Method for calculating the mass and consumption of grinding media inside a ball mill

Abstract

This invention discloses a method for calculating the mass and consumption of grinding media inside a ball mill, comprising: obtaining the operating current of the ball mill under different grinding media loading masses; fitting the current driving the grinding media in the operating current with the corresponding data of the grinding media loading mass to obtain a fitting curve; during ball mill operation, obtaining the real-time operating current of the ball mill, and obtaining the current driving the grinding media based on the real-time operating current, and then calculating the current mass of grinding media inside the ball mill through the fitting curve; based on the grinding media mass and the previous loading mass, the ball consumption of the grinding media can be obtained. This invention provides more accurate data guidance for the state of the internal grinding media during ball mill operation, enabling the mass ratio and filling rate of the grinding media inside the ball mill to be stabilized at a specific optimal value, which helps to maintain production process stability, improve energy utilization efficiency, and provides a new method and idea for energy saving and consumption reduction in on-site production processes.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ore grinding, and particularly relates to a method for calculating the quality and consumption of grinding medium in a ball mill. BACKGROUND

[0002] In the application practice of the ball mill, the strategy of using steel balls and ceramic balls as mixed grinding medium is increasingly favored. Compared with the traditional method of using only steel balls as grinding medium for grinding, this mixed grinding medium method has unique advantages. However, there is a higher requirement for precisely controlling the quality ratio of the two kinds of grinding medium. Due to the differences in hardness, density and wear resistance of ceramic balls and steel balls, their action mechanisms in the grinding process are different, which directly relates to the grinding efficiency, product particle size distribution and energy consumption and other key production indexes.

[0003] Therefore, how to scientifically adjust and monitor the quality ratio of the mixed grinding medium, so as to ensure that it can not only play the advantages of high wear resistance and reduction of iron pollution of ceramic balls, but also combine the good crushing capacity of steel balls, has become a new challenge.

[0004] Therefore, the applicant considers providing a method for calculating the quality and consumption of grinding medium in a ball mill, which can be used to adjust and monitor the quality ratio of the mixed grinding medium. SUMMARY

[0005] In order to overcome the shortcomings of the above-mentioned technology, the purpose of the present application is to provide a method for calculating the quality and consumption of grinding medium in a ball mill, which aims to accurately control the quality ratio of the mixed grinding medium, so as to achieve the optimal ratio under certain working conditions, thereby maximizing the grinding efficiency, reducing the energy consumption, and ensuring the quality and stability of the final product.

[0006] In order to achieve the above-mentioned purpose, the technical solution adopted by the present application is as follows:

[0007] A method for calculating the quality and consumption of grinding medium in a ball mill, comprising the following steps:

[0008] 1) obtaining the running current of the ball mill under different grinding medium loading qualities;

[0009] 2) calculating the current I driving the grinding medium based on the running current 球 , and fitting the current I driving the grinding medium 球 with the grinding medium loading quality corresponding data M 球 to obtain a fitting curve;

[0010] 3) obtaining the real-time running current of the ball mill during the running of the ball mill, and obtaining the current I driving the grinding medium according to the real-time running current 球, and the current ball mill internal grinding medium mass is calculated through the fitting curve;

[0011] 4) Based on the current ball mill internal grinding medium mass and the grinding medium past adding mass, the grinding medium ball consumption can be obtained.

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

[0013] Preferably, the step 1) comprises:

[0014] The grinding medium mass M1 when the ball mill interior has only steel balls is obtained, and the running current I1 is recorded;

[0015] The ball mill empty running test: at this time, the interior grinding medium mass M 球 is 0, and the running current I2 is recorded;

[0016] The mixed grinding medium with the grinding medium mass M3 is loaded for running test: the running current value I3 is recorded;

[0017] After running stabilization, the ball loading running test is carried out, at this time, the interior grinding medium mass M4 = M3 + M 添加 , and the running current value I4 is recorded.

[0018] Preferably, the fitting process in the step 2) adopts at least four groups of driving grinding medium current I 球 and grinding medium loading mass corresponding data M 球 .

[0019] Preferably, in the step 2), the driving grinding medium current 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 running current; I 球 is the driving grinding medium current; I 其他 is the driving device and lining plate current; I 矿 is the driving ore pulp current; and I 衬损 is the current change value due to the lining plate wear during long-term running of the device.

[0022] Preferably, the current determination method of each type is as follows:

[0023] The driving ore pulp current I 矿 : when the machine is just started, the ore pulp flow has not entered the ball mill, at this time, I 运 = I球 +I 其他 +I 衬损 ; the current value when the ball mill is running empty is I 矿 ;

[0024] the current value of the driving device and the liner 其他 ; the current value when the ball mill is running empty is I 其他 ;

[0025] the current value of the driving device and the liner when the liner is worn out after long-term operation of the device 衬损 ; I 衬损 = t x ΔI 运 / Δt, wherein t is the working time of the liner after replacement, ΔI 运 is the current value change before and after the replacement of the liner, and Δt is the use time of the liner before replacement; or, I 衬损 is combined into the current value of the driving device and the liner 其他 .

[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 medium based on the filling rate;

[0028] 4.2) calculating the mass of each grinding medium in the mixed grinding medium in the current ball mill based on the average bulk density, and obtaining the ball consumption of each grinding medium in the mixed grinding medium based on the previous added mass of the mixed grinding medium.

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

[0030]

[0031] , wherein ρ 现 is the current average bulk density of the mixed grinding medium; V 现 is the current filling rate in the ball mill, which is obtained by manual measurement in the shutdown state; and M 球 is the mass of the grinding medium in the current ball mill calculated by the fitting curve in the step 3).

[0032] Preferably, in the 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] wherein p 现 is the current average bulk density of the mixed grinding media; M 球 is the current grinding media mass in the ball mill calculated by the fitting curve in step 3); M T is the current weight of the ceramic balls in the ball mill, M G is the current weight of the steel balls in the ball mill, p T is the bulk density of the ceramic balls, p G is the bulk density of the steel balls.

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

[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] wherein M T(耗) is the loss value of the grinding media mass in a period of time, M T(i-1) is the initial weight of the ceramic balls in the calculation period, M T(加) is the addition amount of the ceramic balls in the period, M T(i) is the current weight of the ceramic balls; M G(耗) is the loss value of the grinding media mass in a period of time, M G(i-1) is the initial weight of the steel balls in the calculation period, M G(加) is the addition amount of the steel balls in the period, M G(i) is the current weight of the steel balls.

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

[0041] This invention provides a method for calculating the mass and consumption of grinding media inside a ball mill using ceramic balls and steel balls as mixed grinding media. By decomposing the ball mill's operating current into several types of current, and measuring the values ​​of different types of current during the ball mill's grinding media replacement process, the method reveals the relationship between the current applied to the grinding media and the total amount of grinding media inside the ball mill. Furthermore, it provides a method for calculating the mass ratio of the mixed grinding media inside the ball mill and the consumption per ball. This method, targeting the state of the internal grinding media during ball mill operation, provides more accurate data guidance for on-site production technicians, enabling the mass ratio and filling rate of the grinding media inside the ball mill to be stabilized at a specific optimal value. This helps maintain stable production processes, improves energy utilization efficiency, and provides a new method and approach for energy saving and consumption reduction in on-site production processes. Attached Figure Description

[0042] Figure 1 This is a flowchart illustrating a method for calculating the quality and consumption of grinding media inside a ball mill according to the present invention.

[0043] Figure 2 This is a curve showing the relationship between the operating current and the mass of grinding media loaded in this invention.

[0044] Figure 3 This is a schematic diagram showing the current changes during the start-up and operation of the ball mill in this invention;

[0045] Figure 4 This is a schematic diagram showing the comparison of power changes before and after replacing the liner over a long period of time in this invention.

[0046] Figure 5 The mass M of the mixed grinding media in Example 1 球 With the current I driving the grinding media 球 A curve showing the relationship between the fitted data;

[0047] Figure 6 The mass M of the mixed grinding media in Example 2 球 With the current I driving the grinding media 球 A curve showing the relationship between the fitted data;

[0048] Figure 7 The mass M of the mixed grinding media in Example 3 球 With the current I driving the grinding media 球 The relationship curves of the fitted data. Detailed Implementation

[0049] To better explain the present invention, the main contents of the present invention are further illustrated below with reference to the accompanying drawings and specific embodiments, but the contents of the present invention are not limited to the following embodiments.

[0050] The calculation method in the application is based on the implementation of the transformation process of replacing the all-steel ball grinding medium in a ball mill with a mixed grinding medium of steel balls and ceramic balls.

[0051] As shown in the formula (1), the calculation method of the quality and consumption of the grinding medium in the ball mill of the application comprises the following steps: Figure 1

[0052] Step 1) For a single type of ball mill, the running current of the ball mill under different grinding medium loading conditions is obtained; the specific operation is as follows:

[0053] 1.1) Before the ball mill is stopped and unloaded, the grinding medium in the ball mill is all steel balls, the filling rate of the grinding medium in the ball mill is obtained, and the total ball loading mass (M1) at this time is calculated, and the running current (I1) is recorded.

[0054] 1.2) After the ball mill is emptied of all the grinding medium, the ball mill is tested for running empty: at this time, the grinding medium mass M 球 in the ball mill is 0, and the running current (I 运 ) value is I2.

[0055] 1.3) After the transformation, a certain amount of mixed grinding medium (M3) is loaded and tested for running: the running current value (I3) is recorded.

[0056] 1.4) After running stably, immediately add balls and test for running: at this time, the total ball loading mass (M4=M3+M 添加 ), and the running current value (I4) is recorded.

[0057] Step 2) The current I 球 that drives the grinding medium and the grinding medium loading mass M 球 corresponding data are fitted to obtain a fitting curve;

[0058] The running current and the grinding medium loading mass corresponding data can also be fitted, and the fitting relationship curve is as shown in the formula (2); Figure 2

[0059] The running current can be decomposed into the current (I 球 ) that drives the grinding medium, the current (I 矿 ) that drives the ore pulp, the current (I 其他 ) that drives the equipment and the lining, and the current change value (I 衬损 ) caused by the long-term running of the equipment and the wear of the parts. The running current of the ball mill has a relationship as shown in the formula (1); the current that drives the grinding medium has a corresponding relationship with the total ball loading mass in the ball mill as shown in the formula (2).​​

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

[0061] I 球 =f(M 球 ); (2)

[0062] In the process of replacing the grinding medium of the ball mill, various current measurement methods include:

[0063] The current (I 矿 ) driving the ore pulp: when the machine is just started, the ore pulp flow has not yet entered the ball mill, at this time I 运 =I 球 +I 其他 +I 衬损 ; after running for a period of time, the ore pulp flow enters the ball mill, causing the running current to increase, as shown in Figure 3 , at this time the running current change value is the current (I 矿 ) driving the ore pulp.

[0064] The current (I 其他 ) driving the equipment and the lining plate: after all the ball mill medium is poured out during the replacement of the ball mill medium, the current value measured when the ball mill is idling is I 其他 .

[0065] The current change value (I 衬损 ) generated by the wear of the parts during long-term operation of the equipment, such as the lining plate: the wear of the parts is mainly the wear of the lining plate, I 衬损 only needs to calculate the current change value generated by the wear of the lining plate. The lining plate wears with the operation of the ball mill, and under a long time span, the current change before and after the replacement of the lining plate can be calculated by comparing the currents before and after the replacement of the lining plate, as shown in Figure 4 : I 衬损 =t×△I 运 / △t, in the formula, t is the working time of the replaced lining plate, △I 运 is the current change value before and after the replacement of the lining plate, and △t is the use time of the lining plate before replacement; I 衬损 in a short period of time can be combined into I 其他 .

[0066] The current (I 球 ) driving the grinding medium: after knowing the other components of the running current (I 运 ), the running current can be decomposed and the other values are subtracted to calculate the corresponding value of I 球 , and I 球The data corresponding to the filling mass of the grinding medium is fitted to obtain I 球 The relationship curve of the mixed grinding medium mass.

[0067] Step 3) For the operation process of the ball mill, the current driving current I 球 of the grinding medium is obtained based on the real-time operation current, and the fitting curve of the data M 球 corresponding to the filling mass of the grinding medium is obtained by the driving current I 球 of the grinding medium in step 2), so as to obtain the mass (M 球 ) of the grinding medium in the current ball mill.

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

[0069] 4.1) Combined with the current filling rate (V 现 ) in the ball mill, the current average bulk density ρ 现 of the mixed grinding medium can be obtained by calculation according to formula (3); the current filling rate of the ball mill is obtained by manual measurement in the shutdown state.

[0070]

[0071] 4.2) The mass and ball consumption of the ceramic balls and steel balls in the current ball mill are calculated according to the mass of the grinding medium in the current ball mill and the current average bulk density of the mixed grinding medium.

[0072] a. The calculation method of the mass of the ceramic balls and steel balls in the ball mill is as follows: the bulk density of the ceramic balls and steel balls is known, combined with the average bulk density (ρ 现 ) and the mass (M 球 ) of the grinding medium in the current ball mill calculated by the fitting curve in step 3), the mass of the ceramic balls and steel balls can be calculated by formula (4) and formula (5); in the formula, M T is the weight of the ceramic balls in the current ball mill, M G is the weight of the steel balls in the current ball mill, ρ T is the bulk density of the ceramic balls, and ρ G is the bulk density of the steel balls.

[0073]

[0074] M 球 = M T + M G ; (5)

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

[0076] The specific calculation method of the ball consumption of the ceramic ball and the steel ball under certain conditions is that, based on the current mass of the different grinding media, in connection with the past data, the loss values of the ceramic ball and the steel ball in the past period of time are respectively obtained by formula (6) and formula (7):

[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] In the formula, M T(耗) is the loss value of the mass of the grinding medium in a period of time, M T(i-1) is the initial weight of the ceramic ball in the calculation period, M T(加) is the added amount of the ceramic ball in the period, and M T(i) is the weight of the ceramic ball at the current moment; M G(耗) is the loss value of the mass of the grinding medium in a period of time, M G(i-1) is the initial weight of the steel ball in the calculation period, M G(加) is the added amount of the steel ball in the period, and M G(i) is the weight of the steel ball at the current moment.

[0080] The technical scheme of the present application is described below in combination with specific examples 1-3.

[0081] Example 1

[0082] The reformation test of replacing the grinding medium in a certain plant's two-stage ball mill model 4270x7300 overflow type ball mill is carried out, which plans to replace the internal grinding medium of the mill from all steel balls to ceramic ball+steel ball mixed grinding medium. Through the previous laboratory experiment, it is determined that the mass ratio of the mixed ball loading of the ceramic ball and the steel ball is 5:5, the ball loading system of the ceramic ball is Φ30mm:Φ25mm:Φ20mm=50%:30%:20%, the steel ball is all 30mm, the filling rate is 36%, and the average bulk density of the grinding medium at this time is 3.06t / m 3 ; the material parameters of the steel ball and the ceramic ball are as shown in Table 1, and the initial ball loading amount of the ball mill under different filling rates is as shown in Table 2.

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

[0084]

[0085] Table 2: Initial ball loading amount of ball mill under different filling rates

[0086]

[0087] This embodiment describes a method for calculating the amount and consumption of internal media in a ball mill. The specific steps are as follows:

[0088] 1) Based on Table 3, the detection data of each sampling point were recorded at different stages of the modification experiment. The specific data are shown in Table 4.

[0089] Table 3: Sampling Locations and Testing Methods

[0090]

[0091]

[0092] Table 4: Sampling Locations and Results

[0093]

[0094] 2) Based on the above data, a second-order polynomial is fitted using the least squares method to obtain I. 球 With the mass of mixed grinding media (M) 球 The relationship curve is as follows: 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 normal operation of the ball mill, the operating current before stopping and adding balls is 134.1A. Based on the above measurements: I 矿 =8A,I 其他 =45.2A, I 衬损 Merge into I 其他 The set value is calculated to obtain I at this time. 球 =80.9A; further, the amount of grinding media in the ball mill at this time (M) is obtained. 球 The value is 108.72t.

[0096] 4) The filling rate was measured to be 37.5% at the time of shutdown. Using the formula ρ... 现 =M 球 / V 现 Calculate the average bulk density ρ inside the ball mill at this time. 现 It is 3.037 t / m 3 (When the mass ratio of ceramic balls to steel balls is 5:5, the average bulk density is 3.06 t / m³.) 3 ), combined with average bulk density (ρ) 现 ) and the amount of grinding media inside the ball mill (M 球 The formula is as follows:

[0097]

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

[0099] According to the past data, the last time before adding the ball, the running current is 133.9 A, the filling rate is 35.8%, and the conventional amount of adding the ball is 300 kg of 30 mm ceramic balls and 500 kg of 30 mm steel balls, and the running time after adding the ball is 17.8 h; it is calculated that the mass of the grinding ore medium (M 球 ) in the ball mill before the last time before adding the ball is 108.45 t, of which the mass of the ceramic balls is 55.21 t, and the mass of the steel balls is 53.24 t; it is easily obtained from the values before the two times of adding the ball that the ball consumption during the period is 0.12 t of ceramic balls and 0.41 t of steel balls; under the condition that the filling rate in the ball mill is kept unchanged and the running condition is stable, the next time of adding the ball should be 0.12 t of ceramic balls and 0.41 t of steel balls.

[0100] Example 2

[0101] A 3600x6000 type overflow ball mill of a certain plant is subjected to a modification test of replacing the grinding ore medium in the mill, which is planned to be replaced from all steel balls to ceramic balls + steel ball mixed grinding ore medium. Through the previous laboratory experiment, it is determined that the mass ratio of ceramic balls and steel balls mixed with balls is 5:5, the initial ball loading system of ceramic balls is Φ30 mm:Φ25 mm:Φ20 mm=50%:30%:20%, the steel balls are all 30 mm, and the initial filling rate is 36%, at which the average bulk density of the grinding ore medium is 3.06 t / m 3 ; the initial ball loading amount of the ball mill is shown in Table 5.

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

[0103]

[0104] The specific steps of the ball mill internal medium mass and consumption calculation method of the embodiment are as follows:

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

[0106] Table 6: Sampling point and result

[0107]

[0108]

[0109] 2) Based on the above data, the least square method is used for second-order polynomial fitting, and I球 With the mass of mixed grinding media (M) 球 The relationship curve is as follows: 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 normal operation of the ball mill, the operating current before stopping and adding balls is 71.7A. Based on the above measurements: I 矿 =2.1A, I 其他 =46.4A, I 衬损 Merge into I 其他 The set value is calculated to obtain I at this time. 球 =23.2A; further, the amount of grinding media in the ball mill at this time (M) is obtained. 球 The value is 61.28t.

[0111] 4) The filling rate was measured to be 36.9% at the time of shutdown. Using the formula ρ... 现 =M 球 / V 现 The calculated average bulk density ρ inside the ball mill at this point is 3.02 t / m³. 3 (When the mass ratio of ceramic balls to steel balls is 5:5, the average bulk density is 3.06 t / m³.) 3 ), combined with average bulk density (ρ) 现 ) and the amount of grinding media inside the ball mill (M 球 The formula is as follows:

[0112]

[0113] The mass of the ceramic balls in the ball mill can be calculated to be 31.68t, and the mass of the steel balls is 29.6t.

[0114] Reviewing past data, the operating current before the last ball addition was 71.6A, and the filling rate was 36.8%. The usual ball addition rate is 300kg of 30mm ceramic balls and 500kg of 30mm steel balls every two days, with a running time of 48 hours after ball addition. The amount of grinding media (M) in the ball mill before the last ball addition was calculated. 球 The total mass of the ball mill is 61.09t, of which the mass of ceramic balls is 31.61t and the mass of steel balls is 29.48t. It is easy to calculate from the values ​​before the two ball additions that the ball consumption during the period is 0.23t of ceramic balls and 0.38t of steel balls. Under the condition of keeping the filling rate in the ball mill stable and adjusting the mass ratio to 5:5, because there are too few steel balls, ceramic balls should not be added next time, and 0.904t of steel balls should be added instead.

[0115] Example 3

[0116] A modification test was conducted on a 4500×6400 overflow ball mill (two-stage type) at a certain factory to replace the grinding media. The proposed modification involved replacing all steel balls with a mixture of ceramic and steel balls. Preliminary laboratory experiments determined the mass ratio of ceramic to steel balls to be 5:5. The initial ceramic ball loading was Φ30mm:Φ25mm:Φ20mm = 20%:30%:50%, and the steel balls were all 30mm, with an initial filling rate of 38%. At this point, the average bulk density of the grinding media was 3.06 t / m³. 3 The initial ball load of the ball mill is shown in Table 7.

[0117] Table 7: Initial Ball Loading Amount at Various Filling Ratios of Ball Mill

[0118]

[0119] This embodiment describes a method for calculating the amount and consumption of internal media in a ball mill. The specific steps are as follows:

[0120] 1) At different stages of the modification experiment, the data of each point were recorded as shown in Table 8. The recording method was the same as in Example 1.

[0121] Table 8: Sampling Locations and Results

[0122]

[0123] 2) Based on the above data, a second-order polynomial is fitted using the least squares method to obtain I. 球 With the mass of mixed grinding media (M) 球 The relationship curve is as follows: 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 normal operation of the ball mill, the operating current before stopping and adding balls is 114.8A. Based on the above measurements: I 矿 =3.4A, I 其他 =80.68A, I 衬损 Merge into I 其他 The set value is calculated to obtain I at this time. 球 =30.72A; further, the amount of grinding media in the ball mill at this time (M) is obtained. 球 The value is 108.1t.

[0125] 4) The filling rate was measured to be 38.34% at the time of shutdown. Using the formula ρ... 现 =M 球 / V现 The average bulk density ρ in the ball mill at this time is 3.13 t / m 3 (average bulk density is 3.06 t / m when the mass ratio of ceramic balls to steel balls is 5:5 3 ), combined with the average bulk density (ρ 现 ) and the mass of the grinding medium (M 球 ) in the ball mill, the formula is used:

[0126]

[0127] The mass of the ceramic balls in the ball mill at present can be calculated as 50.80 t, and the mass of the steel balls is 57.3 t.

[0128] According to the past data, the last time before adding balls, the operating current was 114.7 A, and the filling rate was 38.21%. According to the conventional method, 300 kg of 30 mm ceramic balls and 500 kg of 30 mm steel balls were added, and the operating time after adding balls was 24 h. The mass of the grinding medium (M 球 ) in the ball mill before the last time of adding balls was 107.84 t, including the mass of the ceramic balls of 50.55 t and the mass of the steel balls of 57.29 t. The consumption of ceramic balls and steel balls during the period between the two times of adding balls was 0.05 t and 0.48 t, respectively. Under the condition of keeping the filling rate of the ball mill at 38% and the mass ratio at 5:5, because the ceramic balls are insufficient and the steel balls are excessive, no steel balls should be added next time, and 0.261 t of ceramic balls should be added.

[0129] Compared with the traditional method of adding balls according to experience and habits, the amount of adding balls calculated by the relationship curve obtained by the production technical personnel in the field based on the specific working system of the ball mill can keep the mass ratio and filling rate of the grinding medium in the ball mill at a certain specific optimal value, thereby keeping the production process stable, which is conducive to improving the 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 inside a ball mill, characterized in that: Includes the following steps: 1) Obtain the operating current of the ball mill under different grinding media loading masses; 2) Calculate the current I driving the grinding media based on the operating current. 球 And will drive the grinding media with the current I 球 Data M corresponding to the mass of grinding media charged 球 A fitting curve is obtained by fitting the data; the current driving the grinding media is calculated by the following formula: I 球 =I 运 -(I 其他 +I 矿 +I 衬损 ); In the formula, I 运 I is the operating current. 球 The current driving the grinding media; I 其他 For the current driving the equipment and the liner; I 矿 The current driving the slurry; I 衬损 This represents the change in current caused by liner wear during long-term operation of the equipment. 3) During ball mill operation, acquire the real-time operating current of the ball mill, and obtain the current I driving the grinding media based on the real-time operating current. 球 Then, the current grinding media quality inside the ball mill is calculated using the fitted curve. 4) Based on the current mass of grinding media in the ball mill and the previous mass of grinding media added, the ball consumption of the grinding media can be obtained; including: 4.1) Obtain the current filling rate inside the ball mill, and calculate the current average bulk density of the mixed grinding media based on the filling rate; 4.2) Based on the average bulk density, calculate the mass of each grinding medium in the current ball mill mixed grinding media. Based on the previous added mass of the mixed grinding media, the ball consumption of each grinding medium in the mixed grinding media can be obtained.

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

3. The method for calculating the mass and consumption of grinding media inside a ball mill according to claim 2, characterized in that: Step 1) includes: Obtain the grinding media mass M1 when the ball mill contains only steel balls, and record the operating current I1. Ball mill no-load operation test: At this time, the mass M of the internal grinding media is... 球 The value is 0, and the meter reading records the operating current I2; A mixed grinding media with a mass of M3 was loaded and tested during operation: the operating current value I3 was recorded; After the operation stabilizes, a ball-addition test will be conducted. At this time, the internal grinding media mass M4 = M3 + M 添加 Record the operating current value I4.

4. The method for calculating the mass and consumption of grinding media inside 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 M corresponding to the mass of grinding media charged 球 .

5. The method for calculating the mass and consumption of grinding media inside a ball mill according to claim 1, characterized in that: The specific methods for measuring various currents are as follows: The current I driving the slurry 矿 When the machine is first started, the slurry has not yet entered the ball mill. At this time, I 运 =I 球 +I 其他 +I 衬损 ; The flow of slurry into the ball mill causes an increase in operating current. This change in operating current is the current I that drives the slurry. 矿 ; Current I of drive equipment and liner 其他 The current value measured when the ball mill is running idle is I. 其他 ; The change in current I caused by liner 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 replaced liner, △I 运 The current change before and after the liner replacement is given, where Δt is the service life of the liner before replacement; or, I... 衬损 The current I incorporated into the drive equipment and the liner 其他 Calculated value.

6. The method for calculating the mass and consumption of grinding media inside a ball mill according to claim 1, characterized in that: In step 4.2), the mass of the grinding media in the ball mill is calculated by the following formula; M 球 =M T +M G ; In the formula, ρ 现 M represents the current average bulk density of the mixed grinding media. 球 M is the current grinding media mass inside the ball mill calculated using the fitted curve in step 3); T M represents the current weight of the ceramic balls inside the ball mill. G ρ represents the current weight of the steel balls inside the ball mill. T ρ is the bulk density of ceramic spheres. G This represents the bulk density of the steel balls.

7. The method for calculating the mass and consumption of grinding media inside a ball mill according to claim 1, characterized in that: In step 4.2), the ball consumption calculation method for various grinding media in the mixed grinding media is as follows: Based on the current quality of different grinding media and referring to previous data, the consumption values ​​of ceramic balls and steel balls over a period of time are calculated using 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) ; In the formula, M T(耗) M represents the loss value of grinding media mass over a period of time. T(i-1) To calculate the initial weight of the ceramic balls during the time period, M T(加) M represents the amount of ceramic balls added during this period. T(i) M represents the current weight of the ceramic ball. G(耗) M represents the loss value of grinding media mass over a period of time. G(i-1) To calculate the initial weight of the steel ball during the calculation period, M G(加) M represents the amount of steel balls added during this period. G(i) Let be the weight of the steel ball at the current moment.

Images