An energy-saving process optimization method using mixed ceramic balls and steel balls as grinding media

Abstract

The application discloses an energy-saving process optimization method using ceramic balls and steel balls as mixed grinding media, comprising: determining the medium ratio and process parameters: the grinding media uses mixed media of ceramic balls and steel balls, wherein the filling rate of the ceramic balls accounts for 29-32% of the total filling rate, the filling rate of the steel balls accounts for 3-6% of the total filling rate, the grinding concentration is controlled to be 65-70%, the mill processing capacity is controlled to be within a target range, and the grinding time is ensured to meet the requirement of grinding the feed ore to the target fineness of the discharge ore; equipment modification; mill ball loading and production operation; monitoring and optimization: according to the production data, the medium ratio, filling rate and grinding concentration are optimized and adjusted to realize the lowest power consumption and ball consumption under the requirement of meeting the product fineness. Through reasonable ratio and process parameter optimization, the application not only improves the grinding efficiency, but also significantly reduces the energy consumption and the occurrence of over-grinding.

Description

Technical Field

[0001] This invention belongs to the field of mineral processing technology, and in particular relates to an energy-saving process optimization method that uses a mixture of ceramic balls and steel balls as grinding media. Background Technology

[0002] In iron ore beneficiation, grinding is one of the most energy-intensive processes, accounting for a large proportion of the total beneficiation cost in terms of electricity and grinding media consumption. Traditional grinding media commonly use steel balls, which, while providing strong crushing force, have high density, wear quickly, consume a lot of electricity, and are prone to over-grinding. In recent years, ceramic balls, due to their low density, high hardness, and good wear resistance, have begun to be used in fine grinding operations to reduce mill load and grinding media consumption.

[0003] However, in the two-stage grinding process, where the feed particle size is relatively coarse and both impact crushing and grinding refinement need to be considered, simply using ceramic balls may affect the crushing efficiency of coarse particles due to insufficient impact force; while simply using steel balls results in high energy consumption, relatively poor fine grinding effect, and a tendency to over-grind.

[0004] Therefore, we propose an energy-saving process optimization method that uses a mixture of ceramic balls and steel balls as grinding media. Summary of the Invention

[0005] The present invention mainly addresses the technical problems existing in the prior art. The purpose of the present invention is to provide an energy-saving process optimization method that uses a mixture of ceramic balls and steel balls as grinding media.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] This invention provides an energy-saving process optimization method using a mixture of ceramic balls and steel balls as grinding media, specifically comprising the following steps:

[0008] Step 1: Determine the media ratio and process parameters: The grinding media is a mixture of ceramic balls and steel balls, with the ceramic balls accounting for 29%-32% of the total filling rate and the steel balls accounting for 3%-6% of the total filling rate. The grinding concentration is controlled at 65%-70%, and the mill throughput is controlled within the target range to ensure that the grinding time meets the requirements of grinding the feed to the target fineness of the discharge.

[0009] Step 2: Equipment modification: Install a grate or fence at the discharge end of the ball mill to prevent the lightest ceramic balls from being discharged excessively with the slurry. Seal the feed bend of the ball mill by using a packing seal or rubber seal. Adapt the cylindrical screen that is matched with the ball mill to suit the characteristics of the ceramic balls.

[0010] Step 3: Ball mill loading and production operation: Install a grate or fence at the discharge end of the ball mill to prevent the lightest ceramic balls from being discharged excessively with the slurry. Seal the feed bend of the ball mill using packing seals or rubber seals. Adapt the cylindrical screen that is matched with the ball mill to suit the characteristics of the ceramic balls.

[0011] Step 4: Monitoring and Optimization: The system monitors the mill feed particle size, discharge particle size, hydrocyclone overflow particle size, grinding concentration, mill current, concentrate grade and throughput. It also replenishes media daily and records the type, weight and power consumption of replenished balls periodically. Based on the production data, the media ratio, filling rate and grinding concentration are optimized and adjusted to achieve the lowest power consumption and ball consumption while meeting the product fineness requirements.

[0012] Furthermore, the ceramic balls in the first step are a mixed grade of multiple ball diameters, including three specifications: Φ35mm, Φ30mm, and Φ25mm.

[0013] Furthermore, the preferred gradation weight ratio is Φ35mm:Φ30mm:Φ25mm = 1:3:6.

[0014] Furthermore, the diameter of the steel ball in the first step is Φ30mm.

[0015] Furthermore, the daily replenishment of media in the fourth step is as follows: 200-400 kg of Φ35mm ceramic balls and 100-200 kg of Φ30mm steel balls are added daily.

[0016] Furthermore, 400 kg of Φ35mm ceramic balls and 100 kg of Φ30mm steel balls are added daily.

[0017] Furthermore, 300 kg of Φ35mm ceramic balls and 150 kg of Φ30mm steel balls are added daily.

[0018] Furthermore, 250 kg of Φ35mm ceramic balls and 150 kg of Φ30mm steel balls are added daily.

[0019] Furthermore, 200 kg of Φ35mm ceramic balls and 200 kg of Φ30mm steel balls are added daily.

[0020] Compared with the prior art, the beneficial technical effects of the present invention are as follows:

[0021] 1. This energy-saving process optimization method uses a mixture of ceramic balls and steel balls as grinding media. By using a mixture of ceramic balls and steel balls as grinding media, the advantages of the two media can be effectively combined. Ceramic balls have low density and good wear resistance, which can reduce mill load and media consumption, while steel balls have strong impact crushing ability and are suitable for processing coarser particles. Through reasonable ratio and process parameter optimization, not only is grinding efficiency improved, but energy consumption and over-grinding phenomenon are also significantly reduced.

[0022] 2. This energy-saving process optimization method, which uses a mixture of ceramic balls and steel balls as grinding media, further enhances the stability and adaptability of the system through equipment modification measures, ensuring that the ceramic balls play a full role in the grinding process.

[0023] 3. This energy-saving process optimization method, which uses a mixture of ceramic balls and steel balls as grinding media, achieves dynamic adjustment of media ratio, filling rate and grinding concentration through continuous monitoring and analysis of production data, thereby maximizing the saving of energy and material costs while ensuring product quality. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings.

[0025] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Example 1:

[0028] An energy-saving process optimization method using a mixture of ceramic and steel balls as grinding media, such as... Figure 1As shown, it specifically includes the following steps: Step 1: Determine the medium proportioning and process parameters: the grinding medium adopts a mixed medium of ceramic balls and steel balls, wherein the filling rate of ceramic balls accounts for 29% of the total filling rate, and the filling rate of steel balls accounts for 6% of the total filling rate; the grinding concentration is controlled at 65%, the processing capacity of the mill is controlled within the target range, so as to ensure that the grinding time meets the requirement of grinding the feed to the target fineness of the discharge; Step 2: Equipment modification: a grate plate or a fence is additionally installed at the discharge end of the ball mill to prevent the low-density ceramic balls from being excessively discharged along with the ore pulp; the feed elbow of the ball mill is sealed with packing seal or rubber seal; the cylindrical screen matched with the ball mill is adaptively modified to adapt to the characteristics of ceramic balls; Step 3: Ball charging and production operation of the mill: a grate plate or a fence is additionally installed at the discharge end of the ball mill to prevent the low-density ceramic balls from being excessively discharged along with the ore pulp; the feed elbow of the ball mill is sealed with packing seal or rubber seal; the cylindrical screen matched with the ball mill is adaptively modified to adapt to the characteristics of ceramic balls; Step 4: Monitoring and optimization: the system monitors the feed particle size, discharge particle size, cyclone overflow particle size, grinding concentration, mill current, concentrate grade and processing capacity of the mill; the medium is replenished daily, the type, weight and power consumption data of the replenished balls are recorded regularly; the medium proportioning, filling rate and grinding concentration are optimized and adjusted according to the production data, so as to achieve the lowest power consumption and medium consumption under the condition of meeting the product fineness requirement. The ceramic balls in Step 1 are mixed grading with multiple ball diameters, including three specifications of Φ35mm, Φ30mm and Φ25mm, and the weight ratio of the preferred grading is Φ35mm:Φ30mm:Φ25mm = 1:3:6. The diameter of the steel balls in Step 1 is Φ30mm. The daily medium replenishment system in Step 4 is: 200kg of Φ35mm ceramic balls and 200kg of Φ30mm steel balls are replenished every day. By adopting the mixture of ceramic balls and steel balls as the grinding medium, the advantages of the two media can be effectively combined. Ceramic balls have low density and good wear resistance, which can reduce the mill load and medium consumption, while steel balls have strong impact crushing capacity and are suitable for processing coarser particles. Through reasonable proportioning and process parameter optimization, the grinding efficiency is improved, and the energy consumption and the occurrence of over-grinding are also significantly reduced.

[0029] Example 2:

[0030] An energy-saving process optimization method adopting mixture of ceramic balls and steel balls as grinding medium, as Figure 1As shown, it specifically includes the following steps: Step 1: Determine the medium ratio and process parameters: the grinding medium adopts a mixed medium of ceramic balls and steel balls, wherein the filling rate of ceramic balls accounts for 30% of the total filling rate, and the filling rate of steel balls accounts for 5% of the total filling rate. The grinding concentration is controlled at 65%, the processing capacity of the mill is controlled within the target range, so as to ensure that the grinding time meets the requirement of grinding the feed to the target fineness of the discharge; Step 2: Equipment modification: a grate plate or a grid fence is additionally installed at the discharge end of the ball mill to prevent ceramic balls with lower density from being excessively discharged along with the ore slurry. The inlet elbow of the ball mill is sealed, and packing seal or rubber seal is adopted. The cylindrical screen matched with the ball mill is modified adaptively to adapt to the characteristics of ceramic balls; Step 3: Ball charging and production operation of the mill: a grate plate or a grid fence is additionally installed at the discharge end of the ball mill to prevent ceramic balls with lower density from being excessively discharged along with the ore slurry. The inlet elbow of the ball mill is sealed, and packing seal or rubber seal is adopted. The cylindrical screen matched with the ball mill is modified adaptively to adapt to the characteristics of ceramic balls; Step 4: Monitoring and optimization: the system monitors the feed particle size, discharge particle size, cyclone overflow particle size, grinding concentration, mill current, concentrate grade and processing capacity of the mill, replenishes the medium daily, regularly records the type, weight and power consumption data of the replenished balls, and optimizes and adjusts the medium ratio, filling rate and grinding concentration according to the production data, so as to achieve the lowest power consumption and ball consumption while meeting the product fineness requirements. The ceramic balls in Step 1 have a mixed gradation of multiple ball diameters, including three specifications of Φ35mm, Φ30mm and Φ25mm, and the weight ratio of the preferred gradation is Φ35mm:Φ30mm:Φ25mm = 1:3:6. The diameter of the steel balls in Step 1 is Φ30mm. The daily medium replenishment system in Step 4 is: 250kg of Φ35mm ceramic balls are replenished daily, and 150kg of Φ30mm steel balls are replenished. The stability and adaptability of the system are further enhanced through equipment modification measures, so as to ensure that ceramic balls can fully play their role in the grinding process.

[0031] Example 3:

[0032] An energy-saving process optimization method using a mixture of ceramic balls and steel balls as grinding medium, as Figure 1As shown, it specifically includes the following steps: Step 1: Determine medium ratio and process parameters: the grinding medium is a mixed medium of ceramic balls and steel balls, wherein the filling rate of ceramic balls accounts for 31% of the total filling rate, and the filling rate of steel balls accounts for 6% of the total filling rate; the grinding concentration is controlled to be 65% to 70%, the processing capacity of the mill is controlled within the target range, and the grinding time is ensured to meet the requirement of grinding the feed to the target fineness of the discharge; Step 2: Equipment modification: a grate plate or a fence is additionally installed at the discharge end of the ball mill to prevent excessive discharge of low-density ceramic balls along with the slurry; the inlet bend of the ball mill is sealed by packing seal or rubber seal; the cylindrical screen matched with the ball mill is modified adaptively to adapt to the characteristics of ceramic balls; Step 3: Mill ball charging and production operation: a grate plate or a fence is additionally installed at the discharge end of the ball mill to prevent excessive discharge of low-density ceramic balls along with the slurry; the inlet bend of the ball mill is sealed by packing seal or rubber seal; the cylindrical screen matched with the ball mill is modified adaptively to adapt to the characteristics of ceramic balls; Step 4: Monitoring and optimization: systemically monitor the feed particle size, discharge particle size, cyclone overflow particle size, grinding concentration, mill current, concentrate grade and processing capacity of the mill, replenish the medium daily, regularly record the type, weight and power consumption data of the replenished balls, and optimize and adjust the medium ratio, filling rate and grinding concentration according to production data, so as to achieve the minimum power consumption and ball consumption while meeting the product fineness requirements. The ceramic balls in Step 1 are mixed gradation of various ball diameters, including three specifications of Φ35mm, Φ30mm and Φ25mm, and the weight ratio of the preferred gradation is Φ35mm:Φ30mm:Φ25mm = 1:3:6. The diameter of the steel balls in Step 1 is Φ30mm. The daily medium replenishment system in Step 4 is: 250kg of Φ35mm ceramic balls and 150kg of Φ30mm steel balls are replenished every day. Through continuous monitoring and analysis of production data, dynamic adjustment of medium ratio, filling rate and grinding concentration is realized, so that energy and material costs are saved to the maximum extent on the premise of ensuring product quality.

[0033] Example 4: An energy-saving process optimization method using a mixture of ceramic balls and steel balls as grinding medium, as Figure 1As shown, it specifically includes the following steps: Step 1: Determine medium ratio and process parameters: the grinding medium adopts a mixed medium of ceramic balls and steel balls, wherein the filling rate of ceramic balls accounts for 31% of the total filling rate, and the filling rate of steel balls accounts for 4% of the total filling rate; the grinding concentration is controlled to 65%, the processing capacity of the mill is controlled within the target range, and it is ensured that the grinding time meets the requirement of grinding the feed to the target fineness of the discharge; Step 2: Equipment transformation: a grate plate or grid is additionally installed at the discharge end of the ball mill to prevent ceramic balls with lower density from being excessively discharged along with the ore slurry; the feed elbow of the ball mill is subjected to sealing treatment, adopting packing seal or rubber seal; the cylindrical screen matched with the ball mill is subjected to adaptive transformation to adapt to the characteristics of ceramic balls; Step 3: Mill ball charging and production operation: a grate plate or grid is additionally installed at the discharge end of the ball mill to prevent ceramic balls with lower density from being excessively discharged along with the ore slurry; the feed elbow of the ball mill is subjected to sealing treatment, adopting packing seal or rubber seal; the cylindrical screen matched with the ball mill is subjected to adaptive transformation to adapt to the characteristics of ceramic balls; Step 4: Monitoring and optimization: the system monitors the feed particle size, discharge particle size, cyclone overflow particle size, grinding concentration, mill current, concentrate grade and processing capacity of the mill; the medium is supplemented daily, the type, weight and power consumption data of supplemented balls are recorded regularly; the medium ratio, filling rate and grinding concentration are optimized and adjusted according to production data, so as to achieve the lowest power consumption and ball consumption while meeting the product fineness requirements. The ceramic balls in Step 1 are mixed gradation with various ball diameters, including three specifications of Φ35mm, Φ30mm and Φ25mm, and the weight ratio of the preferred gradation is Φ35mm:Φ30mm:Φ25mm = 1:3:6. The ball diameter of the steel balls in Step 1 is Φ30mm. The daily medium supplementation system in Step 4 is: 300kg of Φ35mm ceramic balls are supplemented daily, and 150kg of Φ30mm steel balls are supplemented daily.

[0034] Example 5: An energy-saving process optimization method using a mixture of ceramic balls and steel balls as grinding medium, as Figure 1As shown, it specifically includes the following steps: Step 1: Determine the medium ratio and process parameters: The grinding medium adopts a mixed medium of ceramic balls and steel balls, wherein the filling rate of ceramic balls accounts for 32% of the total filling rate, and the filling rate of steel balls accounts for 3% of the total filling rate. The grinding concentration is controlled at 65%, the throughput of the mill is controlled within the target range, and the grinding time is ensured to meet the requirement of grinding the feed to the target fineness of the discharge; Step 2: Equipment modification: A grate plate or a grid fence is additionally installed at the discharge end of the ball mill to prevent the low-density ceramic balls from being excessively discharged along with the ore slurry. The feeding bent pipe of the ball mill is subjected to sealing treatment, adopting packing sealing or rubber sealing. The cylindrical screen matched with the ball mill is modified adaptively to adapt to the characteristics of ceramic balls; Step 3: Ball loading and production operation of the mill: A grate plate or a grid fence is additionally installed at the discharge end of the ball mill to prevent the low-density ceramic balls from being excessively discharged along with the ore slurry. The feeding bent pipe of the ball mill is subjected to sealing treatment, adopting packing sealing or rubber sealing. The cylindrical screen matched with the ball mill is modified adaptively to adapt to the characteristics of ceramic balls; Step 4: Monitoring and optimization: The system monitors the feed particle size, discharge particle size, cyclone overflow particle size, grinding concentration, mill current, concentrate grade and processing capacity of the mill, adds medium regularly in daily production, records the type, weight and power consumption data of supplementary balls periodically, and optimizes and adjusts the medium ratio, filling rate and grinding concentration according to production data, so as to achieve the minimum power consumption and ball consumption under the condition of meeting the product fineness requirement. The ceramic balls in Step 1 have a mixed gradation of multiple ball diameters, including three specifications of Φ35mm, Φ30mm and Φ25mm, and the weight ratio of the preferred gradation is Φ35mm:Φ30mm:Φ25mm = 1:3:6. The diameter of the steel balls in Step 1 is Φ30mm. The daily medium supplement system in Step 4 is: 400kg of Φ35mm ceramic balls and 100kg of Φ30mm steel balls are supplemented every day.

[0035] Working principle of the present invention: By adopting a mixture of ceramic balls and steel balls as the grinding medium, combined with reasonable filling rate and process parameter control, the grinding efficiency can be effectively improved and energy consumption can be reduced. Ceramic balls have high wear resistance and low density, which can reduce the wear of equipment while ensuring the grinding effect, while steel balls play an important role in the coarse grinding stage by virtue of their high density. The mixed use of the two not only optimizes the energy distribution in the grinding process, but also significantly reduces the cost of medium consumption. In addition, through the modification of key parts of the ball mill, such as additionally installing grate plates, sealing the feeding bent pipe and improving the cylindrical screen, the characteristics of ceramic balls are further adapted, and production problems caused by medium loss or equipment mismatch are avoided. The systematic monitoring and optimization mechanism ensures that the process parameters are always in the optimal state, thereby achieving the goals of stable product quality and minimum energy consumption. This method shows good economy and environmental protection in practical application, and provides a practical and feasible technical solution for relevant industries.

[0036] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. An energy-saving process optimization method using a mixture of ceramic balls and steel balls as grinding media, characterized in that, Specifically, the following steps are included: Step 1: Determine the media ratio and process parameters: The grinding media is a mixture of ceramic balls and steel balls, with the ceramic balls accounting for 29%-32% of the total filling rate and the steel balls accounting for 3%-6% of the total filling rate. The grinding concentration is controlled at 65%-70%, and the mill throughput is controlled within the target range to ensure that the grinding time meets the requirements of grinding the feed to the target fineness of the discharge. Step 2: Equipment modification: Install a grate or fence at the discharge end of the ball mill to prevent the lightest ceramic balls from being discharged excessively with the slurry. Seal the feed bend of the ball mill by using a packing seal or rubber seal. Adapt the cylindrical screen that is matched with the ball mill to suit the characteristics of the ceramic balls. Step 3: Ball mill loading and production operation: Install a grate or fence at the discharge end of the ball mill to prevent the lightest ceramic balls from being discharged excessively with the slurry. Seal the feed bend of the ball mill using packing seals or rubber seals. Adapt the cylindrical screen that is matched with the ball mill to suit the characteristics of the ceramic balls. Step 4: Monitoring and Optimization: The system monitors the mill feed particle size, discharge particle size, hydrocyclone overflow particle size, grinding concentration, mill current, concentrate grade and throughput. It also replenishes media daily and records the type, weight and power consumption of replenished balls periodically. Based on the production data, the media ratio, filling rate and grinding concentration are optimized and adjusted to achieve the lowest power consumption and ball consumption while meeting the product fineness requirements.

2. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 1, characterized in that, The ceramic balls used in the first step are a mixed grade of various diameters, including three specifications: Φ35mm, Φ30mm, and Φ25mm.

3. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 2, characterized in that, The preferred gradation weight ratio is Φ35mm:Φ30mm:Φ25mm = 1:3:

6.

4. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 1, characterized in that, The diameter of the steel ball in the first step is Φ30mm.

5. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 1, characterized in that, The routine replenishment of media in the fourth step is as follows: 200-400 kg of Φ35mm ceramic balls and 100-200 kg of Φ30mm steel balls are added daily.

6. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 5, characterized in that, 400 kg of Φ35mm ceramic balls and 100 kg of Φ30mm steel balls are added daily.

7. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 5, characterized in that, 300 kg of Φ35mm ceramic balls and 150 kg of Φ30mm steel balls are added daily.

8. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 5, characterized in that, 250 kg of Φ35mm ceramic balls and 150 kg of Φ30mm steel balls are added daily.

9. The energy-saving process optimization method for using a mixture of ceramic balls and steel balls as grinding media according to claim 5, characterized in that, 200kg of Φ35mm ceramic balls and 200kg of Φ30mm steel balls are added daily.

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