Iron Ore Crushing Sequence for Fine Pellet Feed Preparation
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Solution Overview
Problem
Conventional techniques are inadequate for efficiently crushing powdery iron ores with coarse particles, particularly those with low crushability, and fail to address the mixing of ores with high hardness or high water content.
Innovation Solution
A method involving coarsely crushing iron ores with a jaw crusher to reduce the proportion of particles greater than 1 mm, followed by finely crushing with a ball mill to increase the proportion of particles less than 63 µm, optionally using a wet ball mill for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional crushing methods are used on powdery iron ores with coarse particles, then the crushing process becomes inefficient and time-consuming, but the particle size reduction is insufficient
Solution Approach 1:
The crushing process is divided into two distinct stages: coarse crushing to reduce large particles, and fine crushing to achieve the desired fine particle size. This segmentation allows each stage to be optimized independently, improving overall efficiency and particle size reduction effectiveness.
Solution Approach 2:
Coarse crushing is performed as a preliminary action before fine crushing. By pre-reducing the particle size through coarse crushing, the subsequent fine crushing process becomes more efficient and achieves better particle size reduction with less energy input and time.
2Ease of manufacture
If iron ores with high hardness are used as crushing auxiliary material, then the crushability of the ore is improved, but the energy consumption increases
Solution Approach 1:
The hardness parameter of the crushing auxiliary material is optimized to achieve the right balance. Instead of using extremely hard materials that would consume excessive energy, a moderate hardness level is selected that provides sufficient crushability improvement while maintaining reasonable energy consumption.
3Manufacturing precision
If prolonged fine crushing is applied to difficult-to-crush iron ores, then the particle size is reduced, but the processing time and energy consumption increase significantly
Solution Approach 1:
The crushing operation is segmented into coarse and fine stages, allowing the fine crushing process to start with pre-reduced particles. This segmentation enables achieving fine particle size with significantly reduced processing time compared to attempting fine crushing from the outset.
Solution Approach 2:
Coarse crushing serves as a preliminary action that prepares the material for efficient fine crushing. By reducing particles to a smaller size range before fine crushing, the time required to achieve the desired fine particle size is dramatically reduced.
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
This approach allows for efficient fine crushing of difficult-to-crush iron ores, enhancing their granularity and enabling the production of high-strength pellets suitable for sintered-ore raw materials.
Implementation Method 1
coarsely crushing iron ores with a jaw crusher
Implementation Method 2
finely crushing with a ball mill
Implementation Method 3
finely crushing with a ball mill
Implementation Method 4
finely crushing with a wet ball mill for improved efficiency
Data Source
Figure 1
AI summary
Provided is an ore crushing method capable of efficiently crushing iron ores that are difficult to finely crush. The ore crushing method includes coarsely crushing the iron ores to reduce the proportion of particles with a particle size of greater than or equal to 1 mm, and then finely crushing the iron ores to increase the proportion of particles with a particle size of less than 63 µm. The average pore size of the iron ores is preferably less than or equal to 10 µm, the proportion of the particles with a particle size of greater than or equal to 1 mm in the iron ores is preferably greater than or equal to 30 mass%, the iron ores are preferably coarsely crushed so that the proportion of the particles with a particle size of greater than or equal to 1 mm becomes less than or equal to 20 mass%, the iron ores are preferably finely crushed so that the proportion of the particles with a particle size of less than 63 µm becomes greater than or equal to 70 mass%, and the iron ores are preferably finely crushed with a wet ball mill. A pellet production method is also provided that includes granulating a raw material, which includes the iron ores crushed with the ore crushing method, into pellets.