袁家村赤铁矿二元介质体系细磨特征
Fine grinding characteristics of binary media system in Yuanjiacun hematite ore
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摘要: 针对袁家村赤铁矿现场钢锻介质磨矿产品粒度特征差的问题,采用批次磨矿试验与数值模拟相结合的方法,研究了二元介质条件下赤铁矿细磨过程的粒度分布规律与能量传递特征。通过条件试验得到二元介质磨矿最佳条件为磨矿质量分数70%、介质充填率35%(其中25 mm钢球占4%充填率)、瓷球配比为ϕ30 mm∶ϕ25 mm∶ ϕ20 mm = 50%∶30%∶20%(质量分数),在最佳条件下磨矿产品中小于0.045 mm产率相较钢锻磨矿提高5.05个百分点,小于0.023 mm产率降低3.03个百分点。基于磨矿动力学特征对比表明,赤铁矿细磨过程符合一阶动力学模型,二元介质磨矿第一粒级比破碎速率为钢锻磨矿的2.03倍。通过离散元法(discrete element method,DEM)模拟揭示了钢锻磨矿以少量高能碰撞为主,冲击集中且能量分布不均,以瓷球介质为主的磨矿则通过大量中低能碰撞实现持续破碎,其中二元介质磨矿体系碰撞频率较钢锻提高2.24倍,单次碰撞能量降低61.57%。连续磨矿试验进一步验证“高频低能”的碰撞特征可提升易选粒级(0.019 ~0.045 mm)产率6.61个百分点,降低返砂比72个百分点,解决了现场钢锻磨矿效率低、循环负荷高的问题,体现出二元介质磨矿体系在赤铁矿细磨作业中的优越性。Abstract: To address the poor particle size characteristics of grinding products produced by steel cylpeb in the Yuanjiacun hematite grinding circuit, batch grinding experiments combined with numerical simulations were conducted to investigate the particle size distribution behavior and energy transfer characteristics during the fine grinding of hematite under binary media conditions. The optimal conditions for binary media grinding were determined. These conditions include grinding concentration of 70%, media filling rate of 35% (with 25 mm steel balls accounting for 4% of the filling rate), and ceramic ball size ratio of ϕ30 mm∶ϕ25 mm∶ϕ20 mm = 50%∶30%∶20%(mass fraction). Under the optimal conditions, the yield of the fraction finer than 0.045 mm was increased by 5.05 percentage points compared with that of steel cylpeb grinding, whereas the yield of the fraction finer than 0.023 mm was decreased by 3.03 percentage points. Comparative analysis of grinding kinetics indicates that the fine grinding process of hematite follows a first-order kinetic model. The specific breakage rate of the first size fraction in binary media grinding is 2.03 times that of steel cylpeb grinding. Discrete element method (DEM) simulations reveal that steel cylpeb grinding is dominated by a small number of high-energy collisions, resulting in localized impacts and uneven energy distribution. In contrast, grinding dominated by ceramic balls achieves continuous breakage through a large number of medium- and low-energy collisions. The collision frequency of the binary media grinding system is 2.24 times higher than that of steel cylpeb grinding, while the energy per collision is reduced by 61.57%. Continuous grinding experiments further demonstrate that the high-frequency and low-energy collision characteristics increase the yield of the easily separable size fraction (0.019-0.045 mm) by 6.61 percentage points and reduce the circulating load ratio by 72 percentage points. These characteristics effectively alleviate the problems of low grinding efficiency and high circulating load in steel cylpeb grinding, demonstrating the advantages of the binary media grinding system in hematite fine grinding operations.
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