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高效低碳碎磨技术与装备现状及展望

Current status and prospects of high-efficiency and low-carbon comminution technologies and equipment

  • 摘要: 在选矿生产过程中,碎磨工序的能耗占比一直居于高位,是矿山节能降碳的重难点工序,如何降低碎磨环节的能耗成为矿业领域急需解决的难题。总结分析了目前矿石碎磨预处理技术、高效碎磨技术装备以及新型低碳碎磨工艺流程的研究及应用情况。微波辅助粉碎利用矿物介电属性不同而产生的微裂纹进行粉碎,高压电脉冲粉碎则是通过施加高压脉冲电场从而促使矿石解离,是目前主流的两种矿石预处理技术。在碎磨装备方面,高压辊磨机基于层压粉碎机理可以降低矿石可磨度,具有选择性破碎效果明显、粉碎产品微裂纹多、细粒级含量高和单位破碎能耗低等特点;(半)自磨机兼具破碎和磨矿两种功能,采用冲击和磨剥的作用使物料粉碎,具有投资小、占地小、人工成本低及环保效益好的特点;在细磨装备方面,立式搅拌磨机和艾砂磨机依靠介质与颗粒之间的摩擦、冲击和剪切作用来实现粉碎,比传统的以冲击破碎为主的球磨机的能量传递效率更高,已经成为解决微细粒嵌布矿物单体解离难题的重要装备;在新型低碳碎磨工艺方面,高压辊直连搅拌磨短流程工艺为低碳碎磨提供了新的思路;陶瓷球与钢球协同磨矿工艺节能效果明显,已经在大型选矿厂得到了大规模应用。最后对碎磨技术低碳化、高效化、智能化的未来发展趋势进行了展望,旨在为矿山碎磨系统的节能降碳和提质增效提供一定的理论参考和技术借鉴。

     

    Abstract: In mineral processing production, comminution has always been a large energy consumer and remains a critical yet difficult stage for mine energy conservation and carbon reduction. Thus, how to reduce the energy consumption of crushing and grinding has become a problem to be urgently solved in the mining industry. The research and application of current ore pretreatment technologies for comminution, high-efficiency comminution equipment, and novel low-carbon comminution flowsheets were systematically summarized and analyzed. Microwave-assisted comminution utilizes differences in dielectric properties among minerals to generate microcracks for comminution, while high-voltage electric pulse comminution promotes ore liberation by applying a high-voltage pulsed electric field. These approaches are currently the two mainstream ore pretreatment technologies. In terms of comminution equipment, the high-pressure grinding roll (HPGR) based on the interparticle compression mechanism can reduce ore grindability and is characterized by a pronounced selective breakage effect, abundant microcracks in the product, high content of fine particles, and low specific energy consumption. (Semi-)autogenous mills combine crushing and grinding functions and comminute materials through impact and abrasion, featuring low capital investment, a small footprint, low labor cost, and good environmental performance. In terms of fine grinding equipment, vertical stirred mills and IsaMills achieve comminution through friction, impact, and shearing between the grinding media and particles, exhibit higher energy transfer efficiency than traditional ball mills that rely mainly on impact breakage, and have become important equipment for solving the liberation problem of finely disseminated minerals. In terms of novel low-carbon comminution processes, the short-circuit process in which HPGR is directly coupled with stirred mills provides a new approach for low-carbon comminution. The synergistic grinding process using ceramic and steel balls delivers significant energy conservation and has been applied on a large scale in major concentrators. Finally, future trends of low-carbon, high-efficiency, and intelligent comminution were prospected to provide some theoretical and technical reference for energy conservation, carbon reduction, and quality and efficiency improvement in mine comminution systems.

     

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