How to automate the beneficiation process

In recent years, with the rapid development of applied physics and computer technology such as acoustics and optics, the research and application of beneficiation automation technology has made great progress, which has fundamentally changed the production operation error of the concentrator, the management is inefficient, and the production index is unstable. And other issues. More and more concentrators are aware that beneficiation automation can reduce labor costs in the beneficiation process, streamline operations, increase labor productivity, reduce energy consumption, and stabilize product quality. In recent years, almost all of the newly built and remodeled large and medium-sized concentrators have introduced beneficiation automation technology. Mineral processing automation has become one of the indispensable technical means of modern mineral processing.

1 main testing instrument for mineral processing

The key detection instrument is the "eye" of the entire beneficiation automation system. Whether the instrument is accurate and reliable is often the key to the success of the beneficiation automation system.

A concentration detection

At present, the detection equipment for slurry concentration is still dominated by γ-rays, but the application is greatly limited due to the safety hazard of the radioactive sources. In recent years, with the development of acoustics, the ultrasonic concentration meter technology has become more and more perfect, and the use of ultrasonic concentration meter to measure the slurry concentration has many advantages. Although the accuracy of the ultrasonic concentration meter measurement is greatly affected by the bubble, it is still a good substitute for the gamma ray concentration meter, and the application prospect is very wide.

The basic principle of ultrasonic concentration meter:

The propagation speed of ultrasonic waves in a liquid varies according to the concentration and temperature of the liquid. According to this characteristic, according to the change of the sound velocity and temperature of the measured liquid, the calibration curve recorded in the data component can be used for the chemical solution. The concentration is calculated and the concentration value is obtained.

B particle size detection

In recent years, online particle size analyzers have become more and more widely used, and particle size detection technology is transitioning from offline indirect detection to online direct detection. At present, the more representative online particle size detectors are the PSM400 online particle size analyzer from Denver Automation, the PSI200 online particle size analyzer from Outokumpu, Finland, and the CLY-2000 online particle size analyzer developed by Maanshan Mine Research Institute. The BPSM-I and BPSM-II online particle size analyzers developed by the Research Institute of Mining and Metallurgy.

Laser particle size analyzer

Laser particle size analyzer using schematic

C taste test

Realizing online taste detection is of great significance to beneficiation automation. In recent years, a variety of online grade detection devices have been successfully applied in industry. At present, the online grade analyzers used in China mainly include the Courier series of Outokumpu in Finland and the WDPF online grade analyzer of Maanshan Mine Research Institute. The Curry series of grade analyzers are used in many mines in China, which greatly improves the level of mineral processing automation in China. WDPF online grade analyzer, multiple mines in Yiliang Chihong Mining, Jinduicheng Molybdenum Group, Zhejiang flat water, copper ore and other applications have achieved good effects.

Taste analyzer

Taste analyzer use schematic

D level detection

The traditional level detection instrument technology is relatively mature, but it needs to be correctly selected according to the application conditions. In recent years, with the rapid development of laser technology, laser level gauges have become more and more widely used in beneficiation automation. The laser level gauge has been applied in many fields such as flotation tank liquid level detection and mine ore volume detection in China, and its application is good.

Laser level meter

Laser level measurement principle

2 Control of the crushing process

In recent years, China has carried out automation research on two new crushers . Through the detection and analysis of the crusher load, the crusher is optimized to control the mine. Through the detection of the silo material level and the analysis of the crusher capacity, Implement automatic fabric and crusher load optimization balance control.

3 Control of grinding operations

The grinding system is the most energy-intensive process in the entire concentrator. Due to the inherent characteristics of the grinding system, it is difficult to accurately measure the mill load, so the introduction of the integrated automation system is the key to solving the problem. In recent years, the automation control of the crushing and grinding system has gradually realized multi-information collection, centralized processing and inter-distribution monitoring of multiple devices, and chain control. Shizhuyuan Nonferrous Metals Co., Ltd. cooperated with Changsha Yikong Industrial Automation Co., Ltd. to introduce an advanced automatic control system for grinding, which improved the quality and efficiency of grinding and grading operations and stabilized the process parameters. Liaoning Jia Jiabao iron ore using a highly efficient integrated automation system grinding, grinding to achieve a comprehensive automation system, improve the economic efficiency of the concentrator.

4 Control of the flotation process

Flotation dosing control

Dosing is an important part of flotation production, and the control technology of pharmaceuticals is relatively mature. There are many types of drug control equipment. From the perspective of actuators for drug addition, there are mainly two types of solenoid valves and dosing pumps. In recent years, some new types of quantitative devices have appeared, but their applications are not extensive. At present, the most widely used field control is solenoid valve control. Xu Weichao et al. designed an automatic control system that integrates dispensing and dosing. The practical application shows that the control system achieves a high degree of automation of dispensing and dosing operations, and has significant effects in reducing drug consumption and improving flotation efficiency.

B Flotation tank level control

Reasonable and effective control of the flotation tank liquid level plays an important role in improving the flotation index. At present, when detecting the level of the slurry in the flotation tank, the float type liquid level transmitter is often used, but the liquid level cannot be accurately monitored. The Beijing Research Institute of Mining and Metallurgy independently developed a new type of laser level gauge, which successfully realized the automatic control of the flotation tank level of the KYF-200 flotation machine, and realized industrial application in the Dashan Concentrator.

5 major problems and trends

Problems in the concentrator: The automation system requires a lot of maintenance work, and the maintenance cost is high; there is no perfect maintenance means after the equipment such as the test instrument is put into operation; the concentrator cannot solve the failure of the system by itself; the automatic detection instrument of each parameter in the beneficiation process Lack of pertinence and innovation; there is no breakthrough in the research and development of important testing instruments and related core equipment. Some important parameters of the instrument still have problems such as low measurement accuracy and short service life, and unique parameter fluctuations in the beneficiation process. Lack of response measures.

The digitization, intelligence and virtualization of the development trend sensor have been greatly developed. The digital and intelligent sensors replace the traditional one-way, single-variable input and output of the sensor to meet the requirements of the beneficiation process. The virtualization of the sensor allows the mining sensor to work longer and more accurately and stably. Therefore, digitalization, intelligence and virtualization are still the inevitable trend of future mineral processing automation development.

The development and application of wireless data communication systems such as OPC technology has become a new trend in the development of mineral processing automation. Lu Bo, Wang Baosheng and others from the Beijing Research Institute of Mining and Metallurgy developed a wireless data management system used in the concentrator. The system is used for parameter inspection, equipment maintenance and paperless mobile data entry in the process of mineral processing automation.

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