The status quo and development characteristics of large-scale crushing equipment (2)

In recent years, the grinding equipment of mines in the international mining industry is still dominated by cylindrical grinding machines. The development trend is large-scale and comprehensive use of contemporary advanced technology. Due to the large-scale barrel mill, the construction and production costs of large-scale concentrators can be significantly reduced, so its large-scale development has been continuously developed.

The domestic self-grinding (semi-self-grinding) machine has been completely rid of the basic stagnation of nearly 20 years since the mid-1980s, and has achieved rapid development and is close to or reaching the world advanced level. In recent years, CITIC Heavy Industry Machinery Co., Ltd. has made great progress in the design and manufacture of large-scale cylindrical grinding machines. Currently the maximum size of the autogenous grinding and domestic self-developed applications (SAG) The machine is designed and manufactured Φ10.37 × 5.19 m, 11.172 MW SAG mill in 2010 for Dexing Copper Mine in Jiangxi Copper Industry Company .
The mill uses a dual motor drive and a self-aligning pure static cylinder sliding support. Specifications of the world's largest short cylindrical SAG mill is the company CITIC Pacific SINO Australian iron ore produced six Φ12.19 × 10.97 m, 28 MW from the mill. The latest 12.8×7.6 m, 28 MW semi-autogenous grinding machine manufactured by Metso Finland has a daily production capacity of 100,000 tons per unit. It is also the world's largest self-grinding (semi-self-grinding) machine. The world's largest specification of the long-tube semi-autogenous mill is Φ9.76×10.37 m, driven by a ring motor with a power of 16 500 kW for Peru.
Autogenous grinding of application (SAG) machine is basically a short cylindrical, one exception is the Green Hill Beach Stream gold ore from South Africa purchased a second-hand large long tube SAG mill, specifications for Ф4.90 × 10.29 m, with an installed power of 3 500 kW, was put into operation at the end of 2005. This is the largest cylindrical self-grinding (semi-self-grinding) machine in China.

So far, regardless of international or domestic mines, the role and status of ball mills in metal ore crushing operations are still irreplaceable. In the 1980s, there were predictions in the world that the reasonable maximum diameter was 5 m due to the inefficient creep zone of the ball mill. However, the pace of development of large-scale ball mills has not stopped.
Since the beginning of the 21st century, the world record for wet ball mill specifications and installation power has been continuously refreshed at a faster rate: in June 2001, 3 sets of Ф7.32 by FFE Minerals (now Afa Smith, the same below) 11.58 m, 13.43 MW overflow ball mill for Escondida, Chile; December 2002, FFE Minerals manufactured three Ф7.62 × 11.0 m, 11.2 MW overflow ball mill, a zinc-copper ore Antamina Peru In 2003, two Ф7.92 × 11.58 m, 14.3 MW overflow ball mills manufactured by Metso Finland were used in the Collahuasi copper mine in Chile. At the end of 2007, two Ф 2 7.92 × 12.2 m manufactured by FFE Minerals 17.5 MW overflow ball mill for the Anglo Platinum platinum mine in South Africa; currently, six Φ7.9 × 13.6 m, 15.6 MW overflow ball mills manufactured by CITIC Heavy Industries, Ltd. are used in CITIC Pacific Australia's SINO iron ore.
The Φ7.32×10.68 m and 11.172 MW overflow ball mill designed and manufactured by CITIC Heavy Industry Machinery Co., Ltd. is the largest ball mill developed and applied by China at present. It was used in Dexing Copper Mine of Jiangxi Copper Company in 2010. For the first time, the mill uses a dual motor drive and a self-aligning pure static cylinder sliding support. The world's largest dry ball mill is the Φ6.2 × 25.5 m, 11.2 MW ball mill from ThyssenKrupp Hughes. It is driven by a ring motor and was used in a gold mine in the United States in 1994 for handling difficult gold. ore.
In the cement industry, Tianjin Cement Industry Design and Research Institute designed and manufactured the largest domestically produced Ф5×10 m+2.5 m drying medium unloading tube mill in 2004 for the disposal of municipal waste by Beijing Jinyu Group Co., Ltd. In the demonstration project. The mill is supported by a cylinder hydraulic sliding shoe. The cylinder is an integral welded structure with a mounting power of 4 000 kW, a mass of 382 t, and a medium-hard material design capacity of 250 t/h. CITIC Heavy Industry Machinery Co., Ltd. has developed the world's first large-scale cement ball mill supported by pure static-pressure sliding bearings. The specification is Ф4.2×13m. The friction coefficient of the hydrostatic bearing is 1/100 to 1/1 000 of the dynamic pressure bearing, so that the mechanical and electrical consumption of the grinding machine can be reduced by 10% to 15%.

The roller mill is mostly used in the cement industry. Due to the rapid development of the cement industry, the large-scale roller mill has also achieved corresponding development. At present, the world's largest roller mill is the LM63.4 roller mill from Loesche, Germany. The machine belongs to the disc roller mill with an installation power of 5.4 to 6 MW, a grinding disc diameter of 6.3 m and a mass of about 230 t. There are 4 grinding rolls with a large end diameter of 3 m and a mass of approximately 45 t. The roll face and the disk face are high chrome castings . The equipment is used for grinding cement raw materials with a feed size of 0 to 150 mm, a product particle size of −90 μm 85% and a production capacity of 840 t/h.

With the expansion of the production scale, the specification of crushing and grinding equipment has increased, and the screening and grading equipment has also been developed in the direction of large-scale. The original Swedish Svidala Group has produced a double-layer linear vibrating screen that is said to be the world's largest specification. The equipment has a mass of 33 t, a screen width of 3.6 m, a length of 7.3 m and a processing capacity of 5 000 t/h. The equipment is used in the Grasberg open-pit copper-gold mine in Irian Jaya, Indonesia, to process Φ11.58 m semi-automatic mill discharge. Germany's Haver & Soecker manufactures the world's largest single-layer vibrating screen, model R-TE 4 000 × 10 500 mm, with a total power of 264 kW and a total mass of 115 t. The equipment was used in November 2003 for the Syncrude Oil Company of Canada to screen oil sands . The maximum size of oil sands is 600 × 600 × 900 mm and the maximum processing capacity is 10 000 t / h.

Our country is coal country, there is an urgent demand for large-scale screening machine. Since 1986, the former Luoyang Mining Machinery Plant and the former Luoyang Mining Machinery Research Institute have introduced the linear screen of model ZK3675 by introducing the technology of Kobe Steel Co., Ltd., which is the first large-scale vibrating screen with a screen area of ​​27 m ² in China. There are many used in the coal industry. In recent years, the 2ZKP3660 large linear vibrating screen manufactured by Anshan Heavy Mining Machinery Plant has a screen size of 3.6×6.0 m and a screen area of ​​21.6 m ² . It was used in the Tianzhuang Coal Preparation Plant in April 2000 with a processing capacity of 350 ～ 400 t / h. The large-scale vibrating screen of CWS3660 type static static fixed mesh beam manufactured by China National Mining Electromechanical Equipment Manufacturing Co., Ltd. has a screen area of ​​21.6m ² and is used for de-watering. The processing capacity is 100 t/h. Tianshan Branch of Tiandi Technology Co., Ltd. developed SXJ4261 large-scale incense-type linear vibrating screen. It was used in Inner Mongolia Qinghua Bailing Coal Washing Co., Ltd. in December 2004. The vibrating screen adopts the equal-thickness screening method, the single-layer sieve surface, the screen surface size is 4.2×6.1 m, the area is 25.6 m ² , the installation power is 90 kW, and the production capacity is 150-800 t/h. QLS30120 type strong vibrating screen manufactured by Taihang Vibration Machinery Co., Ltd., the screen surface vibrates, the screen frame does not vibrate, the screen surface size is 3×12 m, and the area is 36 m ² . The vibrating screen is used in the coal preparation plant of Fenghuangshan Coal Mine of Jincheng Mining Bureau, with a treatment capacity of more than 250 t/h.
An example of a large-scale screening machine used in domestic metal mines is that the Panzhihua Iron and Steel Group Mining Company has used 2 2DK3073 double-layer circular vibrating screens developed by Anshan Heavy Mining Machinery Co., Ltd. since 2002 to screen vanadium- titanium magnetite ore. Up to 800 to 1 000 t / h. The vibrating screen has a face size of 3 x 7.3 m and an area of ​​22.3 m ² . In 2004, Anshan Heavy Mining Machinery Co., Ltd. further developed a larger size 2DYK3880 double-layer circular vibrating screen with a screen size of 3.8×8.0 m, an area of ​​30.4 m ² and a production capacity of up to 1 500 t/h.
In the classification of metal mines, hydrocyclones are in an important position. Foreign countries, whether rough grinding or fine grinding, have basically used hydraulic cyclones for classification. The hydrocyclone has been fully used in the domestic fine grinding stage. Most of the large-scale concentrating plants in the rough grinding stage have selected hydrocyclones. Only some small and medium-sized concentrators have chosen spiral classifiers for their convenience in configuration, and some concentrators that have been built for many years have also used spiral classifiers.
From the perspective of reducing construction investment and operating costs, the field of beneficiation classification has always required large-scale hydrocyclone. In the 1970s, the former Soviet Union used 15 large hydrocyclones of Φ1 400 mm in the beneficiation classification. In 1990, Denmark's Alfred Krebs developed a large hydrocyclone of Φ838 mm for coarse-grain grading of the Grasberg copper-gold mine in Freeport, Indonesia, in a horizontal installation. This is the largest hydrocyclone reported in the world in recent years. The largest known ore dressing grade hydrocyclone in China is a FX710 hydrocyclone used by the Sanshandao Gold Mine of Shandong Gold Mining Co., Ltd., which is manufactured by Weihai Haiwang Co., with an overflow particle size of -200 mesh and 57.2%. The concentration is 38.0% and the daily production capacity is 3,000 tons. The largest domestic hydrocyclone with the most specifications is Φ660 mm.
The technological advancement of large hydrocyclones is reflected in the acceptable overflow particle size at high overflow concentrations. The hydrocyclone of Denmark's Alpha Smith Krebs is still internationally leading in technology. Its new gMAX hydrocyclone allows for fine particle grading at high concentrations and its high specification allows for low pressure feed. China's Jiangxi Copper Company Dexing Copper Mine uses the Φ660 mm gMAX hydrocyclone unit.

In recent years, the foreign metal mine regrind field has successfully replaced the conventional regrind ball mill with a large agitating mill. The urgent need to re-grind large metal mines has provided conditions for their large-scale production. The most prominent of these is the two types of equipment: the Isa mixing mill and the vertical agitator of the spiral mixer.
Isa agitation mill is Australia's Mount Isa zinc and lead Germany Netzsch - Feinmahltechnik company in 1990 to develop, is the disc agitator horizontal stirring mill. This type of mill is not new in its structural form, and small products have been industrially applied in the chemical industry in the 1960s and 1970s. Its innovation lies in its large size, high input energy density and re-grinding for metal ore.
In 1994, the Mount Isa lead-zinc mine in Australia began to use the M3000 Isa agitator mill with a volume of 3 m ³ and a power of 1.1 MW. The medium was slag and heavy medium workshop tailings, and the material was ground from 20 μm 80% to 12 μm 80%. The output is 65 t/h and the unit power consumption is 7.6 kW · h/t. In 1995, the machine was used in the McArthur River lead-zinc mine in Australia. The medium was a 0.8-1.8 mm grade product in the semi-autogenous mill discharge, and the material was ground from 30-45 μm 80% to 7 μm 80%, and the output was 15 t/ h, the unit power consumption is 36 kW · h / t. Since 2000, the Isa mixing mill has created an unprecedented large-scale and high input energy density, resulting in the largest size and power of the world's largest mixing mill, model M10000, volume 10 m ³ , motor power 2.6 ~3.0 MW. The disc has a peripheral speed of up to 20 to 23 m / s and an input power (energy density) per unit volume of up to 300 kW/m ³ .
The M10000 was first finely ground in 2001 with the Anglo-Platinum gold mine in South Africa, and in October 2005 it was used for the fine grinding of the Kumtor gold mine at Centerra Gold in Kyrgyzstan. Five more units were purchased from the Anglo Platinum mine for grinding. Flotation feedstock. The machine is successfully used for wet regrind of metal minerals. It can reach the micron-sized and narrowly distributed product particle size by open circuit work. It can be self-grinded by using river sand or ground material particles as grinding media, and for subsequent flotation and leaching. Create low activity pulp conditions.
In 2006, the Kumtor gold mine replaced the ball mill with a M10000-type Isa agitator with a power of 2.6 MW during the 4-month maintenance of its 4.1 MW regrind ball mill, and the rough concentrate was removed from 135 μm 80% open powder. Grinding to 62 μm 80%, operating power is 1 885 kW, power consumption is less than half of the re-grinding ball mill, and the hydrocyclone and its feed pump are eliminated. The vertical agitator of the spiral agitator is another large-scale agitating mill suitable for beneficiation and re-grinding. The peripheral speed of the spiral outer edge is about 3 m/s, and the medium is a steel ball with a diameter of 12 to 30 mm. The particle size is often between 20 and 45 μm. There are two such companies manufactured by foreign companies. One is the VertiMill mixing mill from Metso Finland.
Australia's Newcrest's Cadia Valley copper and gold mines use multiple VertiMill mixer mills for regrind and semi-self-grinding subsequent grinding operations, which are 30% to 40% more energy efficient than conventional regrind ball mills. The mine has recently ordered a VTM-3000-WB VertiMill mixer mill, which is intended for the third stage of grinding. It is the latest and largest specification equipment in the mixer mill with an installation power of 2 235 kW. The Brazilian MMX Mining Company has ordered 14 VTM-3000-WB VertiMill mixer mills for iron ore re-grinding in its SerraAzul iron ore expansion project. The second is the tower mill of Japan's Ericsson Company. The Karara magnetite project jointly invested by Anshan Iron and Steel and Australia has selected its largest specification KW-1500 tower mill with an installation power of 1 250kW. The Shandong Gold Mining (Laizhou) Co., Ltd. refinery uses a KW-1250 tower mill with an installed power of 1 000 kW, which is the largest size of this type of mill in China. The machine is used for fine grinding of gold ore with a feed size of −200 mesh and 50%, a product particle size of −400 mesh and 95%, and a throughput of 53.75 t/h.

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