Discharge End Wall Plug Elements Reduce Carryover
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In grinding mills, the issue of 'carryover' occurs where pulp is not fully evacuated from pulp chambers during rotation, leading to increased wear on certain surfaces, reduced throughput, and higher energy consumption due to incomplete discharge, resulting in premature replacement of components and significant operational costs.
Innovation Solution
A discharge end wall system with plug elements positioned in selected pulp chambers to reduce the volume of these chambers, optimizing the flow of pulp and minimizing carryover, which includes pairs of pulp lifters and plug elements that occupy a portion of the pulp chambers to define reduced pulp chambers, allowing for improved pulp evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pulp chamber volume is reduced by adding plug elements, then carryover is minimized and throughput increases, but the chamber capacity for pulp storage is reduced
Solution Approach 1:
The pulp chamber is segmented into two distinct zones by the plug element: a reduced-volume first portion for active pulp processing and evacuation, and a second portion that maintains additional capacity. This segmentation allows the system to optimize evacuation efficiency in the first portion while preserving storage capacity in the second portion, thereby increasing throughput without completely sacrificing chamber volume.
Solution Approach 2:
The plug element creates local quality differentiation within the pulp chamber by modifying the geometry of the first portion specifically. This localized modification optimizes pulp flow characteristics and evacuation efficiency in the critical discharge zone without affecting the overall chamber structure or the second portion, thus improving productivity while maintaining necessary storage capacity.
2Reliability
If plug elements are added to reduce pulp chamber volume, then wear on components is decreased, but the structural complexity of the discharge end wall system increases
Solution Approach 1:
The plug element extracts or removes the problematic excess volume from the pulp chamber that causes carryover and subsequent wear. By taking out this specific portion and replacing it with the plug element, the system eliminates the root cause of wear on discharge components, thereby improving reliability while adding only a single, relatively simple structural element.
Solution Approach 2:
The plug element acts as an intermediary structure that mediates between the pulp flow and the discharge end wall components. It modifies the pulp chamber geometry to optimize flow patterns and reduce harmful carryover effects, thereby protecting downstream components from wear while introducing a manageable level of structural complexity through this intermediate element.
3Use of energy by moving object
If the pulp chamber volume is reduced, then energy consumption decreases, but the initial setup and installation complexity increases
Solution Approach 1:
The plug element is designed as a relatively simple, potentially replaceable component that can be manufactured and installed without complex procedures. Its straightforward geometry and function allow for ease of manufacture and installation, making the increased setup complexity minimal compared to the significant energy savings achieved through reduced pulp chamber volume and improved evacuation efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The introduction of plug elements in selected pulp chambers reduces carryover, decreases wear on components, and increases throughput without decreasing performance, as the reduced pulp chamber volume ensures more efficient pulp evacuation and reduced energy consumption.
Implementation Method 1
The mill shell is rotatable about an axis of rotation thereof in a direction of rotation to produce a pulp including ore particles and water
Implementation Method 2
The movement of the ore particles and water through the discharge grates and into the pulp chambers
Data Source
AI summary
A discharge end wall system including a discharge wall assembly in which a number of pulp chambers are defined, and one or more plug elements at least partially occupying one or more of the pulp chambers.