اصلاح طراحی صنعتی مجرای خوراک‌دهی در سنگ‌شکن‌ مخروطی مرحله سوم مجتمع مس سرچشمه

نوع مقاله : علمی-پژوهشی

نویسندگان

1 دانشجوی دکتری، گروه فرآوری مواد معدنی، دانشکده‌ فنی و مهندسی، دانشگاه شهید باهنر کرمان، کرمان

2 کارشناس ارشد، گروه فرآوری مواد معدنی، دانشکده‌ فنی و مهندسی، دانشگاه شهید باهنر کرمان، کرمان

3 استاد، گروه فرآوری مواد معدنی، دانشگاه ولی عصر رفسنجان، رفسنجان

4 دکتری، گروه فرآوری مواد معدنی، مرکز تحقیقات فرآوری مواد کاشی‌گر، کرمان

5 استاد، گروه مهندسی معدن، دانشکده‌ فنی و مهندسی، دانشگاه شهید باهنر کرمان، کرمان

چکیده

بیشترین انرژی مصرفی در کارخانه‌های فرآوری مواد معدنی صرف خردایش سنگ‌ معدن می‌شود، بنابراین استفاده از حداکثر ظرفیت عملیاتی تجهیزات، در بهینه‌سازی مصرف انرژی موثر است. همچنین به دلیل تاثیر کارآیی سنگ‌شکن‌ها بر کارآیی تجهیزات پایین‌دست، بهینه‌سازی مدارهای سنگ‌شکنی همواره مورد توجه بوده است. در این تحقیق، تاثیر شکل مجرای خوراک‌دهی بر عملکرد سنگ‌شکن مخروطی مرحله سوم مجتمع مس سرچشمه مطالعه شد. در پایش‌ها، نوسانات زیاد توان‌کشی سنگ‌شکن و سایش شدید و غیریکنواخت آسترهای آن به عنوان مشکلات این بخش شناسایی شدند که نشانه‌ای از خوراک‌دهی نامناسب به سنگ‌شکن بودند. به همین دلیل، با استفاده از شبیه‌سازی‌های روش اجزای گسسته (راگ) با نرم‌افزار KMPCDEM©، طرح‌های مختلف مجرای خوراک‌دهی با هدف رسیدن به بالاترین درجه یکنواختی در توزیع خوراک روی صفحه توزیع‌کننده سنگ‌شکن بررسی شدند. نتایج نشان داد که با تغییر شکل مجرای خوراک‌دهی از مکعبی به استوانه‌ای، افزایش طول بالای مجرا از صفر به 45 سانتی‌متر، افزایش طول پایین آن از 53 به 95 سانتی‌متر و کاهش سطح مقطع از 34/0 به 24/0 مترمربع، جداشدگی در توزیع خوراک به سنگ‌شکن به حداقل ممکن رسید و خوراک‌دهی یکنواخت انجام شد. با نصب این مجرای جدید در یکی از سنگ‌شکن‌های مخروطی سرچشمه، نوسانات توان‌کشی سنگ‌شکن از 13 به 3 کیلووات کاهش یافت و امکان کنترل خودکار سنگ‌شکن و شرایط خوراک‌دهی خفه فراهم شد. در نتیجه، تناژ سنگ‌شکن 36 درصد افزایش یافت و محصول آن ریزتر و یکنواخت‌تر شد. علاوه بر این، با کاهش نرخ سایش و یکنواختی آن، عمر محور خردکننده و آسترهای سنگ‌شکن، از 8 به 15 ماه افزایش یافت. 

کلیدواژه‌ها

عنوان مقاله [English]

Modification of Design of Feed Chute in A Tertiary Cone Crusher at the Sarcheshmeh Copper Complex

نویسندگان [English]

  • E. Nematollahi 1
  • S. Zare 2
  • F. Ghorbani 2
  • M. Maleki Moghaddam 3
  • A. Ghasemi 4
  • S. Banisi 5
1 Ph.D Student, Kashigar Mineral Processing Research Center, Shahid Bahonar University of Kerman, Kerman, Iran
2 M.Sc, Kashigar Mineral Processing Research Center, Shahid Bahonar University of Kerman, Kerman, Iran
3 Professor, Mineral Processing Group, Vali-e-Asr University of Rafsanjan, Rafsanjan, Iran
4 Ph.D, Kashigar Mineral Processing Research Center, Shahid Bahonar University of Kerman, Kerman, Iran
5 Professor, Mineral Processing Group, Shahid Bahonar University of Kerman, Kerman, Iran
چکیده [English]

Comminution is the most energy intensive operation which constitutes the major portion of operating and capital costs of the mineral processing plants.  Working at the maximum operating capacity of comminution equipment plays a significant role in the efficiency of the circuit.  Also, due to the effect of crusher efficiency on the downstream circuit performance, optimization of the crushing circuits has received considerable attention.  In this research, the effect of feed chute design on tertiary cone crusher performance at the Sarcheshmeh copper complex was studied.  A close monitoring of the performance crusher revealed that main problems were high fluctuations of power draw and uneven and high-rate wear of crusher liners.  Such pitfalls were clear evidences of an improper feeding arrangement into the crusher.  Accordingly, various feed chute designs were employed in the simulations by an in-house developed DEM software called KMPCDEM© to find more uniform feed distribution on the distribution plate of the crusher.  Results showed that by changing the shape of feed chute from cubic to cylindrical, decreasing its surface area from 0.34 to 0.24 m2 and increasing the cylinder length above and below the feed chute plate from 0 to 45 cm and from 53 to 95 cm, respectively, uniform feed distribution was obtained.  After installing the new feed chute design in the plant, a detail monitoring over a period of 15 months showed a reduction of the standard deviation of crusher power draw from 13 to 3 kW.  A better crusher control caused choke feeding.  Therefore, 36% increase in the crusher throughput and finer and narrower product size distribution occurred.  Furthermore, the life of crusher liners increased from 8 months to 15 months on account of more uniform and lower rate of wear on mantle and liners.

کلیدواژه‌ها [English]

  • Open Pit Mine
  • Ultimate Pit Limit
  • Optimization
  • Heuristic algorithm

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نشریه مهندسی منابع معدنی
دوره 7، شماره 1 - شماره پیاپی 23
فروردین 1401
صفحه 159-181

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سابقه مقاله

  • تاریخ دریافت: 15 مهر 1399
  • تاریخ بازنگری: 20 تیر 1400
  • تاریخ پذیرش: 19 خرداد 1400

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