Advanced Powder Technology, Vol.31, No.5, 2079-2091, 2020
Enhancing the capacity of large-scale ball mill through process and equipment optimization: An industrial test verification
The production capacity of the large-scale ball mill in the concentrator is a crucial factor affecting the subsequent separation and the economic benefits of the operation. The main aim of this study is to improve the processing capacity of the large-scale ball mill. Taking a 05.49 x 8.83 m ball mill as the research object, the reason for the low processing capacity of the ball mill was explored via process min- eralogy, physicochemical analysis, workshop process investigation, and the power consumption method. Based on this framework, a series of laboratory grinding optimization tests were conducted and verified via industrial tests. The results show that the ore primarily contained hematite and magnetite, the dis- seminated particle size of magnetite was primarily a coarse -grained inlay that was easy to separate from gangue, while the disseminated particle size of hematite was primarily an uneven and medium-sized inlay, which increased the grinding difficulty. Under optimum conditions of +6.0 mm material suitable for a 100 mm ball diameter, -6.0 + 2.0 mm material suitable for an 80 mm ball diameter, -2.0 mm mate- rial suitable for a 70 mm ball diameter; medium ratio of 090 mm 34.62%, 070 mm 26.92%, 060 mm 23.08%, 040 mm 15.38%; filling ratio of 32%; material ball ratio of 1.0; rotation speed rate of 80%; and grinding concentration of 78%, the -0.074 mm content in the grinding product increased from 55.10% to 58.86% and the processing capacity of the ball mill increased from 310 to 320 t/h to 350 t/h. Scanning electron microscopy/energy dispersive X-ray spectrometry (SEM-EDS) micrograph analysis shows that the fineness of the ore and dissociation degree of useful minerals were apparently improved by optimizing the process and equipment.