A Domestic Technology of Liner Design for Tumbling Mills

Document Type : Technical Note

Authors

1 Mineral Processing Group, Vali-e-Asr University of Rafsanjan, Rafsanjan, Iran

2 Dept. of Mining, Shahid Bahonar University of Kerman, Kerman, Iran

10.29252/anm.2020.12207.1399

Abstract

Summary
Liners in tumbling mill transfer energy to the mill load and has a significant impact on the load behavior. In order to achieve a domestic technology of liner design, a knowledge-based package of liner design was developed by using of domestic equipment and software packages. At the first stage, a proposed liner that provides an appropriate load trajectory is obtained by simulation using GMT (grinding media trajectory) software and discrete component method (3D-DEM, KMPCDEM software). In the next stage, the proposed design after validating by a model mill, the manufacturing drawings are prepared. This domestic liner design technology was applied for liners at the Gol-e-Gohar mining and industrial company AG mill and the Sarcheshmeh copper complex ball mill. The results indicated that changing the liners design by using this domestic technology resulted in an overall increase in the mills throughput and more importantly, reduction in the number of liner breakdown. This research has developed a novel and domestic technology that provides a highly reliable and low cost method for designing and changing the tumbling mill liners.
 
Introduction
Since direct observation of charge shape and its motion in industrial mills are not possible, a combination of analytical and physical studies was used to determine charge trajectory and design new liners. Aims of new designs are to improve the effective grinding through changes in liner design.
 
Methodology and Approaches
At the first stage, a proposed liner that provides an appropriate load trajectory is obtained by using a software called GMT (Grinding Media Trajectory) and KMPCDEM software which has been developed based on discrete element method (DEM). In the next stage, after validating by a model mill, the manufacturing drawings of proposed design are prepared. After the construction and installation of the proposed liners, while optimizing the mill operation, the liners wear is recorded using a special measuring device and after preparing a three-dimensional model of liners, a new design is proposed in order to increase its life and reduce the amount of scrap.
 
Results and Conclusions
This domestic liner design technology was applied for AG mill liners at the Gol-e-Gohar mining and industrial company indicated that increasing the liner lifter face angle from 7 to 30° while keeping the original lifter height could provide an appropriate charge trajectory. Installation of proposed liners resulted in an overall increase of 17% in the mill throughput and a reduction of standard deviation. By use of this design package in the Sarcheshmeh copper complex ball and increasing the liner lifter face angle from 0 to 15° and the lifter height from 18 to 21cm, the amount of particles smaller than 75 microns in ball mill 4 product (with proposed design) compared with ball mill 3 (with current design) increased by 2.5% and the liners life of the first half and second half increased by 18% and 20%, respectively.

Keywords

Main Subjects

Full Text

در کارخانه‌های فرآوری مواد معدنی، آسیاکنی بیشترین سهم مصرف انرژی و هزینه‌های عملیاتی و سرمایه‌ای را دارد و کمتر از 5 درصد از این انرژی صرف خرد کردن مواد می‌شود [1]. از میان تجهیزاتی که جهت خردایش مواد معدنی استفاده می‌شود، آسیاهای گردان بیشترین کاربرد را دارند. آسیاهای گردان تجهیزاتی استوانه‌ای شکل هستند که به صورت افقی در کارخانه‌های فرآوری نصب می‌شوند. مواد معدنی به طور پیوسته از یک طرف وارد آسیا شده و پس از خردایش، از طرف دیگر آسیا، خارج می‌شوند. نحوه حرکت مواد در آسیا، به طور مستقیم بر عملکرد آسیاها (ظرفیت و اندازه محصول خروجی) تاثیرگذار است [2].

سطوح داخلی آسیا با آسترهایی پوشیده می‌شود که عمده وظایف آن مقاومت در برابر ضربات وارده شده از طرف مواد و واسطه، مقاومت در برابر سایش و ایجاد حرکتی مطلوب برای بار است [1، 3]. آسترهای جداره دارای بالابرهایی (Lifter) با اشکال مختلف هستند. در شکل 1 مدل صنعتی آستر‌های جداره و دیواره ورودی و خروجی آسیای نیمه‌خودشکن مجتمع مس سرچشمه نشان داده شده است.

 

شکل 1: مدل صنعتی آستر‌های آسیای نیمه‌خودشکن مجتمع مس سرچشمه

فهم بهتر سازوکار انرژی مصرفی و رفتار بار درون آسیا می‌تواند منجر به صرفه‌جویی چشمگیری در انرژی مصرفی شود [2، 5]. با درک دقیق رفتار بار می‌توان با تغییر عواملی مانند سرعت و طرح آستر، ظرفیت خردایش و کارایی آسیاکنی را افزایش داد و کنترل آسیا را آسان‌تر نمود. در آسیاهای گردان، انرژی وارد شده از موتور به آسیا (به‌ جز بخش‌هایی که به ‌صورت‌های مختلف تلف می‌شود) صرف حرکت بار می‌شود. در این میان، آستر آسیا عامل انتقال انرژی وارد شده به مواد داخل آسیا است و تاثیر قابل توجهی بر رفتار بار داخل آسیا دارد. به همین دلیل، بررسی نقش آستر بر الگوی حرکت بار در داخل آسیا موضوع تحقیقات زیادی بوده است [7-5].

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Journal of Analytical and Numerical Methods in Mining Engineering
Volume 10, Issue 22
May 2020
Pages 95-106

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History

  • Receive Date: 18 May 2019
  • Revise Date: 12 August 2019
  • Accept Date: 06 January 2020

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