present invention is described below in conjunction with specific embodiments 1 to 3.

[0081] Example 1

[0082] A modification test was conducted on the second-stage ball mill of a factory, model 4270×7300 overflow ball mill, to replace the grinding media in the mill. It was planned to replace the grinding media inside the mill from all steel balls to ceramic balls + steel balls mixed grinding media. The preliminary laboratory experiments determined that the mass ratio of ceramic balls and steel balls mixed balls was 5:5, the ceramic ball filling system was Φ30mm﹕Φ25mm﹕Φ20mm=50%﹕30%﹕20%, the steel balls were all 30mm, and the filling rate was 36%. At this time, the average bulk density of the grinding media was 3.06t / m 3 ; The material parameters of steel balls and ceramic balls are shown in Table 1, and the initial ball loading of the ball mill is shown in Table 2.

[0083] Table 1: Material parameters of steel balls and ceramic balls

[0084]

[0085] Table 2: Initial ball loading at various filling rates of the ball mill

[0086]

[0087] This embodiment provides a method for calculating the amount of medium and consumption in a ball mill, and the specific steps are as follows:

[0088] 1) Based on Table 3, at different stages of the transformation test, the test data of each sampling point was recorded. The specific data is shown in Table 4.

[0089] Table 3: Sampling points and detection methods

[0090]

[0091]

[0092] Table 4: Sampling points and results

[0093]

[0094] 2) Based on the above data, the second-order polynomial fitting was performed using the least squares method to obtain I 球 and the mass of the mixed grinding media (M 球 ) relationship curve, such as Figure 5 As shown. The functional relationship of this curve is: M 球 =1×10 -5 I 球 2 +1.343·I 球 +0.0003.

[0095] 3) During the normal operation of the ball mill, the operating current before the ball mill is stopped and the balls are added is 134.1A. Based on the above measurement, I 矿 =8A,I 其他 =45.2A, I 衬损 Merge into I 其他 The calculated value is I 球 =80.9A; furthermore, the grinding medium volume (M 球 ) is 108.72t.

[0096] 4) The filling rate is measured at 37.5% when the machine is shut down. The formula ρ 现 =M 球 / V 现 Calculate the average bulk density ρ in the ball mill at this time 现 3.037t / m 3 (When the mass ratio of ceramic ball to steel ball is 5:5, the average bulk density is 3.06t / m 3 ), combined with the average bulk density (ρ 现 ) and the amount of grinding media inside the ball mill (M 球 ), using the formula:

[0097]

[0098] It can be calculated that the mass of the ceramic balls in the current ball mill is 55.39t and the mass of the steel balls is 53.32t.

[0099] According to the past data, the running current before the last ball addition was 133.9A, the filling rate was 35.8%, the ball addition amount was 300kg of 30mm ceramic balls and 500kg of 30mm steel balls according to the convention, and the running time after the ball addition was 17.8h; the grinding medium amount (M 球 ) is 108.45t, of which the mass of ceramic balls is 55.21t and the mass of steel balls is 53.24t; the ball consumption during the period is calculated from the values ​​before the two ball additions: 0.12t for ceramic balls and 0.41t for steel balls; while keeping the filling rate in the ball mill unchanged and the operating conditions stable, the next ball addition amount should be 0.12t for ceramic balls and 0.41t for steel balls.

[0100] Example 2

[0101] A modification test was conducted on the second-stage ball mill of a factory, model 3600×6000 overflow ball mill, to replace the grinding media in the mill. It was planned to replace the grinding media inside the mill from all steel balls to ceramic balls + steel balls mixed grinding media. The preliminary laboratory experiments determined that the mass ratio of ceramic balls and steel balls mixed balls was 5:5, the initial ceramic ball system was Φ30mm:Φ25mm:Φ20mm=50%:30%:20%, the steel balls were all 30mm, and the initial filling rate was 36%. At this time, the average bulk density of the grinding media was 3.06t / m 3 ; The initial ball loading amount of the ball mill is shown in Table 5.

[0102] Table 5: Initial ball loading at various filling rates of the ball mill

[0103]

[0104] This embodiment provides a method for calculating the amount of medium and consumption in a ball mill, and the specific steps are as follows:

[0105] 1) At different stages of the transformation test, the data of each sampling point is recorded as shown in Table 6, and the recording method is the same as in Example 1.

[0106] Table 6: Sampling points and results

[0107]

[0108]

[0109] 2) Based on the above data, the second-order polynomial fitting was performed using the least squares method to obtain I球 and the mass of the mixed grinding media (M 球 ) relationship curve, such as Figure 6 As shown. The functional relationship of this curve is: M 球 =-0.0338I 球 2 +3.4253·I 球 +0.0006.

[0110] 3) During the normal operation of the ball mill, the operating current before the ball mill is stopped and the balls are added is 71.7A. Based on the above measurement, I 矿 =2.1A, I 其他 =46.4A, I 衬损 Merge into I 其他 The calculated value is I 球 =23.2A; furthermore, the grinding medium volume (M 球 ) is 61.28t.

[0111] 4) The filling rate is measured at the shutdown time and is 36.9%. Using the formula ρ 现 =M 球 / V 现 The average bulk density ρ in the ball mill is calculated to be 3.02t / m 3 (When the mass ratio of ceramic balls to steel balls is 5:5, the average bulk density is 3.06t / m 3 ), combined with the average bulk density (ρ 现 ) and the amount of grinding media inside the ball mill (M 球 ), using the formula:

[0112]

[0113] It can be calculated that the mass of the ceramic balls in the current ball mill is 31.68t and the mass of the steel balls is 29.6t.

[0114] According to the past data, the running current before the last ball addition was 71.6A, the filling rate was 36.8%, and the conventional amount of balls added was 300kg of 30mm ceramic balls and 500kg of 30mm steel balls every two days, and the running time after adding balls was 48h. The amount of grinding media in the ball mill before the last ball addition (M 球 ) is 61.09t, of which the mass of ceramic balls is 31.61t and the mass of steel balls is 29.48t; the ball consumption during the period is calculated from the values ​​before the two additions of balls: 0.23t for ceramic balls and 0.38t for steel balls; while keeping the filling rate in the ball mill stable and adjusting the mass ratio to 5:5, due to the small number of steel balls, no ceramic balls should be added during the next addition, and 0.904t of steel balls should be added.

[0115] Example 3

[0116] A modification test of replacing the grinding media in the second-stage ball mill of a factory with the overflow ball mill model of 4500×6400 was carried out. It was planned to replace the grinding media in the mill from all steel balls to ceramic balls + steel balls mixed grinding media. The preliminary laboratory experiments determined that the mass ratio of ceramic balls and steel balls mixed balls was 5:5, the initial ceramic ball system was Φ30mm﹕Φ25mm﹕Φ20mm=20%﹕30%﹕50%, the steel balls were all 30mm, and the initial filling rate was 38%. At this time, the average bulk density of the grinding media was 3.06t / m 3 ; The initial ball loading amount of the ball mill is shown in Table 7.

[0117] Table 7: Initial ball loading at various filling rates of the ball mill

[0118]

[0119] This embodiment provides a method for calculating the amount of medium and consumption in a ball mill, and the specific steps are as follows:

[0120] 1) At different stages of the transformation test, the data of each point is recorded as shown in Table 8, and the recording method is the same as in Example 1.

[0121] Table 8: Sampling points and results

[0122]

[0123] 2) Based on the above data, the second-order polynomial fitting was performed using the least squares method to obtain I 球 and the mass of the mixed grinding media (M 球 ) relationship curve, such as Figure 7 As shown. The functional relationship of this curve is: M 球 =-0.0275I 球 2 +4.3637·I 球 +0.0031.

[0124] 3) During the normal operation of the ball mill, the operating current before the ball mill is stopped and the balls are added is 114.8A. Based on the above measurement, I 矿 =3.4A, I 其他 =80.68A, I 衬损 Merge into I 其他 The calculated value is I 球 =30.72A; furthermore, the grinding medium volume (M 球 ) is 108.1t.

[0125] 4) The filling rate is measured at shutdown and is 38.34%. The formula ρ 现 =M 球 / V现 The average bulk density ρ in the ball mill is calculated to be 3.13t / m 3 (When the mass ratio of ceramic balls to steel balls is 5:5, the average bulk density is 3.06t / m 3 ), combined with the average bulk density (ρ 现 ) and the amount of grinding media inside the ball mill (M 球 ), using the formula:

[0126]

[0127] It can be calculated that the mass of the ceramic balls in the current ball mill is 50.80t and the mass of the steel balls is 57.3t.

[0128] According to the past data, the running current before the last ball addition was 114.7A, the filling rate was 38.21%, and the ball addition amount was 300kg of 30mm ceramic balls and 500kg of 30mm steel balls according to the convention. The running time after adding balls was 24h. The grinding medium amount (M 球 ) is 107.84t, of which the mass of ceramic balls is 50.55t and the mass of steel balls is 57.29t; the ball consumption during the period is calculated from the values ​​before the two times of adding balls: 0.05t of ceramic balls and 0.48t of steel balls; while keeping the filling rate in the ball mill stable at 38% and adjusting the mass ratio to 5:5, because there are too few ceramic balls and too many steel balls, no steel balls should be added when adding balls next time, and 0.261t of ceramic balls should be added.

[0129] Compared with the traditional method of adding balls according to experience and convention, on-site production technicians rely on the relationship curve obtained by the present invention for a specific ball mill working system to calculate the amount of balls added, which can stabilize the grinding medium mass ratio and filling rate inside the ball mill at a certain optimal value, thereby maintaining the stability of the production process, which is beneficial to improving energy utilization efficiency and achieving the purpose of energy saving and consumption reduction.

Claims

1. A method for calculating the mass and consumption of grinding media in a ball mill, characterized in that: The following steps are involved: 1) Obtain the operating current of the ball mill under different grinding medium loading masses; 2) Calculate the current I driving the grinding medium based on the operating current 球 , and the current I that drives the grinding media 球 Data corresponding to the grinding media loading mass M 球 Perform fitting to obtain a fitting curve; 3) When the ball mill is running, obtain the real-time operating current of the ball mill, and obtain the current I that drives the grinding medium based on the real-time operating current 球 , and then calculate the mass of the grinding medium in the current ball mill through the fitting curve; 4) Based on the current mass of grinding media in the ball mill and the mass of grinding media previously added, the ball consumption of grinding media can be obtained.

2. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 1, characterized in that: The grinding medium is a mixed grinding medium consisting of steel balls and ceramic balls.

3. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 2, characterized in that: The step 1) comprises: Obtain the grinding medium mass M1 when there are only steel balls inside the ball mill, and read the meter to record the operating current I1; Ball mill empty machine running test: the internal grinding medium mass M 球 is 0, the meter reads the running current I2; Load the mixed grinding medium with a grinding medium mass of M3 to conduct an operation test: record the operating current value I3; After the operation is stable, the ball adding operation test is carried out. At this time, the internal grinding medium mass M4=M3+M 添加 , record the operating current value I4.

4. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 1, characterized in that: The fitting process in step 2) uses at least four sets of currents I driving the grinding media. 球 Data corresponding to the grinding media loading mass M 球 .

5. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 1, characterized in that: In step 2), the current driving the grinding medium is calculated by the following formula: I 球 =I 运 -(I 其他 +I 矿 +I 衬损 ); In the formula, I 运 is the operating current; I 球 I is the current driving the grinding medium; 其他 I is the current driving the equipment and lining; 矿 is the current driving the slurry; I 衬损 It is the current change value caused by lining wear during long-term operation of the equipment.

6. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 5, characterized in that: The specific methods for measuring various types of current are as follows: The current I driving the slurry 矿 : When the machine is just started, the slurry flow has not yet entered the ball mill. 运 =I 球 +I 其他 +I 衬损 ; The slurry flows into the ball mill, causing the operating current to increase. At this time, the change in the operating current is the current I that drives the slurry. 矿 ; Current I of driving equipment and lining 其他 :The current value when the ball mill is idling is I 其他 ; The current change value I caused by lining wear during long-term operation of the equipment 衬损 :I 衬损 =t×△I 运 / △t, where t is the working time of the liner after replacement, △I 运 is the current change before and after the liner is replaced, △t is the usage time of the liner before replacement; or, I 衬损 The current I merged into the drive equipment and lining 其他 Calculated value.

7. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 2, characterized in that: The step 4) comprises: 4.1) obtaining the current filling rate in the ball mill, and calculating the current average bulk density of the mixed grinding media based on the filling rate; 4.2) Based on the average bulk density, the mass of various grinding media in the mixed grinding medium in the current ball mill is calculated, and the ball consumption of various grinding media in the mixed grinding medium can be obtained based on the mass of the mixed grinding medium added in the past.

8. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 7, characterized in that: The current average bulk density of the mixed grinding medium in step 4.1) is calculated by the following formula: In the formula, ρ 现 V is the current average bulk density of the mixed grinding media; 现 is the current filling rate in the ball mill, which is obtained by manual measurement in the shutdown state; M 球 is the mass of the grinding medium in the current ball mill obtained by calculating the fitting curve in step 3).

9. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 7, characterized in that: In step 4.2), the mass of the grinding medium in the current ball mill is calculated by the following formula: M 球 =M T +M G ; In the formula, ρ 现 M is the current average bulk density of the mixed grinding media; 球 M is the mass of the grinding medium in the current ball mill obtained by calculating the fitting curve in step 3); T is the weight of ceramic balls in the current ball mill, M G is the current weight of the steel balls inside the ball mill, ρ T is the bulk density of ceramic balls, ρ G is the bulk density of steel balls.

10. The method for calculating the mass and consumption of grinding media in a ball mill according to claim 7, characterized in that: In step 4.2), the ball consumption of various grinding media in the mixed grinding medium is calculated as follows: based on the current mass of different grinding media and in connection with past data, the loss values ​​of ceramic balls and steel balls over a period of time are calculated by the following formulas: M T(耗) =M T(i-1) +M T(加) -M T(i) ; M G(耗) =M G(i-1) +M G(加) -M G(i) ; Where M T(耗) M is the loss value of grinding medium quality over a period of time, T(i-1) is the initial weight of the ceramic ball during the calculation period, M T(加) is the amount of ceramic balls added during this period, M T(i) is the weight of the ceramic ball at the current moment; M G(耗) M is the loss value of grinding medium quality over a period of time, G(i-1) is the initial weight of the steel ball during the calculation period, M G(加) is the amount of steel balls added during this period, M G(i) is the weight of the steel ball at the current moment.

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