Process test is to provide a basis for beneficiation plant design (or existing concentrator transformation), carried out before the initial concentrator design (or proposed site transformation program). Generally, the laboratory test is carried out, and then based on the test of the laboratory, it is decided whether to conduct a semi-industrial or industrial test depending on the situation.
The content of the mineral processing process test and the necessary data collection are generally formulated by the experimental research unit, and the conditions can be determined by the combination of the test, design and production departments.
1. The general content of the collected materials is as follows, but the specific project needs to be treated differently according to different conditions.
(1) Understand the objectives of the task assigned by the higher authorities and the requirements submitted by the entrusting unit, such as: the size of the concentrator, the length of service; the comprehensive utilization of the main useful components and companion; the division of the test phase; the date of completion of the test; the single treatment of the concentrator The ore of the deposit is also several deposits, different types of ore; the special requirements of the user on the chemical composition of the concentrate and the requirements of the grade and grain size of the concentrate; the supply and performance of the water source, mineral processing agent, roasting fuel, etc. Analyze data and so on.
(2) Understand relevant geological data, such as: type of deposit; geological reserves; ore body occurrence; ore type; grade characteristics; inlay characteristics; changes in surrounding rock gangue; prospect evaluation; sampling design.
(3) Understand the information on mining design, such as: mining development plan and mining method; mixed mining and mining of different types of ore; surrounding rock mixing rate and ore mining grade; ore type ratio and average of mining design mining area Grade; mining design of ore type and average grade for mining in 5-10 years.
(4) Understand the mineral processing information, for example: the special requirements of the ore dressing design for the test. The experimental research and production practice of similar ores at home and abroad, and the selection techniques that may be applied.
Second, the main content of the beneficiation process test
(1) Study on ore properties
It is the basis for comparison and analysis with similar ore production practices when selecting the beneficiation plan and determining the design plan of the plant. Some of the data are the original data necessary for the specific design of the plant.
Ore properties include: spectral qualitative and semi-quantitative, chemical analysis, rock and mineral identification, phase analysis, particle size analysis, magnetic analysis, heavy liquid analysis, gold analysis, grinding fineness, ore grindability, and various Physical properties (specific gravity, specific magnetic susceptibility, electrical conductivity, moisture, true specific gravity and pseudo specific gravity, stacking angle and friction angle, hardness, viscosity, etc.).
(2) Mineral processing method, process structure, mineral processing index and process conditions
It is directly related to the design plan and specific composition of the concentrator. It is the main raw material for the design of the plant. It must be carefully considered. The ore dressing method and process structure are required, and the ore dressing index is reliable.
If the ore is complex in nature or has less ore dressing practices, certain exploratory tests should be conducted before the development of the test plan. The test plan to be developed should include a program with similar production practices and a plan for applying new technologies (referring to new technologies that have some successful experience at present, and can be put into production after a certain effort). In general, more than two multi-scenario trials should be conducted to provide a technical and economic comparison of the design. In the multi-program test, we should focus on one or two of the process plans.
For the beneficiation process conditions, it is mainly to find out the influence law and determine the optimal range of the main process conditions for the main operations. In determining the conditions (factors and levels) of the test, the existing experience should be fully utilized to grasp the main contradictions and minimize the amount of test work.
The process structure should determine the number of grinding and sorting segments in the process, the structure and number of coarse, fine, sweeping, and give the quality process. The slurry process should be given in the necessary fashion. The process conditions used should be indicated in the flow chart.
(III) Analysis of mineral processing products
For the analysis of concentrates, medium mines and tailings products, in special cases, the ore and products of a certain operation should also be subjected to spectral analysis, chemical analysis, gold analysis, phase analysis, particle size analysis and Rock mine identification, etc., to illustrate the following issues:
1. Why raise the concentrate grade is not high? Why low recovery? Chromium, manganese ore ratio Why ferrochrome, ferromanganese ratio below standard? Why mine in the election and so on.
2. The enrichment direction of some companion generation points that can be comprehensively utilized.
3. The use of certain mineral processing operations and certain new technologies, indicating their recovery and separation depth for different minerals.
Certain properties of the product, such as chemical composition, particle size characteristics, true specific gravity and bulk specific gravity, sedimentation speed of concentrates and tailings, are also essential for plant design.
(4) Special test items are special requirements put forward by users and design units according to the situation. For example, the use of backwater flotation and beneficiation wastewater purification test, flotation concentrate filtration test, graded ore utilization test, production test after the supplementary test.
Third, the laboratory small process test
The laboratory small-scale process test is the basic test of the beneficiation process test. If the test does not meet the requirements of the design work, the laboratory continuous test, semi-industrial test or industrial test is carried out as needed. The latter are based on the content of the former test, and the tests are verified, supplemented or added according to the purpose and requirements of the test. The single ore dressing technology test should also start from the small test of the laboratory, and gradually expand the scale of the test. The content of each test is determined according to the purpose of the test. Before the various types of mineral processing tests as the design basis, the design requirements of the various types of mineral processing tests in the “test requirements†proposed by the design unit to the test unit are as follows:
(1) Study on the properties of raw ore
1. Spectral analysis. Identify the approximate content of various elements and the presence or absence of rare elements and other elements for comprehensive recovery.
2. Multi-element analysis or full analysis. Identify the content of major components, associated beneficial and harmful components in the ore. Chemical analysis of the properties of the slurry is also carried out when necessary to determine soluble salts.
3. Analysis of the test gold. Find out the types and contents of gold, silver and other precious metals (including precious metals such as gold and silver).
4. Microscopic identification. Identify the ore type, mineral composition and content, ore structure, mineral size and embedding characteristics and co-production systems. The analysis of the minerals selected for the purpose of mineral processing.
5. Phase analysis. The state of occurrence of the main useful components of ore and associated beneficial and harmful components, ie their different forms of mineral production. For example, copper ores for an assay NATURAL copper sulfide content relative primary, secondary sulfides, oxides and salts such as copper; iron ore required measurement magnetite, hematite, siderite, hematite the relative content of limonite, pyrite, pyrrhotite, and iron silicate of titanium ore or the like.
6, particle size analysis. Through the sieve analysis and water analysis, the ore particle size characteristics and the respective grain fraction content and metal distribution rate of the primary slime are determined. If necessary, use different concentrations of heavy liquid to determine the yield and metal distribution rate of each fraction according to different density, which provides a basis for heavy liquid separation.
7. Heavy liquid separation. In the ore and rare metal ore of tungsten, tin , lead , zinc , iron, etc., if it is possible to separate most of the gangue without fine grinding, heavy liquid separation test should be carried out to provide for heavy medium pre-selection test. in accordance with.
8. Determination of physical and mechanical properties of ore. Density, loose density, angle of repose, internal friction angle, friction coefficient, hardness, viscosity, moisture, specific magnetic susceptibility, electrical conductivity, mud content, etc. of the ore were measured.
9. Other necessary analytical research content.
(II) Experimental study on the grinding process (including washing and pre-selection)
The laboratory should generally perform the following tests and measurements:
1. Determination of work index. If the calculation of the crushing and grinding equipment is carried out according to the Bond formula, the determination of the crushing and grinding work index should be carried out. The measured work index has the following types: coarse, medium and fine crushing work index; self-hardening work index; rod grinding work index; ball grinding work index; and coarse concentrate or medium ore re-grinding index.
2, the wearability measurement. If the grinding method is used to calculate the grinding equipment, the ore grinding degree of each section of the grinding should be determined. In the ore grindability test, the standard ore sample used as a comparative test shall be adopted. The non-ferrous metal ore dressing plant shall design the ore of the Yangjiazhangzi molybdenum ore as the standard ore sample, and the chemical mine pyrite ore dressing plant shall be designed to the mountain. when ore pyrite ore sample standard deposited in metamorphic rock phosphate ore Jinping standard phosphate ore, phosphate rock and silicon deposition type calcium phosphate rock when employed in multi-stage grinding ore Wangji third layer The ore is a standard ore sample, and the ferrous metal ore dressing plant is designed to produce the ore of the ore dressing plant as a standard ore sample in a similar grinding process. In view of the often changing nature of the ore mined in the production mine, the standard ore sample should be taken at the same time as the mill processing capacity, technical conditions and relevant technical parameters of the mine at the time of processing the ore.
3. Abrasion index test. The consumption of grinding media and grinding machine liners is a major consumption indicator of the ore dressing plant, so the consumption index should be determined.
4. Self-grinding medium performance test. When self-grinding is proposed, the self-grinding medium test should be selected to determine whether semi-industrial or industrial tests are required for self-grinding or semi-self-grinding.
5. When studying the crushing process, it should be considered whether it is necessary and possible to wash the mine according to the ore content and the nature of the slime and its influence on the crushing, grinding, sorting and dewatering operations. If it is necessary to wash the mine, it is necessary to carry out the corresponding washing and washing overflow treatment test.
6. Experimental study on ore pre-selection. The ore pre-selection may be carried out before the original ore is ground, depending on the waste rock mixing rate at the time of mining or the need for enrichment of the ore grade. If possible, an ore pre-selection test is required, and a grinding process for pre-selected ore is included in the grinding process test plan.
7. Experimental research on grinding methods and grinding processes. Commonly used grinding methods can be divided into ball milling, rod grinding, self-grinding, semi-self-grinding, gravel grinding, etc. depending on the grinding medium. According to the nature and characteristics of the ore, the relevant experimental data, the similar experience of production and testing, and other factors, the possibility of grinding methods and the necessity of expanding the test should be analyzed, and 1-2 should be selected and recommended. Single or combined grinding method. On this basis, a grinding process or multi-stage grinding, multi-stage continuous grinding or stage grinding (including rough grinding and tailing, medium ore and coarse concentrate re-grinding, etc.) and other grinding processes and grinding fineness Program comparison test.
8. Analysis of grinding products. The grinding feedstock and products (including medium ore, coarse concentrate, etc.) shall be sieved and the degree of monomer dissociation shall be determined.
(III) Experimental study on mineral processing methods and processes
1. Research on mineral processing methods. Due to the development of mineral processing technology, a variety of mineral processing methods can be used to treat an ore. Therefore, in the test, according to the nature of the ore, the requirements of the user for product quality and the construction conditions, the multi-program comparison test of the beneficiation method should be selectively carried out. And choose a reasonable method of mineral processing.
2, the selection condition test
(1) Flotation: tests such as grinding fineness, slurry concentration, pulp temperature, pulp pH (pH), pharmaceutical system, stirring and flotation time should be carried out. In some cases, tests such as water reuse, water quality, drug withdrawal, mud removal, wind pressure and air volume should be used.
(2) Magnetic separation: Generally, magnetic induction strength, material inclusion size, processing capacity, material classification and non-gradation comparison test should be carried out. In addition, for dry weak magnetic separation, the influence of ore water on the selection index should be tested. The effect of ore washing and non-washing on the selection index should be tested. For wet strong magnetic separation, the slurry concentration and washing water should be carried out. Pressure and water volume, tooth-shaped dielectric plate gap (or ball medium diameter, medium filling rate), rotational speed test, etc., as well as the assembly and impact test of ferromagnetic minerals.
(3) Calcination magnetic separation: The calcination atmosphere, calcination temperature, calcination time, fuel type, amount, volatile component, material particle size and other conditions shall be tested and the technical parameters of the production shall be determined.
(4) Re-election: tests should be carried out on the amount of ore, the size and range of the ore, the concentration of the slurry (solid-liquid ratio), the water pressure and water volume, the discharge method and the interception position. In addition, the corresponding process parameters should be tested according to the re-election equipment used.
(5) Heavy medium beneficiation: The test should be carried out on the amount of ore, the size and range of the ore, the density of the heavy medium suspension, the raw materials, density, particle size, addition amount, recovery measures and consumption of the weighting agent. In addition, the corresponding process parameters should be tested according to the different heavy medium equipment used.
(6)Electrical selection: In addition to the selection of the number of segments, operating voltage, pole distance and electrode position, drum speed, ore supply, particle size, temperature, humidity, etc., drum speed and voltage, particle size should also be performed. The relationship between the test, the feedstock analysis and the different levels of comparative tests, the separation plate position adjustment comparison test.
(7) Light picking: First, the washing analysis is carried out, and then the comparative test of the relationship between the ore size and the treatment amount is carried out in the case where the layer is a single layer of ore.
(8) Comparison test of main raw materials such as mineral processing chemicals, fuels and media: comparison of different mineral processing methods and equipment, the types of main chemicals, fuels, media, performance, specifications, consumption, ore dressing effects, etc. Conduct comparative tests and select varieties with good mineral processing indicators, low prices, sufficient sources, low environmental pollution or easy to treat.
3. Experimental study on the selection process structure
(1) Determine the number of selected segments.
(2) Exploring the reasonable number of selection and sweeping operations, increasing the grade and recovery rate of the concentrate, reducing the impurity content of the product, enriching the associated beneficial components or adding the components. Care should also be taken to maintain the self-fluxing properties of concentrates for self-fluxing or alkaline ores.
(3) Identify the nature of the mine and determine the reasonable location or separate treatment plan for the return of the mine.
(4) Carry out the comprehensive condition test of the open circuit on the basis of sufficient unit condition test. The test should pay attention to the stability of the process and operating conditions, and the index should be reproducible.
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