无钢球磨矿能耗基础及其工艺发展趋势

The Theoretical Foundation and Development Trend of Non-steel-ball Grinding Technology

磨矿能耗占粉碎工艺过程的能耗2/3以上。一般爆破和粗中碎作业能耗均为0.4k Wh/t,细碎作业能耗为1.25~2.25 kWh/t,但磨矿作业能耗却高达8~15 kWh/t。通过采用高压辊磨机进行超细碎和瓷球作磨矿介质,可大幅度降低当前钢球磨矿过程能耗。当入磨粒度为-3 mm和磨矿粒度为-0.3 mm时,瓷球磨矿过程能耗为4.8 kWh/t,粉碎工艺总能耗为7.25 kWh/t;当入磨粒度为-1 mm和磨矿粒度为-0.1 mm时,瓷球磨矿过程能耗为9 kWh/t,粉碎工艺总能耗为12.45 kWh/t。因此,合理设计粉碎工艺过程中各作业产品粒度大小、装备选型和研磨介质类型,对以最小的能耗获得最佳磨矿效果至关重要。可以预见,以高压辊磨机和瓷球磨矿为特征的无钢球磨矿工艺,将会成为未来粉碎工艺设计的主流。

Energy consumption in grinding accounts for more than 2/3 of that in comminution.Generally,the energy consumption for blasting,coarse crushing and medium crushing is 0.4 kWh/t respectively,and the energy consumption for fine crushing operations is 1.25~2.25 kWh/t.However,the grinding energy consumption can reach 8~15 kWh/t.By using high pressure grinding roller(HPGR)for ultrafine grinding and ceramic balls as grinding media,the current energy consumption in the steel ball grinding process can be greatly reduced.When the feed size is-3 mm and the grinding size is-0.3 mm,the energy consumption in the grinding process with ceramic balls as the media is 4.8 kWh/t,and the total energy consumption of the comminution process is 7.25 kWh/t.When the feed size is-1 mm andthe grinding size is-0.1 mm,the energy consumption during ceramic ball grinding is 9 kWh/t,and the total energy consumption of the comminution process is 12.45 kWh/t.Therefore,the selection of moderate product size,equipment,and grinding mediafor the comminution process is very important to achieve the optimum grinding fineness with minimum energy consumption.It can be predicted that the non-steel-ball grinding process characterized by HPGR and ceramic balls grinding will become the mainstream of comminution process design.