A method for reducing steel ball consumption in ball mills through multi-dimensional regulation and synergistic control of raw material silicon control.

Abstract

This invention discloses a method for reducing steel ball consumption in ball mills through multi-dimensional regulation and control of raw material silicon content, including: (1) grading and closed-loop control of silicon content in the raw material fed into the mill, and controlling the proportion of <200 mesh particles in the ball mill output to be 72%~75% throughout the process; (2) calculating the comprehensive SiO2 content of the feed mixture in real time using the DCS control system, and dynamically adjusting the steel ball loading gradation according to the comprehensive SiO2 content of the feed mixture in three levels; (3) dividing the ball mill cylinder along the axial direction into an impact zone at the feed end, a grinding zone in the middle section of the cylinder, and a fine crushing zone at the discharge end, and arranging the ball mill cylinder liner according to the differentiated material selection of the above three zones; (4) equipping the main drive motor of the ball mill with a frequency converter, and connecting the frequency converter signal to the DCS control system to automatically adjust the operating parameters according to the real-time comprehensive SiO2 content; (5) collecting and storing data throughout the process and optimizing periodic parameters. This invention reduces steel ball wear from four dimensions: raw materials, grinding media, equipment lining, and unit operation, resulting in a significant improvement in consumption reduction.

Description

Technical Field

[0001] The present invention relates to the technical field of ball mills, and specifically relates to a method for reducing the consumption of steel balls in ball mills by silicon control and collaborative multi-dimensional regulation of raw materials. Background Art

[0002] The ball mill supporting the pellet production line is a key equipment for crushing iron-containing raw materials. As the core consumable of the mill, the unit consumption of steel balls will directly affect the grinding production cost. With the diversified development of purchased raw materials, the types of raw materials entering the mill are often more than a dozen, and the fluctuation range of the silicon dioxide content in the raw materials is 1% - 18%. Production measurement data shows that for every 1% increase in the ratio of high-silicon hard raw materials with SiO2 > 6%, the unit consumption of steel balls will increase by 0.0125 kg / t. Under the condition of uncontrolled random batching and without changing the technological index that the proportion of the self-grinding material < 200 mesh in the grinding is 72% - 75%, the unit consumption of steel balls remains high.

[0003] Most of the existing energy-saving technologies only optimize the raw material ratio singly, and the energy-saving space is limited. At the same time, the following supporting loss problems generally exist in the industry: 1) The filling gradation of steel balls remains fixed and cannot be adjusted according to the change of the silicon hardness of raw materials. The high-silicon hard materials exacerbate the abnormal wear of small steel balls; 2) The same lining plate material is used throughout the whole section of the mill cylinder. The lining plate in the feeding impact area wears and deforms, causing disordered bouncing and empty collision losses of steel balls; 3) The feeding amount and the cylinder rotation speed of the mill are constant for a long time and cannot be adjusted in real time according to the hardness of the incoming materials. The grinding load of high-silicon materials is relatively large, further accelerating the loss of steel balls. Therefore, how to develop a complete set of energy-saving solutions with integrated linkage of batching control, steel ball selection, lining plate zoning, and mill operation parameters has become a difficult problem that needs to be solved urgently at present. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for reducing the consumption of steel balls in ball mills by silicon control and collaborative multi-dimensional regulation. On the premise of stabilizing the qualified particle size of the grinding powder, the collaborative implementation of four technologies, namely intelligent control of the ratio of high-silicon raw materials, dynamic steel ball gradation, selection of lining plate materials in different zones of the cylinder, and linkage adjustment of the frequency conversion parameters of the mill, is adopted to reduce the wear of steel balls from four dimensions of raw materials, grinding media, equipment lining, and unit operation. The energy-saving amplitude is significantly improved, the production indexes are stable and controllable, the service life of the lining plate is extended synchronously, the cost is reduced and the efficiency is increased, and the production is made intelligent and the data is traceable.

[0005] To solve the above technical problems, the present invention adopts the following technical solutions: A method for reducing the consumption of steel balls in ball mills by silicon control and collaborative multi-dimensional regulation of the present invention is innovative in that it includes: (1) Classification of the silicon content of the raw materials entering the mill and closed-loop control of batching, and全程控制 the proportion of the particle size < 200 mesh in the discharge of the ball mill is 72% - 75%; (2) The DCS control system calculates the comprehensive SiO2 content of the feed mixture in real time and dynamically adjusts the steel ball loading gradation in three levels according to the comprehensive SiO2 content of the feed mixture. (3) The ball mill cylinder is divided into the feed end impact zone, the middle section grinding zone and the discharge end fine crushing zone along the axial direction, and the ball mill cylinder liner is arranged according to the above three zones with differentiated material selection. (4) The main drive motor of the ball mill is equipped with a frequency converter, and the frequency converter signal is connected to the DCS control system to automatically adjust the operating parameters according to the real-time comprehensive SiO2 content; (5) Data collection and storage throughout the entire process and optimization of periodic parameters.

[0006] Preferably, in step (1) above, the classification of silicon content of the raw materials fed into the mill is specifically as follows: the SiO2 content of the raw materials fed into the mill is sampled and tested in batches, and the raw materials fed into the mill are divided into two categories according to the test results, namely, the raw materials fed into the mill with SiO2 content ≤ 6% are classified as low silicon raw materials, and the raw materials fed into the mill with SiO2 content > 6% are classified as high silicon raw materials. Then, the silicon content data of each raw material fed into the mill are entered into the DCS control system to establish a raw material database.

[0007] Preferably, in step (1) above, the closed-loop control of the batching and the control of the proportion of <200 mesh particles in the ball mill output are 72%~75%, specifically: (1.1) The DCS control system has a built-in loss correlation model. The benchmark of this loss correlation model is that for every 1% increase or decrease in the proportion of high silicon raw materials, the steel ball consumption increases or decreases by 0.0125 kg / t. Then, combined with the target consumption reduction index, the upper limit of the high silicon raw material blending in the whole mixture is locked. (1.2) Each batching belt is equipped with a frequency conversion feeding device. The DCS control system outputs a 4-20mA standard current signal and adjusts the feeding amount of the corresponding batching belt in real time based on the PID algorithm. The instantaneous batching ratio is calculated in real time. If the ratio of high silicon raw materials exceeds the limit, the DCS control system will issue an audible and visual alarm and automatically reduce the feeding amount of high silicon raw materials and supplement the feeding amount of low silicon raw materials to bring the ratio back to the control range. (1.3) The ball mill discharge end is equipped with an online particle size analyzer for real-time detection of the powder ratio. If the proportion of <200 mesh particles is 72% to 75%, the existing batching ratio is maintained. If the proportion of <200 mesh particles is <72%, the proportion of low-silicon raw materials is increased. If the proportion of <200 mesh particles is >75%, the proportion of high-silicon raw materials is slightly increased within the upper limit of the ratio.

[0008] Preferably, in step (2) above, the steel balls include large balls of φ90~100mm, medium balls of φ60~70mm, and small balls of φ30~40mm, and the steel ball loading gradation is dynamically adjusted in three grades according to the comprehensive SiO2 content of the mixture entering the mill as follows: (2.1) When the SiO2 content is ≤6%, it is determined to be a low-silicon, easily grindable working condition. At this time, the ratio of large balls, medium balls and small balls should be adjusted to 3:5:2. (2.2) When the total SiO2 content is 6% < ≤ 10%, it is determined to be a medium silicon working condition. At this time, the proportion of large balls is increased, and the ratio of large balls, medium balls and small balls is adjusted to 4:4:2. (2.3) When the total SiO2 content is >10%, it is determined to be a high-silicon, difficult-to-grind working condition. At this time, the ratio of large balls, medium balls and small balls is adjusted to 5:3:2, and the excessive wear of small balls by hard ore is reduced by significantly increasing the proportion of large balls. (2.4) Summarize the average silicon content of raw materials on a monthly basis, and adjust the ball filling specifications and ball filling quantity in a unified manner to avoid gradation imbalance caused by fixed ball filling.

[0009] Preferably, in step (3) above, the ball mill cylinder liner is arranged according to the differentiated material selection of the above three zones as follows: (3.1) High-chromium alloy wear-resistant liner plates are selected for the impact zone at the feed end; (3.2) Medium manganese steel lining plates are selected for the grinding zone in the middle section of the cylinder; (3.3) Ordinary high manganese steel lining plates are used in the fine crushing zone at the discharge end.

[0010] Preferably, in step (4) above, the automatic adjustment of operating parameters based on real-time comprehensive SiO2 content specifically refers to: (4.1) When the overall SiO2 content is >8%, it is determined that the proportion of high silicon raw materials is too high. At this time, the operating speed of the ball mill should be reduced by 3% to 5%, and the feed rate of a single ball mill should be reduced by 4% to 6% accordingly. (4.2) When the overall SiO2 content is ≤6%, it is judged as a low-silicon, easily grindable condition. At this time, the operating speed and feed rate of the ball mill should be appropriately increased to achieve full-load and high-efficiency production. (4.3) Based on the measured results of 72%~75% of the output particles <200 mesh, the ball mill operating speed and feed rate are adjusted in real time to form a closed-loop control of silicon content, batching, ball mill parameters and finished particle size.

[0011] Preferably, in step (5) above, the data collection, storage and periodic parameter optimization of the whole process are as follows: the DCS control system uniformly collects and stores all data such as raw material silicon content, high silicon raw material ratio, steel ball gradation ledger, liner replacement record, ball mill operating speed and feed rate, and daily steel ball consumption, and the data retention period is not less than 1 year; the upper limit of high silicon raw material blending, steel ball ratio and ball mill operating benchmark parameters are optimized monthly based on historical production data to adapt to the seasonal fluctuations of raw material composition entering the plant.

[0012] The beneficial effects of this invention are as follows: Under the premise of stabilizing the qualified particle size of grinding powder, this invention adopts the coordinated implementation of four technologies: intelligent control of high silicon raw material ratio, dynamic steel ball gradation, zoned material selection of cylinder liner, and linkage adjustment of mill frequency conversion parameters. This reduces steel ball wear from four dimensions: raw materials, grinding media, equipment liner, and unit operation, significantly improving the energy consumption reduction, making production indicators stable and controllable, extending the service life of the liner, reducing costs and increasing efficiency, and making production intelligent and data traceable. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] Figure 1 This is a schematic diagram of the principle of a method for reducing steel ball consumption in a ball mill by coordinating raw material silicon control with multi-dimensional regulation according to the present invention. Detailed Implementation

[0015] The technical solution of the present invention will be clearly and completely described below through specific embodiments.

[0016] This invention provides a method for reducing steel ball consumption in ball mills through multi-dimensional regulation and synergistic control of raw material silicon, such as... Figure 1 As shown, it includes: (1) Grading and closed-loop control of silicon content in raw materials fed into the mill, and controlling the proportion of <200 mesh particles in the ball mill output to be 72%~75% throughout the process.

[0017] The specific method for classifying the silicon content of the feed material in this invention is as follows: the SiO2 content of the feed material is sampled and tested batch by batch, and the feed material is divided into two categories according to the test results: feed material with SiO2 content ≤ 6% is classified as low silicon feed material, and feed material with SiO2 content > 6% is classified as high silicon feed material. Then, the silicon content data of each feed material is entered into the DCS control system to establish a raw material database.

[0018] This invention implements closed-loop control of ingredient proportioning and maintains throughout the entire process that the proportion of particles <200 mesh in the ball mill output is 72%~75%, specifically: (1.1) The DCS control system has a built-in loss correlation model. The benchmark of this loss correlation model is that for every 1% increase or decrease in the proportion of high silicon raw materials, the steel ball consumption increases or decreases by 0.0125 kg / t. Then, combined with the target consumption reduction index, the upper limit of the high silicon raw material blending in the whole mixture is locked. (1.2) Each batching belt is equipped with a frequency conversion feeding device. The DCS control system outputs a 4-20mA standard current signal and adjusts the feeding amount of the corresponding batching belt in real time based on the PID algorithm. The instantaneous batching ratio is calculated in real time. If the ratio of high silicon raw materials exceeds the limit, the DCS control system will issue an audible and visual alarm and automatically reduce the feeding amount of high silicon raw materials and supplement the feeding amount of low silicon raw materials to bring the ratio back to the control range. (1.3) The ball mill discharge end is equipped with an online particle size analyzer for real-time detection of the powder ratio. If the proportion of <200 mesh particles is 72% to 75%, the existing batching ratio is maintained. If the proportion of <200 mesh particles is <72%, the proportion of low-silicon raw materials is increased. If the proportion of <200 mesh particles is >75%, the proportion of high-silicon raw materials is slightly increased within the upper limit of the ratio.

[0019] (2) The DCS control system calculates the total SiO2 content of the feed mixture in real time and dynamically adjusts the steel ball loading gradation in three levels according to the total SiO2 content of the feed mixture.

[0020] The steel balls of this invention include large balls with a diameter of 90-100mm, medium balls with a diameter of 60-70mm, and small balls with a diameter of 30-40mm. The steel ball packing gradation is dynamically adjusted in three levels according to the overall SiO2 content of the mixture entering the mill. Specifically: (2.1) When the SiO2 content is ≤6%, it is determined to be a low-silicon, easily grindable working condition. At this time, the ratio of large balls, medium balls and small balls should be adjusted to 3:5:2. (2.2) When the total SiO2 content is 6% < ≤ 10%, it is determined to be a medium silicon working condition. At this time, the proportion of large balls is increased, and the ratio of large balls, medium balls and small balls is adjusted to 4:4:2. In this way, the large balls strengthen the impact crushing of the ore and reduce the grinding load of the small balls. (2.3) When the total SiO2 content is >10%, it is determined to be a high-silicon, difficult-to-grind working condition. At this time, the ratio of large balls, medium balls and small balls is adjusted to 5:3:2, and the excessive wear of small balls by hard ore is reduced by significantly increasing the proportion of large balls. (2.4) Summarize the average silicon content of raw materials on a monthly basis, and adjust the ball filling specifications and ball filling quantity in a unified manner to avoid gradation imbalance caused by fixed ball filling.

[0021] (3) The ball mill cylinder is divided into the feed end impact zone, the middle section grinding zone and the discharge end fine crushing zone along the axial direction, and the ball mill cylinder liner is arranged according to the above three zones with differentiated material selection.

[0022] The ball mill cylinder liner of this invention is arranged according to the differentiated material selection in the above three zones as follows: (3.1) The impact zone at the feed end is made of high chromium alloy wear-resistant liner to resist the strong impact of high silicon ore, delay the deformation of the liner, and prevent the steel ball from bouncing and grinding randomly. (3.2) Medium manganese steel liner is selected for the grinding zone in the middle section of the cylinder to reduce the wear and tear of steel balls caused by the sliding friction of materials; (3.3) Ordinary high manganese steel lining plates are selected for the fine crushing zone at the discharge end to ensure the basic wear resistance while controlling procurement costs.

[0023] (4) The main drive motor of the ball mill is equipped with a frequency converter. The frequency converter signal is connected to the DCS control system and the operating parameters are automatically adjusted according to the real-time comprehensive SiO2 content.

[0024] The present invention automatically adjusts operating parameters based on real-time comprehensive SiO2 content as follows: (4.1) When the SiO2 content is greater than 8%, it is determined that the proportion of high silicon raw materials is too high. At this time, the operating speed of the ball mill is reduced by 3% to 5%, and the feed rate of a single ball mill is reduced by 4% to 6% to extend the crushing time of hard ore and reduce the instantaneous impact load of steel balls. (4.2) When the overall SiO2 content is ≤6%, it is judged as a low-silicon, easily grindable condition. At this time, the operating speed and feed rate of the ball mill should be appropriately increased to achieve full-load and high-efficiency production. (4.3) Based on the measured results of 72%~75% of the output particles <200 mesh, the ball mill operating speed and feed rate are adjusted in real time to form a closed-loop control of silicon content, batching, ball mill parameters and finished particle size.

[0025] (5) Data collection and storage throughout the entire process and optimization of periodic parameters.

[0026] The entire process of data collection, storage, and periodic parameter optimization in this invention is as follows: The DCS control system uniformly collects and stores all data, including raw material silicon content, high-silicon raw material ratio, steel ball gradation ledger, liner replacement records, ball mill operating speed and feed rate, and daily steel ball consumption. The data retention period is no less than one year. Each month, based on historical production data, the upper limit of high-silicon raw material blending, steel ball ratio, and ball mill operating benchmark parameters are optimized to adapt to seasonal fluctuations in the composition of incoming raw materials.

[0027] The beneficial effects of this invention are as follows: Under the premise of stabilizing the qualified particle size of grinding powder, this invention adopts the coordinated implementation of four technologies: intelligent control of high silicon raw material ratio, dynamic steel ball gradation, zoned material selection of cylinder liner, and linkage adjustment of mill frequency conversion parameters. This reduces steel ball wear from four dimensions: raw materials, grinding media, equipment liner, and unit operation, significantly improving the energy consumption reduction, making production indicators stable and controllable, extending the service life of the liner, reducing costs and increasing efficiency, and making production intelligent and data traceable.

[0028] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the concept and scope of the present invention. Without departing from the design concept of the present invention, all modifications and improvements made by those skilled in the art to the technical solutions of the present invention should fall within the protection scope of the present invention. The technical content for which protection is sought in the present invention has been fully described in the technical requirements.

Claims

1. A method for reducing steel ball consumption in a ball mill through multi-dimensional regulation and synergistic control of raw material silicon, characterized in that, include: (1) Grading and closed-loop control of silicon content in raw materials fed into the mill, and controlling the proportion of <200 mesh particles in the ball mill output to be 72%~75% throughout the process; (2) The DCS control system calculates the comprehensive SiO2 content of the feed mixture in real time and dynamically adjusts the steel ball loading gradation in three levels according to the comprehensive SiO2 content of the feed mixture. (3) The ball mill cylinder is divided into the feed end impact zone, the middle section grinding zone and the discharge end fine crushing zone along the axial direction, and the ball mill cylinder liner is arranged according to the above three zones with differentiated material selection. (4) The main drive motor of the ball mill is equipped with a frequency converter, and the frequency converter signal is connected to the DCS control system to automatically adjust the operating parameters according to the real-time comprehensive SiO2 content; (5) Data collection and storage throughout the entire process and optimization of periodic parameters.

2. The method for reducing steel ball consumption in a ball mill by coordinating raw material silicon control with multi-dimensional regulation according to claim 1, characterized in that: In step (1) above, the classification of silicon content of the raw materials fed into the mill is specifically as follows: the SiO2 content of the raw materials fed into the mill is sampled and tested in batches, and the raw materials fed into the mill are divided into two categories according to the test results. That is, the raw materials fed into the mill with SiO2 content ≤ 6% are classified as low silicon raw materials, and the raw materials fed into the mill with SiO2 content > 6% are classified as high silicon raw materials. Then, the silicon content data of each raw material fed into the mill are entered into the DCS control system to establish a raw material database.

3. The method for reducing steel ball consumption in a ball mill by coordinating raw material silicon control with multi-dimensional regulation according to claim 2, characterized in that: In step (1) above, the closed-loop control of the batching and the control of the proportion of <200 mesh particles in the ball mill output at 72%~75% are specifically as follows: (1.1) The DCS control system has a built-in loss correlation model. The benchmark of this loss correlation model is that for every 1% increase or decrease in the proportion of high silicon raw materials, the steel ball consumption increases or decreases by 0.0125 kg / t. Then, combined with the target consumption reduction index, the upper limit of the high silicon raw material blending in the whole mixture is locked. (1.2) Each batching belt is equipped with a frequency conversion feeding device. The DCS control system outputs a 4-20mA standard current signal and adjusts the feeding amount of the corresponding batching belt in real time based on the PID algorithm. The instantaneous batching ratio is calculated in real time. If the ratio of high silicon raw materials exceeds the limit, the DCS control system will issue an audible and visual alarm and automatically reduce the feeding amount of high silicon raw materials and supplement the feeding amount of low silicon raw materials to bring the ratio back to the control range. (1.3) The ball mill discharge end is equipped with an online particle size analyzer for real-time detection of the powder ratio. If the proportion of <200 mesh particles is 72% to 75%, the existing batching ratio is maintained. If the proportion of <200 mesh particles is <72%, the proportion of low-silicon raw materials is increased. If the proportion of <200 mesh particles is >75%, the proportion of high-silicon raw materials is slightly increased within the upper limit of the ratio.

4. The method for reducing steel ball consumption in a ball mill by coordinating raw material silicon control with multi-dimensional regulation according to claim 1, characterized in that: In step (2) above, the steel balls include large balls of φ90~100mm, medium balls of φ60~70mm, and small balls of φ30~40mm. The specific details of dynamically adjusting the steel ball loading gradation according to the comprehensive SiO2 content of the mixture entering the mill are as follows: (2.1) When the SiO2 content is ≤6%, it is determined to be a low-silicon, easily grindable working condition. At this time, the ratio of large balls, medium balls and small balls should be adjusted to 3:5:

2. (2.2) When the total SiO2 content is 6% < ≤ 10%, it is determined to be a medium silicon working condition. At this time, the proportion of large balls is increased, and the ratio of large balls, medium balls and small balls is adjusted to 4:4:

2. (2.3) When the total SiO2 content is >10%, it is determined to be a high-silicon, difficult-to-grind working condition. At this time, the ratio of large balls, medium balls and small balls is adjusted to 5:3:2, and the excessive wear of small balls by hard ore is reduced by significantly increasing the proportion of large balls. (2.4) Summarize the average silicon content of raw materials on a monthly basis, and adjust the ball filling specifications and ball filling quantity in a unified manner to avoid gradation imbalance caused by fixed ball filling.

5. The method for reducing steel ball consumption in a ball mill by coordinating raw material silicon control with multi-dimensional regulation according to claim 1, characterized in that: In step (3) above, the ball mill cylinder liner is arranged according to the differentiated material selection of the above three zones as follows: (3.1) High-chromium alloy wear-resistant liner plates are selected for the impact zone at the feed end; (3.2) Medium manganese steel lining plates are selected for the grinding zone in the middle section of the cylinder; (3.3) Ordinary high manganese steel lining plates are used in the fine crushing zone at the discharge end.

6. The method for reducing steel ball consumption in a ball mill by coordinating raw material silicon control with multi-dimensional regulation according to claim 1, characterized in that: In step (4) above, the automatic adjustment of operating parameters based on real-time comprehensive SiO2 content specifically refers to: (4.1) When the overall SiO2 content is >8%, it is determined that the proportion of high silicon raw materials is too high. At this time, the operating speed of the ball mill should be reduced by 3% to 5%, and the feed rate of a single ball mill should be reduced by 4% to 6% accordingly. (4.2) When the overall SiO2 content is ≤6%, it is judged as a low-silicon, easily grindable condition. At this time, the operating speed and feed rate of the ball mill should be appropriately increased to achieve full-load and high-efficiency production. (4.3) Based on the measured results of 72%~75% of the output particles <200 mesh, the ball mill operating speed and feed rate are adjusted in real time to form a closed-loop control of silicon content, batching, ball mill parameters and finished particle size.

7. The method for reducing steel ball consumption in a ball mill by coordinating raw material silicon control with multi-dimensional regulation according to claim 1, characterized in that: In step (5) above, the data collection, storage and periodic parameter optimization of the whole process are as follows: the DCS control system uniformly collects and stores all data such as raw material silicon content, high silicon raw material ratio, steel ball gradation ledger, liner replacement record, ball mill operating speed and feed rate, and daily steel ball consumption, and the data retention period is not less than 1 year; the upper limit of high silicon raw material blending, steel ball ratio and ball mill operating benchmark parameters are optimized monthly based on historical production data to adapt to the seasonal fluctuations of raw material composition entering the plant.

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