Continuous controllable shock wave ore breaking device and working method

Abstract

This invention relates to the field of mineral processing technology, specifically to a continuous controllable shock wave ore crushing device and its operating method. The crushing device includes a feeding unit, an ore pre-cracking unit, a fine powder washing unit, a controllable shock wave crushing unit, and a washing and discharging unit integrated into a rotary crushing chamber. The feeding unit continuously feeds the ore through a feed pipe; the ore pre-cracking unit uses hydraulically driven extrusion rollers to pre-crack the ore, forming internally water-filled micro-cracks in water; the fine powder washing unit promptly separates and discharges the fine particles generated by pre-cracking using inclined water flow; the controllable shock wave crushing unit generates shock waves to crush the ore through needle-plate electrode discharge; and the washing and discharging unit flushes the crushed products to the central discharge hole using high-pressure water flow. This invention achieves highly efficient and selective crushing of ore, and has outstanding advantages such as compact structure, continuous operation, low energy consumption, and minimal over-crushing.

Description

Technical Field

[0001] This invention relates to the field of mineral processing technology, specifically to a continuous controllable shock wave ore crushing device and its working method. Background Technology

[0002] With the continuous development and utilization of mineral resources, easily beneficiated ores are becoming increasingly depleted, and mineral resources are showing a trend of "poor, fine, and complex" development. This has led to increased difficulty and reduced efficiency of traditional mineral beneficiation technologies, resulting in unsatisfactory mineral recovery rates and resource waste.

[0003] Traditional crushing and grinding processes such as high-pressure roller mills, semi-autogenous mills, and ball mills mainly rely on mechanical extrusion, impact, and grinding to overcome the compressive strength of the ore. These methods generally have low energy efficiency and are prone to over-grinding, which is detrimental to subsequent sorting operations.

[0004] Controlled shock wave fracturing technology is an emerging fracturing method. Its principle involves using pulsed power technology to instantaneously discharge water, creating a high-temperature, high-pressure plasma channel that generates a powerful shock wave. Since the tensile strength of an ore is much lower than its compressive strength, the shock wave releases energy within the ore or along mineral interfaces, effectively overcoming its tensile strength and thus achieving ore fracturing or the creation of microcracks. This method has potential advantages such as low energy consumption and ease of selective dissociation at the interface between valuable minerals and gangue minerals.

[0005] However, in practical applications, controllable shock wave crushing devices mostly adopt intermittent batch crushing, resulting in low production efficiency, poor product quality stability, and difficulty in large-scale industrial production. Furthermore, some plasma channels are formed on the surface of ore particles, which significantly reduces the probability of internal force application in the ore, leading to a decrease in the energy utilization rate of controllable shock waves and a limitation on the degree of pre-enrichment. Summary of the Invention

[0006] In order to solve the above-mentioned technical problems in the prior art, the present invention provides an ore crushing device and method that can realize continuous production, significantly improve the energy utilization rate and crushing efficiency of controllable shock waves, and effectively enhance the selective crushing and pre-enrichment effect. After the ore is pretreated by a specific roller pressing, a large number of microcracks suitable for the action of controllable shock waves can be formed inside the ore with low energy consumption, thereby improving the energy utilization efficiency of controllable shock wave crushing.

[0007] One objective of this invention is to provide a continuous and controllable shock wave ore crushing device, comprising:

[0008] The rotary crushing chamber, as a container for ore crushing, rotates at a constant speed under the drive of the drive mechanism. The feeding unit is used to continuously and quantitatively supply ore into the rotary crushing chamber; An ore pre-splitting unit is disposed within the rotary crushing chamber and downstream of the feeding unit, and is used to apply controllable pressure to the ore bed to form microcracks. A fine powder washing unit is installed inside the rotary crushing chamber and downstream of the ore pre-splitting unit, and is used to wash and separate the fine particles generated by pre-splitting. A controllable shock wave crushing unit, located within the rotary crushing chamber and downstream of the fine powder washing unit, includes a charging unit, needle electrodes and plate electrodes, and an energy monitoring unit. The needle electrodes and plate electrodes are suspended vertically relative to each other, positioned above and below the ore layer, respectively. The top of the needle electrodes and the bottom of the plate electrodes are connected to the charging unit. A controllable shock wave is generated in the water using a high-voltage pulse discharge between the needle and plate electrodes to further crush the ore particles. The energy monitoring unit measures the voltage and current values ​​at the discharge terminals and feeds them back to the processing module for effective discharge statistics. The flushing and discharge unit is used to maintain the liquid level in the crushing chamber and discharge the crushed product through the discharge hole of the rotary crushing chamber. The feeding unit, ore pre-splitting unit, fine powder washing unit, controllable shock wave crushing unit, and washing and discharging unit are arranged sequentially along the circumference of the rotary crushing chamber, forming a continuous crushing operation system.

[0009] As a preferred technical solution, the ore pre-splitting unit includes an extrusion roller, a hydraulic push rod for driving the extrusion roller, and a fixed base; the hydraulic push rod and the extrusion roller are respectively pivotally connected to both sides of the fixed base, forming a lever mechanism, so that the extension action of the hydraulic push rod can drive the extrusion roller to perform a downward pressing action on the ore layer with a predetermined pressure.

[0010] As a preferred technical solution, the ore pre-splitting unit further includes side baffles disposed at both ends of the axial direction of the extrusion roller, with the ore drop point located between the two side baffles.

[0011] As a preferred technical solution, the fine powder rinsing unit includes a fine powder rinsing water pipe, the water outlet direction of which is configured to be radially along the rotary crushing chamber and inclined downward.

[0012] As a preferred technical solution, the rotary crushing chamber is covered by a crushing chamber cover; the crushing chamber cover is equipped with a feed pipe, which delivers the ore to one side of the ore pre-cracking unit through a sloping feeding channel.

[0013] As a preferred technical solution, the flushing and ore discharge unit includes a high-pressure flushing water pipe and an ore discharge pipe; the drain end of the high-pressure flushing water pipe is directly opposite the discharge area of ​​the controllable shock wave crushing unit, and its inlet flow rate is matched with the drainage flow rate of the ore discharge pipe to maintain a constant liquid level in the crushing chamber.

[0014] As a preferred technical solution, the device also integrates a roller pressure intelligent adjustment system. The self-adjusting system is configured to adjust the real-time roller pressure Pt applied to the ore online according to the real-time detected material layer thickness h and the effective probability η of the controllable shock wave, using the following formula: Formula (1); Where: P t For real-time roller pressing, MPa; P0 is the initial set roller pressure, MPa; h represents the real-time material layer thickness, in mm; h0 is the initial set thickness of the roller-pressed material layer, in mm; K p This is the material layer thickness correction coefficient, which is related to the properties of the ore raw material such as particle size, hardness, and density, and takes a value of 0.5 to 1.5. The effective probability adjustment coefficient of the controllable shock wave is related to the properties of the ore such as particle size distribution and electrical conductivity, and its value ranges from 0 to 1. η is the effective probability of a real-time controllable shock wave, % η max This represents the highest probability of a controllable shock wave effectively acting during operation, % η min This represents the lowest probability of a controllable shock wave effectively acting during operation.

[0015] As a preferred technical solution, the extrusion roller surface adopts an arc-shaped groove structure; and / or, the plate electrode adopts a V-shaped structure.

[0016] As a preferred technical solution, the extrusion roller, needle electrode and plate electrode are all arranged inclined along the circumference of the rotary crushing chamber, and the inclination direction of the three is consistent, with a low outer circumference and a high middle circumference.

[0017] As a preferred technical solution, the device consists of multiple sets integrated into the same rotary crushing chamber, arranged continuously according to the process of feeding—extrusion pre-cracking—fine powder washing—controllable shock wave crushing—washing and ore discharge.

[0018] The present invention also discloses a method for efficient ore crushing using the aforementioned device, comprising the following steps: S1. After coarse and medium crushing, the ore raw material is quantitatively and continuously fed into the extrusion roller feed end of the rotary crushing chamber through the feed pipe. S2. The ore rotates with the rotary crushing chamber and is pre-cracked by the extrusion rollers, forming micro-cracks inside and on the surface of the particles. This process is completed in water to ensure that the cracks are filled with water. S3. The pre-cracked ore then enters the fine powder washing zone, where high-speed water flow separates and removes the fine powder generated in advance. S4. The washed ore enters the controllable shock wave crushing zone. The high-voltage pulse current discharges between the needle plate electrodes to generate shock waves. The shock waves propagate along the internal cracks and mineral interfaces of the ore, forming plasma channels to release energy and achieve selective crushing of the ore. S5. The crushed product is flushed to the central discharge pipe by the high-pressure flushing water flow and discharged for subsequent grading and sorting operations.

[0019] As a preferred technical solution, the pre-splitting treatment and the controllable shock wave crushing are carried out in the same liquid circuit, and the temperature of the liquid circuit is controlled to not exceed 50°C.

[0020] The present invention has the following advantages and beneficial effects: First, this device integrates multiple functional units such as feeding, ore pre-cracking, fine powder washing, controlled shock wave crushing, and ore washing and discharge into a single rotary crushing chamber, creating a compact and rationally laid-out continuous operation system. This integrated design not only significantly reduces the equipment footprint but also enables continuous material processing. Secondly, a synergistic crushing mechanism combining extrusion pre-cracking and controlled shock wave crushing was adopted: the ore is first subjected to adjustable roller pressure in water, generating a large number of micro-cracks on the inside and surface, and the cracks are fully filled with water, which creates ideal conditions for the formation of a stable plasma channel in the subsequent shock wave crushing stage; the fine powder washing unit that follows can promptly separate and discharge the fine particles (such as particles with a diameter <0.5mm) generated by pre-cracking. This key step effectively curbs over-grinding and avoids the mud-like accumulation of fine powder in the discharge area, ensuring the stable formation of the plasma channel and the efficient transfer of shock wave energy; the entire process is closely connected, ensuring that the pre-cracked ore can quickly enter the shock wave crushing zone within 3 seconds, maximizing the freshness of the cracks and the high surface energy state, thereby significantly improving the efficiency of subsequent selective crushing; Furthermore, key parameters such as the roller pressure of the extrusion roller, the speed of the crushing chamber, the electrode spacing, and the crushing frequency of the shock wave can all be adjusted as needed. In particular, the equipped intelligent roller pressure adjustment system can dynamically adjust the roller pressure setting based on the real-time monitoring of the material layer thickness and the effective action probability of the shock wave, so that the degree of ore pre-cracking is always kept in the optimal range, thereby ensuring that the entire system can operate continuously, efficiently, and stably, and achieve efficient selective dissociation of ore along the mineral interface. Finally, this device employs a shared liquid circuit design, simplifying the water supply and drainage system and improving operational stability and reliability. The heat generated during the pre-cracking process is absorbed by the water. Appropriately increasing the water temperature within a controllable range actually enhances the thermal motion of water molecules, thereby increasing the propagation speed of the shock wave in the water medium and further promoting the improvement of crushing efficiency. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the crushing device of the present invention; Figure 2 This is a schematic diagram of the rotary crushing chamber and ore pre-splitting unit structure of the present invention. Figure 3 This is a schematic diagram of the bottom structure of the rotary crushing chamber of the present invention; Figure 4 This is a schematic diagram of the driving mechanism of the present invention; Figure 5 This is a schematic diagram of the rotary crushing chamber and extrusion rollers of the present invention; Figure 6 This is a circuit diagram of the controllable shock wave breaking unit of the present invention.

[0022] In the picture: 1. Rotary crushing chamber; 2. Feed pipe; 3. Crushing chamber cover; 4. Feeding channel; 5. Hydraulic push rod; 6. Extrusion roller; 7. Side baffle; 8. Fixed base; 9. Variable frequency motor; 10. Reducer; 11. Drive gear; 12. Driven gear; 13. Fine powder flushing water pipe; 14. Needle electrode; 15. Plate electrode; 16. Slip ring rotating part; 17. Slip ring fixed part; 18. High-pressure flushing water pipe; 19. Discharge pipe; 20. Discharge hole; 21. Lead wire; 22. Grounding cable; 23. High-voltage DC power supply; 24. Current limiting resistor; 25. Diode; 26. Energy storage capacitor; 27. Discharge switch; 28. Rogowski coil; 29. ​​High-voltage tester. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0024] like Figures 1-5 As shown, this embodiment provides a continuous controllable shock wave ore crushing device, including a rotary crushing chamber 1, a feeding unit, an ore pre-splitting unit, a fine powder washing unit, a controllable shock wave crushing unit, and a washing and discharging unit. The above systems are integrated into a rotary crushing chamber 1 to form a compact continuous operation unit.

[0025] The feeding unit includes the feeding pipe 2, which is responsible for the continuous and quantitative supply of materials. The ore pre-cracking unit is located downstream of the feeding unit and is used to apply adjustable roller pressure to the ore layer in the chamber to form micro-cracks inside and on the surface of the ore; specifically, it includes a compression roller unit and a drive mechanism; specifically, the rotary crushing chamber 1 is annular and has a discharge hole 20 at the bottom center, and is driven to rotate at a constant speed by the drive mechanism. The drive mechanism includes a variable frequency motor 9, a reducer 10, a drive gear 11, and a driven gear 12. The driven gear 12 drives the rotary crushing chamber 1 to rotate through a matching gear fixed to the outside of the rotary crushing chamber 1. The crushing chamber material is preferably ceramic to improve wear resistance.

[0026] The rotary crushing chamber 1 is covered by a crushing chamber cover 3, which is equipped with a feed pipe 2. The feed pipe 2 delivers the ore to one side of the ore pre-cracking unit through a feed channel 4 with a slope.

[0027] The extrusion roller unit includes a hydraulic push rod 5, an extrusion roller 6, and a fixed seat 8 fixed on the outside of the rotary crushing chamber 1. The hydraulic push rod 5 and the extrusion roller 6 are respectively located on both sides of the fixed seat 8 and form a lever mechanism. When the hydraulic push rod 5 performs a pushing action vertically upward, it can drive the extrusion roller 6 in the rotary crushing chamber 1 to perform a pressing action and apply a predetermined pressure to the ore in the crushing chamber, thereby generating a large number of microcracks inside and on the surface of the ore.

[0028] The rotary crushing chamber 1 feeds newly delivered ore to the area below the extrusion roller 6 by rotation. To prevent the ore from collapsing when the extrusion roller 6 applies pressure, a side baffle 7 is provided on the feed side of each of the two axial ends of the extrusion roller 6. The bottom drop point of the feeding channel 4 is located between the two side baffles 7, thereby concentrating the ore in the extrusion area and ensuring the extrusion effect. Preferably, the distance between the inner surface of the baffle and the end face of the grinding roller is 1~3mm, and the distance between the bottom of the baffle and the crushing chamber is 1~3mm.

[0029] The fine powder washing unit is located downstream of the ore pre-splitting unit and includes a fine powder washing water pipe 13. Its nozzle is positioned between the ore pre-splitting unit and the controllable shock wave crushing unit. This nozzle washes away fine particles (e.g., fine powder with a particle size <0.5mm) generated during pre-splitting with water flow of a specific direction and velocity before the ore enters the shock wave crushing zone, directly discharging them into the discharge pipe 19 to prevent them from entering subsequent areas. This design effectively reduces over-grinding and prevents the fine powder from becoming muddy in the discharge zone, ensuring the stable formation of the plasma channel.

[0030] The controllable shock wave crushing unit is located downstream of the fine powder washing unit and includes a charging unit, a needle electrode 14, a plate electrode 15, and an energy monitoring unit. The plate electrode 15 is embedded in the bottom of the rotary crushing chamber 1 and is flush with the bottom of the chamber. The bottom of the needle electrode 14 and the plate electrode 15 are suspended vertically opposite each other, located above and below the ore layer, respectively, and their discharge channels pass vertically or nearly vertically through the ore layer being processed. The top of the needle electrode 14 and the bottom of the plate electrode 15 are connected to the charging unit via connecting cables. The charging unit includes a high-voltage DC power supply 23, a current-limiting resistor 24, a diode 25, an energy storage capacitor 26, and a discharge switch 27. The high-voltage DC power supply 23 charges the energy storage capacitor 26 through the current-limiting resistor 24 and the diode 25. The energy monitoring unit includes a Rogowski coil 28 and a high-voltage tester 29 for testing the discharge terminal current and voltage, respectively. The processing module performs effective discharge statistics based on the real-time voltage and current.

[0031] like Figure 5 The pulse power circuit shown generates a high-voltage pulse. When the voltage of the energy storage capacitor reaches the set value, the discharge switch automatically closes, and the high-voltage pulse current is released between the needle electrode 14 and the plate electrode 15, generating a controllable shock wave in the water. This shock wave selectively dissociates the minerals at the interface between the useful minerals and gangue minerals, and further crushes the ore particles.

[0032] In some specific embodiments, the lead 21 at the bottom of the plate electrode 15 is connected to an external grounding wire via a conductive slip ring 24, solving the conductivity problem of the rotating cavity. The conductive slip ring includes a rotating portion 16 and a fixed portion 17. The rotating portion 16 is a conductive ring sleeved on the outside of the discharge pipe 19. The lead 21 of the plate electrode 15 is connected to the rotating portion 16, and the grounding cable 22 is connected to the fixed portion 17 to ensure cable connection when the plate electrode 15 and the cable rotate with the crushing cavity. The conductive slip ring is existing technology and will not be described in detail here. Preferably, the needle electrode 14 is made of tungsten-copper alloy, with an insulating material covering the outer surface except for the discharge tip, and the plate electrode 15 is made of wear-resistant stainless steel.

[0033] The flushing and ore discharge unit is located downstream of the controllable shock wave crushing unit and includes a high-pressure flushing water pipe 18 and an ore discharge pipe 19. The high-pressure flushing water pipe 18 is installed on the crushing chamber cover 3 to connect to an external high-pressure water source, and its drainage end faces the discharge area of ​​the controllable shock wave crushing unit. The inlet water flow rate is consistent with the drainage flow rate in the ore discharge pipe 19 to ensure that the water level in the crushing chamber remains constant. The nozzles in the drainage section provide high-speed water flow to flush the ore particles in the crushing chamber to the discharge hole 20 at the bottom center of the rotary crushing chamber 1. The bottom of the discharge hole 20 is connected to the ore discharge pipe 19, and then the ore particles are discharged through the ore discharge pipe 19.

[0034] When this device is working, the pressing of the extrusion roller 6, the rotation speed of the rotary crushing chamber 1, the distance between the needle plate electrodes, and the controllable shock wave crushing frequency can be adjusted at any time to achieve precise control of ore residence time, pre-cracking degree, and controllable shock wave crushing efficiency.

[0035] like Figure 5 As shown, in some specific embodiments, the extrusion roller surface adopts an arc-shaped groove structure; the plate electrode adopts a V-shaped structure; the extrusion roller, needle electrode and plate electrode are all arranged inclined along the circumference of the rotary crushing chamber, and the inclination direction of the three is consistent, with a low outer circle and a high middle circle arrangement.

[0036] The technical effects of the above structural form are as follows: 1) The arc-shaped groove pressure roller surface + V-shaped plate electrode structure can enhance the horizontal force during ore extrusion, form a multi-directional stress synergy, significantly enhance the three-dimensional pre-crack effect of ore, and promote the multi-dimensional generation and directional expansion of internal microcracks. At the same time, the arc-shaped groove has a certain material aggregation effect, which can effectively prevent the collapse of ore raw materials during extrusion, further enhance the extrusion effect, reduce the edge effect, enrich the density and distribution of microcracks inside the ore after pre-cracking, and help to further improve the energy utilization efficiency of controllable shock wave. 2) The V-shaped plate electrode structure can further reduce the straight distance between the two sides of the needle electrode and the edge of the plate electrode, increase the probability of electrical breakdown at the above positions, thereby improving the energy utilization efficiency of controllable shock wave. 3) The plate electrodes are all arranged circumferentially inclined along the rotary crushing chamber, with the outer side lower and the middle higher, which can effectively prevent coarse particles from being discharged prematurely during fine powder washing, and ensure that coarse particles completely enter the shock wave crushing unit.

[0037] Furthermore, the specifications of the extrusion roller are as follows: diameter D is 220~270mm, axial length B is 90~110mm, radius of curvature R of the arc groove on the roller surface is 300~400mm, the angle α between the center line of the roller shaft and the vertical direction is 86~88°; the distance Lrc between the extrusion roller and the center line of the rotary crushing chamber is 150~180mm, and the pressure of the extrusion roller is 3~8MPa; The material layer thickness is 20~30mm; The diameter Dc of the rotary crushing chamber is 480~520mm, and the rotation speed is 3~5r / min; Fine powder washing water flow velocity: 0.8~1.2m / s; ore discharge water flow velocity: 2.5~3m / s; Plate electrode width: 90~110mm, V-shaped inner angle: 170~175°, the angle β between the axis of the plate electrode and the needle electrode and the horizontal direction is 86~88°, the distance between the needle electrode and the plate electrode is 20~35mm, and the discharge frequency is 3~5HZ.

[0038] This invention provides an integrated ore crushing device based on the synergistic effect of compression pre-fracture and controllable shock wave, the working principle of which is as follows: The ore pre-fracture process is completed in an aquatic environment, ensuring sufficient water filling within the cracks. This facilitates the formation of more and more stable plasma channels during the subsequent controlled shock wave fracturing stage. In contrast, if the ore is pre-fractured in air before entering the water body for controlled shock wave fracturing, residual air within the cracks will hinder the formation of plasma channels, reduce the energy transfer efficiency of the shock wave, and thus weaken the fracturing effect.

[0039] This device adopts a roller-pressing pre-cracking combined with a controllable shock wave ore crushing mechanism. After the ore undergoes a specific roller-pressing pretreatment, a large number of microcracks suitable for the action of controllable shock waves can be formed inside the ore with low energy consumption. The microcracks are adapted to the discharge parameters of the controllable shock wave crushing unit, thereby improving the energy utilization efficiency of the controllable shock wave with low energy consumption.

[0040] After the ore pre-cracking is completed, the device uses a fine powder washing unit to spray an adjustable flow of water downwards along the radial direction of the rotary crushing chamber 1 to wash the ore surface. This water flow rate is precisely controlled to effectively separate fine particles (particle size <0.5mm) generated during the pre-cracking process, allowing them to enter the discharge pipe 19 as crushed products and be discharged, preventing them from entering the subsequent controllable shock wave crushing unit. This design effectively reduces over-crushing of the ore and minimizes the accumulation of fine particles in the discharge area, preventing interference with the formation of the plasma channel and thus improving overall crushing efficiency.

[0041] It is worth noting that after the ore undergoes pre-splitting in water, the tips of the newly formed cracks may become passivated due to water-rock interactions such as chemical oxidation and corrosion, increasing the difficulty of subsequent plasma channel formation. Therefore, this device employs an integrated design to ensure that the ore rapidly enters the controllable shock wave fracturing zone within 3 seconds after pre-splitting and washing, thereby maximizing the preservation of the high surface energy state of the cracks and increasing the probability of plasma channel formation.

[0042] Furthermore, this device employs a shared liquid loop design, with all functional units sharing the same circulation system. This simplifies the water supply and drainage structure and improves the stability of system operation and the reliability of equipment. The heat released during the pre-cracking process of the ore can raise the temperature of the water in the loop. Under the premise of controlling the water temperature to not exceed 50℃, the thermal motion of water molecules is enhanced, which is conducive to the propagation speed of shock waves in the water and improves crushing efficiency.

[0043] In some specific embodiments, this device can be configured as two sets, integrated within the same rotary crushing chamber 1, and arranged continuously according to the process of feeding—extrusion pre-cracking—fine powder washing—controlled shock wave crushing—washing and ore discharge. The number of devices can be flexibly configured according to the volume of the rotary crushing chamber 1 and the scale of the ore to be processed.

[0044] This device adopts an open-circuit crushing process. The crushed products are graded according to their particle size. The graded products can be discarded, processed into the next process, or returned to the crushing device for recycling, thus achieving efficient resource utilization and process optimization.

[0045] This device is suitable for crushing metal ores such as magnetite, with a maximum feed particle size d. max ≤15mm, 1mm particle mass content ≤10%, and target metallic mineral mass fraction in ore ≥30%.

[0046] This invention proposes an intelligent roller pressure adjustment system for a continuous controllable shock wave ore crushing device. It constructs a closed-loop control method for the entire process of "real-time perception-intelligent analysis-dynamic adjustment" to achieve synergistic optimization of the ore roller pressure pre-cracking effect and the efficient effect of the controllable shock wave, thereby improving the ore crushing efficiency and the degree of automation of the crushing system.

[0047] The intelligent roller pressure adjustment system includes: The data acquisition module is used to collect the thickness h of the ore layer in the crushing chamber and the effective probability η of the controllable shock wave crushing unit in real time; the data acquisition module includes: A material layer thickness detection unit is installed on the hydraulic push rod of the ore pre-splitting unit. It includes a micro-pulse displacement sensor, which is used to indirectly measure the real-time material layer thickness h by measuring the actual stroke L1 of the hydraulic push rod. For example, when the material layer thickness is 0, the stroke of the hydraulic push rod is L0; then h = γ(L0-L1), where γ = distance between the center line of the extrusion roller and the fixed seat / distance between the center line of the hydraulic push rod and the fixed seat; the acquisition frequency is 5Hz, and the average value within 0~5s of the start of acquisition is used as the initial set material layer thickness h0 under roller pressing; The effective action probability detection unit includes an energy monitoring unit connected in parallel with the needle plate electrodes of the controllable shock wave breaking unit. This unit determines effective discharge by monitoring the voltage and current at the discharge terminal. Using the first 5 seconds of the acquisition time as a counting interval, the ratio of the number of effective discharges to the total number of discharges within this time window is used as the real-time effective action probability η. Simultaneously, the unit calculates the η value within the first 30 seconds of the acquisition time interval. max and η min If the data collection time is less than 30 seconds, the actual collection time will be used as the counting interval.

[0048] The processing module is used to determine the effective probability extreme value η of the controllable shock wave based on the collected h and η, the preset initial roller pressure P0, the statistically obtained initial material layer thickness h0, and the data. max and η min The real-time roll pressure P is calculated using the following formula. t : Formula (1); Where: P t For real-time roller pressing, MPa; P0 is the initial set roller pressure, MPa; h represents the real-time material layer thickness, in mm; h0 is the initial set thickness of the roller-pressed material layer, in mm; K p This is the material layer thickness correction coefficient, which is related to the properties of the ore raw material such as particle size, hardness, and density, and takes a value of 0.5 to 1.5. The effective probability adjustment coefficient of the controllable shock wave is related to the properties of the ore such as particle size distribution and electrical conductivity, and its value ranges from 0 to 1. η is the effective probability of a real-time controllable shock wave, % η max This represents the highest probability of a controllable shock wave effectively acting during operation, % η min This represents the lowest probability of a controllable shock wave effectively acting during operation.

[0049] The execution module is used to calculate the real-time roll pressure P. t Adjust the roller pressure of the extrusion rollers in the ore pre-splitting unit; the execution module includes a proportional valve or servo valve electrically connected to the processing module, used to adjust the real-time roller pressure P. t Adjust the hydraulic cylinder pressure of the hydraulic push rod.

[0050] The control logic of the intelligent roller pressure adjustment system is as follows: The system starts operation based on a preset initial roller pressure P0. This initial roller pressure P0 is the optimal process setting value determined through experimentation and optimization, taking into account parameters such as throughput, ore particle size, grade, and conductivity. During equipment operation, the roller pressure P... t This is the only actively adjusted operating variable of the system. When the real-time material layer thickness h is detected to be consistent with the initially set material layer thickness h0 under the roller pressure, the system maintains the current roller pressure unchanged; at this time, the system continuously collects and statistically analyzes the effective probability η of the controllable shock wave, and updates its operating extreme value η. max With η min .

[0051] The effective probability η of the controllable shock wave is determined by the statistical module of the power monitoring unit by monitoring the voltage and current sensor signals at the discharge end: when the shock wave generated by a single discharge reaches the preset energy threshold, it is recorded as an effective discharge. The ratio of the number of effective discharges to the total number of discharges within the first 5-second time window is the real-time effective probability η.

[0052] When fluctuations in processing volume or changes in the properties of the ore raw materials cause the real-time material layer thickness h to deviate from the initial set h0, the effective operating probability η of the downstream shock wave crushing system will change accordingly. The basic rule of system regulation is: the greater the deviation of h from h0, the greater the deviation of η from h0. max The greater the degree of η and the smaller the fluctuation range of η, the greater the adjustment range of the system to the roller pressure.

[0053] The specific control strategies are as follows: If h < h0, it indicates that the current roller pressure is too high, resulting in excessive compaction of the ore, hindering the formation of internal cracks and reducing crack density, which is not conducive to the formation of plasma channels and the efficient action of shock waves. The system will automatically reduce the roller pressure according to the preset control formula to restore suitable crack development conditions. If h > h0, it indicates that the current roller pressure is insufficient, the ore has not been fully crushed, and the internal cracks are not fully developed. The system will automatically increase the roller pressure according to the control formula to enhance the pre-cracking effect and increase the crack density.

[0054] When the real-time material layer thickness h is equal to the initial set material layer thickness h0, the current roller pressure remains unchanged.

[0055] Through this adaptive feedback control mechanism, the system can continuously optimize the roller pressing operation parameters to ensure that the ore always obtains a suitable crack density in the pre-cracking stage, thereby maximizing the effective probability of the subsequent controllable shock wave crushing unit and ensuring the continuous, efficient and stable operation of the entire crushing system.

[0056] Before the intelligent roller pressure adjustment system is put into operation, the grinding disc speed, fine powder flushing water flow rate, ore discharge flushing water flow rate, controllable shock wave electrode spacing and discharge frequency are set sequentially; ore is fed in and the initial roller pressure P0 is set. After the continuous and controllable shock wave ore crushing device has been running stably, the intelligent roller pressure adjustment system begins to operate according to the following methods, including the following steps: S1. Real-time acquisition of the thickness h of the ore layer in the rotary crushing chamber and the effective probability η of the controllable shock wave crushing unit; specifically including: 1) A material layer thickness detection unit is installed on the hydraulic push rod of the ore pre-splitting unit. It includes a micro-pulse displacement sensor, which is used to indirectly measure the real-time material layer thickness h by measuring the actual stroke of the hydraulic push rod. The acquisition frequency is 5Hz, and the average value within 0~5s of the start of acquisition is used as the initial setting of the material layer thickness h0 under roller pressing. 2) An effective action probability detection unit, including an energy monitoring unit connected in parallel with the needle plate electrodes of the controllable shock wave breaking unit, comprising a high-voltage tester and a Rogowski coil, used to determine effective discharge by monitoring the voltage and current at the discharge end, and using the 5s before the acquisition time point as the counting interval, the ratio of the number of effective discharges to the total number of discharges within this time window is used as the real-time effective action probability η, and simultaneously using the 30s before the acquisition time point as the counting interval, the η is statistically analyzed. max and η min If the data collection time is less than 30 seconds, the actual collection time will be used as the counting interval.

[0057] S2. After the data acquisition time exceeds 5 seconds, the data is analyzed and processed using formula (1) to calculate the real-time roller pressure P. t .

[0058] S3, Feedback Adjustment: The calculated real-time roll pressure P t Feedback is sent to the hydraulic cylinder of the extrusion roller, and the pressure applied by the extrusion roller to the ore layer is changed by adjusting the pressure of the hydraulic cylinder. When h < h0, the roller pressure is reduced, and when h > h0, the roller pressure is increased.

[0059] The following describes the working method of a continuous controllable shock wave ore crushing device according to an embodiment of the present invention, the process of which is as follows: S1. After coarse and medium crushing, the ore raw material is quantitatively and continuously fed into the feed end of the extrusion roller 6 of the rotary crushing chamber 1 through the feed pipe 2. S2. The ore rotates with the rotary crushing chamber 1 and is pre-cracked by the extrusion roller 6, forming micro-cracks inside and on the surface of the particles. This process is completed in water to ensure that the cracks are filled with water. S3. The pre-cracked ore then enters the fine powder washing zone, where high-speed water flow separates and removes the fine powder generated in advance. S4. The washed ore quickly (within 3 seconds) enters the controllable shock wave crushing zone. The high-voltage pulse current discharges between the needle plate electrodes to generate shock waves. The shock waves propagate along the internal cracks and mineral interfaces of the ore to achieve selective crushing. S5. The crushed product is flushed to the central discharge pipe 19 by the water flow of the high-pressure flushing water pipe 18 for subsequent grading and sorting operations.

[0060] Experimental Example Experiment 1 Using a magnetite ore deposit from Liaoning Province as the test raw material, with a density of 4.8 t / m³, a total iron (TTFe) grade of 31.4%, and a maximum feed particle size of 15 mm, the ore raw material was processed using three different processes. The Bond work index of the +10 mm particle size, the yield of the 1 mm particle size, and the total iron grade were measured in the crushed products. The Bond work index was tested according to the national standard GB / T26567-2011.

[0061] The process settings are as follows: Process 1 (Pre-splitting only): The ore pre-splitting unit of the device of this invention is used for processing, without passing through the controllable shock wave crushing unit. The specific process parameters are as follows: a total of 2 crushing units are set up, with a single unit feed rate of 1t / h; crushing chamber depth of 50mm, water level height of 30mm, rotation speed of 4r / min; extrusion roller diameter of 250mm, roller surface width of 100mm, roller pressure of 5.2MPa; high-pressure flushing water pipe inlet inner diameter of 25mm, drainage end rectangular nozzle size of 15mm×30mm, water inlet flow rate of 1.3t / h.

[0062] Process 2 (Shockwave Crushing Only): The ore bypasses the pre-splitting system and directly enters the controlled shockwave crushing unit. Except for the absence of pre-splitting, the structural parameters are the same as in Process 1. The specific electrical parameters of the shockwave crushing system are: high-voltage DC power supply output voltage 180kV, power 60kW, current-limiting resistor 550kΩ, energy storage capacitor 0.07μF, discharge frequency 5Hz, needle-plate electrode distance 25mm, plate electrode width 100mm.

[0063] Process 3 (Pre-splitting + Shockwave Combined Crushing): This process employs the complete process flow described in this invention, where the ore is first pre-splitting by extrusion rollers, and then enters the controllable shockwave crushing unit for further processing. The parameters of the pre-splitting system and the shockwave crushing system are consistent with those of Process 1 and Process 2, respectively.

[0064] Experimental Results and Analysis: The test results of the crushed products from processes 1 to 3 are compared in Table 1.

[0065] Process 1 (pre-splitting only): Reduces the Bond work index of the +10mm particle size to 96.7% of that of the original ore, increases the yield of the 1mm particle size by 29.2% compared to the original ore, and increases the total iron grade of the 1mm particle size by 1.9% compared to the original ore.

[0066] Process 2 (shock wave crushing only): Reduces the Bond work index of +10mm particle size to 84.5% of that of the original ore, increases the yield of 1mm particle size by 322.2% compared to the original ore, and increases the total iron grade of 1mm particle size by 16.4% compared to the original ore.

[0067] Process 3 (combined crushing): achieved the best results: the Bond work index of the +10mm particle size decreased to 79.0% of that of the raw ore, the yield of the 1mm particle size increased by 452.8% compared with the raw ore, and the total iron grade of the 1mm particle size increased by 27.2% compared with the raw ore.

[0068] To quantify the synergistic gain effect, under the same energy input conditions, assuming that pre-fracture and shock wave fracturing have a simple superposition relationship, the theoretical expected values ​​are: the Bond work index of +10mm particle size decreases to 96.7% × 84.5% = 81.7% of the original ore; the yield of 1mm particle size increases to 129.2% × 422.2% × 100% = 445.5% of the original ore; and the total iron grade of 1mm particle size increases to 101.9% × 116.4% × 100% = 18.6% of the original ore.

[0069] Comparing the actual effects of process 3 with the theoretical superposition values ​​above, it can be seen that the combined crushing process (process 3) provided by the present invention achieves significant synergistic gains: the reduction of the Bond work index of +10mm coarse particles increased by 2.7 percentage points; the increase of the yield of 1mm particle size increased by 7.3 percentage points; and the increase of the grade of useful metals in 1mm particle size increased by 8.6 percentage points.

[0070] Table 1 Results of the comparative experiment in Experiment 1

[0071] Experiment 2 The experiment used a magnetite ore from Xinjiang as the raw material for verification. Its density was 4.6 t / m³, the total iron (TFe) grade was 36.2%, and the maximum feed particle size was also 15 mm. The test methods and detection indicators were the same as in Experiment 1.

[0072] The process settings are as follows: The process definitions for processes 1 to 3 are exactly the same as those for experiment 1, but the key parameters are optimized and adjusted: the roller pressure is adjusted to 5.0 MPa, the output voltage of the shock wave crushing system is adjusted to 175 kV, the distance between the needle plate electrodes is adjusted to 22 mm, and the other conditions are kept the same as those for experiment 1.

[0073] Experimental Results and Analysis: Table 2 shows a comparison of the test results of the crushed products from processes 1 to 3.

[0074] Process 1 (pre-splitting only): Reduces the Bond work index of the +10mm particle size to 89.7% of that of the original ore, increases the yield of the 1mm particle size by 32.2% compared to the original ore, and increases the total iron grade of the 1mm particle size by 6.1% compared to the original ore.

[0075] Process 2 (shock wave crushing only): Reduces the Bond work index of +10mm particle size to 80.3% of the original ore, increases the yield of 1mm particle size by 418.6% compared to the original ore, and increases the total iron grade of 1mm particle size by 11.3% compared to the original ore.

[0076] Process 3 (Combined Crushing): Optimal results were achieved again: the Bond work index of the +10mm particle size decreased to 67.0% of that of the original ore, the yield of the 1mm particle size increased by 598.3% compared to the original ore, and the total iron grade of the 1mm particle size increased by 23.5% compared to the original ore.

[0077] Similarly, the theoretical expected values ​​of the simple superposition of the two treatment methods are calculated: the Bond work index of the +10mm particle size decreases to 89.7% × 80.3% = 71.9% of the original ore; the yield of the 1mm particle size increases to 132.2% × 518.6% × 100% = 585.6% of the original ore; and the total iron grade of the 1mm particle size increases to 106.1% × 111.3% × 100% = 18.1% of the original ore.

[0078] Consistent with the conclusions of Experiment 1, the actual effect of Process 3 is significantly better than the theoretical superposition value. The synergistic gain effect is as follows: the reduction of Bond work index of +10mm coarse particles increased by 4.9 percentage points; the increase of yield of 1mm particles increased by 12.7 percentage points; and the increase of useful metal grade of 1mm particles increased by 5.4 percentage points.

[0079] Table 2 Results of the comparative experiment in Experiment 2

[0080] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention may still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A continuous controllable shock wave ore crushing device, characterized in that, include: The rotary crushing chamber, as a container for ore crushing, rotates at a constant speed under the drive of the drive mechanism. The feeding unit is used to continuously and quantitatively supply ore into the rotary crushing chamber; An ore pre-splitting unit is disposed within the rotary crushing chamber and downstream of the feeding unit, and is used to apply controllable pressure to the ore bed to form microcracks. A fine powder washing unit is installed inside the rotary crushing chamber and downstream of the ore pre-splitting unit, and is used to wash and separate the fine particles generated by pre-splitting. The controllable shock wave crushing unit is located in the rotary crushing chamber and downstream of the fine powder washing unit. It includes a charging unit, needle electrodes and plate electrodes, and an energy monitoring unit. The needle electrodes and plate electrodes are arranged vertically opposite each other and suspended in the air. They are located above and below the ore layer, respectively. The top of the needle electrodes and the bottom of the plate electrodes are connected to the charging unit. The high-voltage pulse discharge between the needle and plate electrodes generates a controllable shock wave in the water to further crush the ore particles. The power monitoring unit measures the voltage and current values ​​at the discharge terminal and feeds them back to the processing module for effective discharge statistics. The flushing and discharge unit is used to maintain the liquid level in the crushing chamber and discharge the crushed product through the discharge hole of the rotary crushing chamber. The feeding unit, ore pre-splitting unit, fine powder washing unit, controllable shock wave crushing unit, and washing and discharging unit are arranged sequentially along the circumference of the rotary crushing chamber, forming a continuous crushing operation system.

2. The apparatus according to claim 1, characterized in that, The ore pre-splitting unit includes a squeezing roller, a hydraulic push rod for driving the squeezing roller, and a fixed base; the hydraulic push rod and the squeezing roller are respectively pivotally connected to both sides of the fixed base, forming a lever mechanism, so that the extension action of the hydraulic push rod can drive the squeezing roller to perform a downward pressing action on the ore layer with a predetermined pressure.

3. The apparatus according to claim 2, characterized in that, The ore pre-splitting unit also includes side baffles disposed at both ends of the axial direction of the extrusion roller, with the ore drop point located between the two side baffles.

4. The apparatus according to claim 1, characterized in that, The fine powder rinsing unit includes a fine powder rinsing water pipe, the nozzle of which is configured to flow water radially and downwards along the rotary crushing chamber.

5. The apparatus according to claim 1, characterized in that, The rotary crushing chamber is covered by a crushing chamber cover; the crushing chamber cover is equipped with a feed pipe, which delivers the ore to one side of the ore pre-cracking unit through a sloping feeding channel.

6. The apparatus according to claim 1, characterized in that, The flushing and ore discharge unit includes a high-pressure flushing water pipe and an ore discharge pipe; the drain end of the high-pressure flushing water pipe is directly opposite the discharge area of ​​the controllable shock wave crushing unit, and its inlet flow rate is matched with the drainage flow rate of the ore discharge pipe to maintain a constant liquid level in the crushing chamber.

7. The apparatus according to any one of claims 1 to 6, characterized in that, The device also integrates a roller pressure intelligent adjustment system, which is configured to: adjust the real-time roller pressure Pt applied to the ore online according to the real-time detected material layer thickness h and the effective action probability η of the controllable shock wave using the following formula (1): Official (1); Where: P t For real-time roller pressing, MPa; P0 is the initial set roller pressure, MPa; h represents the real-time material layer thickness, in mm; h0 is the initial set thickness of the roller-pressed material layer, in mm; K p This is the material layer thickness correction coefficient, which is related to the properties of the ore raw material such as particle size, hardness, and density, and takes a value of 0.5 to 1.

5. The effective probability adjustment coefficient of the controllable shock wave is related to the properties of the ore such as particle size distribution and electrical conductivity, and its value ranges from 0 to 1. η is the effective probability of a real-time controllable shock wave, % η max This represents the highest probability of a controllable shock wave effectively acting during operation, % η min This represents the lowest probability of a controllable shock wave effectively acting during operation.

8. The apparatus according to claim 1, characterized in that, The extrusion roller surface adopts an arc-shaped groove structure; and / or, the plate electrode adopts a V-shaped structure.

9. The apparatus according to claim 1, characterized in that, The extrusion roller, needle electrode, and plate electrode are all arranged inclined around the circumference of the rotary crushing chamber, and the inclination direction of the three is consistent, forming a pattern where the outer side is low and the middle is high.

10. The apparatus according to claim 1, characterized in that, The device consists of multiple sets integrated into the same rotary crushing chamber, arranged continuously according to the process of feeding—extrusion pre-cracking—fine powder washing—controlled shock wave crushing—washing and ore discharge.

11. A method for efficient crushing of ore using the apparatus as described in any one of claims 1 to 10, characterized in that, Includes the following steps: S1. After coarse and medium crushing, the ore raw material is quantitatively and continuously fed into the extrusion roller feed end of the rotary crushing chamber through the feed pipe. S2. The ore rotates with the rotary crushing chamber and is pre-cracked by the extrusion rollers, forming micro-cracks inside and on the surface of the particles. This process is completed in water to ensure that the cracks are filled with water. S3. The pre-cracked ore then enters the fine powder washing zone, where high-speed water flow separates and removes the fine powder generated in advance. S4. The washed ore enters the controllable shock wave crushing zone. The high-voltage pulse current discharges between the needle plate electrodes to generate shock waves. The shock waves propagate along the internal cracks and mineral interfaces of the ore, forming plasma channels to release energy and achieve selective crushing of the ore. S5. The crushed product is flushed to the central discharge pipe by the high-pressure flushing water flow and discharged for subsequent grading and sorting operations.

12. The method according to claim 11, characterized in that, The pre-splitting process and the controlled shock wave crushing are carried out in the same liquid circuit, and the temperature of the liquid circuit is controlled to not exceed 50°C.

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