Optimization measures of reducing cost and increasing benefit in process flow of concentrator Henan Hongxing

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Optimization measures of reducing cost and increasing benefit in process flow of concentrator

The problems of high grade tailings, high water and electricity consumption in a concentrator have been restricting the production cost of beneficiation. In 2014, the concentrator conducted field investigation and Analysis on such problems, and optimized the original process flow, by canceling the dewatering tank and water and electricity consumption Transformation and optimization of magnetic separator At the same time, the water consumption and the number of pumps running on site are reduced.

 Beneficiation process

Brief introduction of original process flow and existing problems

1. Introduction to the original process

The grinding process flow of concentrator is stage grinding, stage separation and magnetic column re concentration under screen. One of them Ball mill And Spiral classifier The overflow of the classifier enters the cyclone after tail flicking through the dewatering tank and the first stage magnetic separator respectively, and the cyclone grit enters the second stage ball mill for regrinding. The overflow of the cyclone enters the second stage magnetic separator together with the second stage ball mill discharge. The magnetic concentrate enters the fine screen, returns to the cyclone on the screen for classification, and enters the magnetic separation column for separation under the screen. The middlings in the magnetic separation column are swept and discarded by the magnetic separator The magnetic separation column concentrate enters the filtration workshop for dehydration.

2. Problems and analysis of original process flow

In 2013, the grade of grinding tailings is planned to be 9.2%, which is 8.73% in fact. Although it meets the requirements, the grade of zero sample often exceeds the standard, and the magnetic iron grade of comprehensive tailings is high. At the same time, in 2013, the annual power consumption was 90.2697 million kwh, and the water consumption was 72.859 million tons, including 14.5718 million tons of new water consumption, with high hydropower energy consumption.

According to the investigation of on-site technological process, it is found that with the change of ore properties and the requirement of next pellet production grade, the fineness requirement of iron concentrate is increasing year by year, and the content of final concentrate - 0.074mm particle size is more than 80%. However, the fine particle size is the main reason for the excessive grade of tailings. Through the on-site tracking detection of each link of the process, it is found that the feed particle size of the dewatering tank is about - 0.074mm 50%. Due to the fine particle size, it is difficult for workers to operate, which is the main reason for the high grade of tailings. At the same time, there are 14 dewatering tanks in 6 process series of the concentrator. The large water consumption of the dewatering tank is the main reason for the high water consumption and power consumption of the concentrator. Therefore, it is very important to cancel the dewatering tank and simplify the beneficiation process flow to reduce the comprehensive tailings grade and water consumption.

Cancel dewatering tank test

In May 2014, the concentrator cancelled various series of dewatering tanks. Among them, the water pressure of the main plant is 0.18mpa, the current of the first stage mill is 40a, the processing capacity per hour is 64t / h, the magnetic field intensity of the magnetic separator is 191ka / m, and the feed concentration of the magnetic separator is controlled at 30%, the test data of the fifth series of magnetic separators before and after canceling the dewatering tank are compared and investigated. The average concentrate grade of the magnetic separator before and after the removal of the dewatering tank is 46.81% The ore grade was reduced by 0.78 percentage points, but the total iron grade of magnetic separation tailings was also reduced by 0.81 percentage points (the magnetic iron of tailings was also reduced from 0.99% to 0.65%).

Modification test of magnetic separator

 Magnetic separator

After canceling the dewatering tank in concentrator, the feeding capacity of the first stage magnetic separator increased obviously. In July 2014, on the basis of canceling the dewatering tank, a series of 1-stage magnetic separators were modified successively, and the data were compared with those before replacement. Among them, five series of field working conditions are as follows: water pressure of main workshop is 0.18mpa, current of mill section 1 is 40a, current of section 2 is 28a, and unit hour processing capacity is 64t / h. The magnetic field intensity of magnetic separator before and after transformation is 191ka / m, and ore feeding concentration of magnetic separator is controlled at about 30%.

After the transformation, the total iron grade of the concentrate of the magnetic separator is reduced by 0.43% compared with that before the transformation, but the final concentrate grade of the magnetic separation column is almost the same, and the comprehensive tailings grade is reduced from 8.57% to 8.15%, which is 0.42% lower than that before the transformation.

Power consumption and water consumption index

After process optimization, one S-type open type single-stage double suction centrifugal pump with a power of 90kw is reduced for the clean water pump, and three centrifugal pumps with the power of 190kw are reduced for the circulating water pump. The power consumption per kilowatt hour is calculated as 0.53 yuan, and the electricity cost can be saved by 285 yuan per year. At the same time, the on-site fresh water consumption also decreased. After the process transformation, the new water consumption decreased by 1.213 million tons compared with the same period in 2013.

Through the concentrator Beneficiation process The comprehensive tailings grade is reduced by 0.42 percentage points compared with that before optimization, which effectively reduces the occurrence of "ore running" phenomenon and improves the metal recovery rate, but has little impact on the final concentrate index of beneficiation, and the production index after transformation can fully meet the requirements of on-site production index. After process optimization, the number of circulating water pumps and clean water pumps is reduced, the labor intensity of workers is reduced, and the loss of spare parts of relevant equipment is reduced at the same time of reducing power and water consumption, so as to achieve the purpose of reducing cost and increasing efficiency.

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