Dry Grinding System with Moisture-Adaptive Screening
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Solution Overview
Problem
Conventional wet grinding methods for ores with high moisture content are inefficient and costly due to the need for thermal drying, which negates the energy and wear advantages of dry grinding systems like roller mills and roll presses.
Innovation Solution
A method and system that involves determining the moisture of starting materials, using a screening stage with a defined cut point to separate oversize and undersize fractions, where the oversize is processed in a dry grinding system and the undersize in a wet grinding system or drying device, allowing for energy-efficient dry grinding while maintaining moisture below a predetermined limit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal drying is applied to high-moisture ores before dry grinding, then the wear and energy consumption of the dry grinding system are reduced, but the overall energy consumption and cost increase due to the drying process
Solution Approach 1:
The ore processing flow is segmented into multiple screening stages with different cut points, separating ores by size before grinding. This allows selective processing where only suitable-sized ores undergo dry grinding, while others are screened first or processed differently, optimizing energy usage across the system.
Solution Approach 2:
The invention changes the operational parameters of the screening stages by adjusting cut points based on ore moisture content and size distribution. This dynamic parameter adjustment ensures that ores are directed to appropriate processing paths, maximizing the efficiency of dry grinding while minimizing unnecessary drying operations.
2Loss of energy
If all ores are processed through the dry grinding system regardless of moisture content, then the wear and energy consumption are reduced, but the grinding efficiency decreases due to moisture-related issues
Solution Approach 1:
The processing system is segmented into multiple pathways: ores are first screened by size, then based on moisture content and size, directed to either dry grinding, wet grinding, or drying followed by grinding. This segmentation ensures each ore type receives the most appropriate processing method for maximum efficiency.
Solution Approach 2:
The system dynamically adjusts the processing path for different ore batches based on real-time characteristics such as moisture content and size distribution. The screening cut points and processing decisions are made adaptively rather than following a fixed sequence, optimizing grinding efficiency for each specific ore condition.
3Device complexity
If a single cut point is used for screening, then the system complexity is reduced, but the ability to optimize grinding efficiency for different ore sizes and moisture contents is limited
Solution Approach 1:
The screening system is divided into multiple stages, each with its own cut point optimized for specific ore size ranges. This multi-stage segmentation allows progressive separation of ores by size, enabling more efficient routing to appropriate grinding processes while maintaining manageable system complexity through modular design.
Solution Approach 2:
The screening cut points are not fixed but can be adjusted dynamically based on ore characteristics and processing requirements. This dynamic adjustment capability allows the system to optimize grinding efficiency for different ore conditions without requiring complete system redesign, balancing complexity and performance.
Data Source
AI summary
Disclosed herein is a method and system for grinding fragmentary starting material, in particular ores, with a dry grinding system. An embodiment of the method includes the steps of determining the moisture of starting material for a certain period of time, preparing at least one screening stage, the cut point of which is selected depending on the determined moisture in such a manner that the moisture of a screen oversize does not exceed a predetermined moisture limit value when starting material having the determined moisture is fed to the screening stage, feeding starting material to the screening stage, transferring a screen oversize arising in the screening stage to the dry grinding system, and grinding the screen oversize in the dry grinding system.