金刚石刀头磨削铁矿石电耗的影响因素

丁彩志; 庄世勇; 宋磊博; 邓勇; 王寰宇; 顾路

doi:10.13394/j.cnki.jgszz.2024.0031

金刚石刀头磨削铁矿石电耗的影响因素

doi: 10.13394/j.cnki.jgszz.2024.0031

1.
辽宁科技学院资源与土木工程学院, 辽宁本溪 117004
2.
绍兴文理学院土木工程学院, 浙江绍兴 312000
3.
招金矿业股份有限公司, 山东烟台 265400

基金项目: 辽宁省教育厅基本科研项目（LJKFZ20220281）；本溪市科技创新课题研究项目（BKYH2304）；辽宁科技学院大学生创新创业训练计划资助项目（202411430062）。

详细信息

作者简介:
通信作者：庄世勇，男，1969年生，副教授、硕士。主要研究方向：采矿设备、数字矿山和工程爆破。E-mail：418966927@qq.com

中图分类号: TD42; TG74; TG58; TQ164
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- 文章访问数: 34
- HTML全文浏览量: 20
- PDF下载量: 2
- 被引次数: 0
出版历程
- 收稿日期: 2024-02-21
- 修回日期: 2024-05-13
- 录用日期: 2024-05-16
- 网络出版日期: 2025-03-24
- 刊出日期: 2025-02-20

Influencing factors of power consumption in grinding iron ore with diamond cutter head

1.
School of Resources and Civil Engineering, Liaoning University of Science and Technology, Benxi 117004, Liaoning, China
2.
School of Civil Engineering, Shaoxing University of Arts and Sciences, Shaoxing 312000, Zhejiang, China
3.
Zhaojin Mining Industry Co., Ltd., Yantai 265400, Shandong, China

摘要

摘要: 金刚石刀头磨削铁矿石的电耗是磨采机作业的核心指标，通过搭建实验台并采用2种金刚石圆锯片和2种磨轮对2种铁矿石样本进行磨削实验，得到不同刀头及磨削线速度、磨削厚度、磨削宽度、磨削移动速率等参数下的电耗实验数据，据此计算及分析磨削效率和电耗间的关系。结果表明：矿石1的磁性铁区、矿石2的石英区和磁性铁区额定电机电耗平均值分别为50.41、36.05和15.17 (kW·h)/ t，且添加铁片的锋利型刀头可有效降低铁矿石的磨削电耗；在一定范围内增加磨削宽度和金刚石磨轮直径，可提高磨削效率并降低电耗，且矿石的岩石特性对磨削电耗影响较大。此外，合适的金刚石刀头磨削方向有利于矿浆收集，并最大化地切向推压对切削力的增益效果。单次磨削移动距离Δs与磨削效率密切相关，且与金刚石切入深度Δh直接相关。在M1～M6 6个实验方案中Δs值范围分别为6.01～14.35、3.23～9.96、4.14～15.04、26.44～32.09、1.62～5.37和2.02～5.64 μm时调整Δs值，能够有效降低磨削电耗；且当M1～M6的Δs值分别为14.35、6.65、15.04、32.09、5.37和3.22 μm时，磨削电耗最低。但要确定最适用的Δs值，需综合考虑金刚石工具的尺寸结构、刀头性能、矿石的岩石特性、作业参数、刀头受力情况等因素，以找到其适应不同情况的合理取值范围。
- 磨采机 /
- 金刚石锯片 /
- 金刚石磨轮 /
- 磨削效率 /
- 磨削电耗
Abstract: Objectives The existing mining equipments, such as coal mining machines, excavators, tunneling machines, and diamond tools, are combined to form a new mining equipment called the“grinding mining machine”, which is used for grinding mining. The main advantage of grinding mining applied in metal mines is that it greatly simplifies the mining process. However, whether it can be popularized and applied depends on whether its operating cost is close to or lower than the mining cost of drilling and blasting methods. Among these, the energy consumption cost of grinding mining machine operation is one of the most critical control indicators. The existing cutter heads of diamond tools, such as diamond circular saw blades and diamond grinding wheels, are used to grind iron ore. The relationship between grinding power consumption and the type of diamond cutter heads, the rock characteristics of iron ore, and the grinding operation parameters are studied. The factors affecting the grinding efficiency and the cost of the grinding mining machine are explored to find a reasonable range of values that can adapt to different situations. Methods An experimental platform was built, and two types of diamond circular saw blades and two types of diamond grinding wheels were used to conduct grinding experiments on two types of iron ore samples. There were a total of six experimental schemes, and power consumption experimental data were obtained for different blade heads and their grinding line speeds, grinding thicknesses, grinding widths, grinding movement rates, etc. Based on this, the rated grinding efficiency, the rated motor power consumption, and the rated grinding power consumption were calculated. The main influencing factors of power consumption in grinding iron ores with diamond cutter heads were analyzed by comparing the above data. Results According to the experimental data and the calculation analysis of the six experimental schemes, the following results were obtained: (1) The average rated motor power consumption of the magnetic iron zone of ore 1, the quartz zone, and the magnetic iron zone of ore 2 are 50.41, 36.05, and 15.17 (kW·h)/t, respectively. This indicates that the rock characteristics of ore, such as uniaxial compressive strength, quartz content, and particle size, have a significant impact on power consumption during grinding. The higher the uniaxial compressive strength of the ore, the higher the quartz content and the smaller the quartz particle size, the higher the power consumption of grinding the ore. (2) Two different types of diamond circular saw blades and two types of diamond grinding wheels were used to conduct grinding experiments on two different iron ore samples. Compared with other types of diamond heads, the use of sharp diamond heads with added iron sheets can significantly reduce power consumption during ore grinding operations. (3) Under the condition of constant rated power of the main motor, the grinding efficiency of the grinding wheel can be improved, and the power consumption of the motor can be reduced by optimizing the width and the diameter of the grinding wheel. (4) The single grinding movement distance Δs is closely related to grinding efficiency and directly related to the diamond cutting depth Δh. When the Δs value ranges from 6.01 to 14.35, 3.23 to 9.96, 4.14 to 15.04, 26.44 to 32.09, 1.62 to 5.37, and 2.02 to 5.64 μm in the six experimental schemes of M1 to M6, the grinding power consumption can be effectively reduced by adjusting the Δs value. When the Δs values of M1 to M6 are 14.35, 6.65, 15.04, 32.09, 5.37, and 3.22 μm, respectively, the grinding power consumption is the lowest. However, to determine the most suitable Δs value, it is necessary to comprehensively consider factors such as the size and the structure of the diamond tool, the performance of the cutting head, the characteristics of the ore rock, the operating parameters, and the force situation of the cutting head, in order to find a reasonable range of values that can adapt to different situations. Additionally, according to the force analysis of the diamond cutter head grinding ore and the phenomena observed in the experiment, selecting the appropriate grinding movement direction is conducive to pulp collection and maximizes the gain effect of tangential pushing on the cutting force. Conclusions The energy consumption of diamond cutter heads grinding ores should be optimized in two aspects: the manufacturing technology and the use parameters of the cutter heads. In terms of diamond cutter head manufacturing technology, optimization should be carried out from the aspects of diamond grade, diamond particle size, and matrix compositions, formula, processing technology, as well as the size design, shape and arrangement of diamond cutting heads. Cutting heads that are both sharp and durable for grinding different types of ores should be developed to reduce energy consumption and operating costs. In terms of using operational parameters, further optimization research should be conducted on grinding size parameters and dynamic parameters to improve grinding efficiency, reduce grinding energy consumption and operational costs, and provide experimental and theoretical basis for the manufacturing of grinding and mining machines. The core technology of the grinding mining machine lies in the manufacturing technology of the grinding drum, and optimizing diamond cutter head grinding ores is fundamental to improving the grinding drum manufacturing technology.
- grinding and mining machine /
- diamond saw blade /
- diamond grinding wheel /
- grinding efficiency /
- grinding power consumption

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图 1 磨矿实验平台

1—主电机；2—纵向移动驱动电机；3—纵向移动装置；4—横向移动装置；5—垂直升降装置；6—传动系统；7—喷水装置；8—矿浆收集槽；9—丝杠升降机顶紧装置；10—配重；11—金刚石磨轮；12—实验大块铁矿石

Figure 1. Mineral grinding experimental platform

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图 2 2种金刚石圆锯片

Figure 2. Two types of diamond circular saw blades

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图 3 2种金刚石磨轮

Figure 3. Two types of diamond grinding wheels

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图 4 2种大块铁矿石

Figure 4. Two types of bulk iron ores

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图 5 磨削效率、电机电耗柱状图

Figure 5. Bar chart of grinding efficiency and motor power consumption

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图 6 额定磨削效率、额定电机电耗柱状图

Figure 6. Bar chart of rated grinding efficiency and rated motor power consumption

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图 7 2种刀头磨削矿石1的表面对比

Figure 7. Surface comparison of two types of cutting heads for grinding ore 1

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图 8 金刚石刀头磨削矿石时的受力图

Figure 8. Force diagram of diamond blade during grinding ore

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图 9 金刚石刀头磨削矿石的过程

Figure 9. Process of grinding ore with diamond blade

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图 10 电机电耗E与Δs间的关系

Figure 10. Relationship between electric power consumptionE and Δs

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图 11 磨削电耗E_g与Δs间的关系

Figure 11. Relationship between Grinding power consumptionE_g and Δs

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表 1 2种金刚石圆锯片参数

Table 1. Two types of diamond circular saw blade parameters

类型	外径 D₁ / mm	刀头宽 w₁ / mm	刀头长 L₁ / mm	刀头高 H₁ / mm	刀头间距 h₁/ mm	刀头数量 n₁ / 个
锯片1	920	7.00	24.00	14.00	17.27	70
锯片2	530	12.60	23.00	15.00	16.25	40

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表 2 2种金刚石磨轮参数

Table 2. Two types of diamond grinding wheel parameters

类型	外径 D₂ / mm	刀头宽 w₂ / mm	刀头长 L₂ / mm	刀头高 H₂ / mm	刀头间距 h₂ / mm	刀头组数 n₂ / 组
磨轮1	150	24.00	70.00	15.00	12.23	13
磨轮2	150	10.00	70.00	8.00	6.82	28

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表 3 4种金刚石工具刀头的主要质量指标

Table 3. Main quality indicators of four types of diamond tool cutting heads

类型	金刚石类型	金刚石粒度标记	金刚石浓度 C / %	结合剂	洛氏硬度 / HRB
锯片1	中南2140	40/45	40	铁基配方	90
锯片2	中南2280	35/40	35	铜基配方	85
磨轮1	中南2160	40/45	30	铁基配方	90
磨轮2	中南2160	35/40	25	铁基配方	90

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表 4 2种铁矿石特性对比

Table 4. Comparison of characteristics of two iron ores

类型	矿石密度 ρ/ (t·m⁻³)	单轴抗压强度 σ / MPa	TFe 平均品位 ω₁ / %	mFe 平均品位 ω₂ / %	石英质量分数 ω₃ / %	石英粒径 d₁ / mm
矿石1	3.4	185.22～ 252.84	30.05		50～60	0.06～0.41
矿石2	2.9	136.90	18.70	8.58	20～35	0.40～1.30

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表 5 6个实验方案典型实验数据

Table 5. Typical experimental data of six experimental schemes

实验方案	实验序号	磨削线速度 v _l / (m·s⁻¹)	磨削厚度 d / cm	磨削宽度 b / cm	磨削移动速率 v_m / (cm·min⁻¹)	电机实际平均功率 P / kW	磨削效率 Q / (t·h⁻¹)	电机电耗 E / [(kW·h)·t⁻¹]	电机空载功率 P_c / kW	额定磨削效率 Q_max / (t·h⁻¹)	额定电机电耗 E_min / [(kW·h)·t⁻¹]
M1	1	23.11	1.40	0.70	225.6	5.91	0.045	112.30	3.00	0.186	69.12
	2	23.11	1.61	0.70	112.8	4.82	0.026	159.28	3.00	0.171	75.18
	3	23.11	1.85	0.70	225.6	7.05	0.060	101.38	3.00	0.177	72.80
	4	23.11	3.51	0.70	112.8	6.44	0.057	97.62	3.00	0.197	65.18
	平均						0.047	117.64		0.183	70.57
M2	1	26.63	8.50	1.26	11.4	4.45	0.025	153.11	3.20	0.235	54.67
	2	26.63	8.80	1.26	22.7	5.56	0.051	92.80	3.20	0.257	50.07
	3	26.63	8.80	1.26	34.0	6.90	0.077	76.89	3.20	0.245	52.41
	4	26.63	12.00	1.26	11.3	4.85	0.035	119.25	3.20	0.249	51.57
	平均						0.047	110.51		0.247	52.18
M3	1	28.26	3.00	7.30	22.6	8.37	0.101	71.04	3.00	0.226	56.97
	2	28.26	3.30	6.30	11.3	5.37	0.048	96.03	3.00	0.243	52.98
	3	28.26	4.00	6.30	33.8	9.37	0.174	46.21	3.00	0.327	39.27
	4	28.26	2.50	7.00	45.1	10.88	0.161	57.91	3.00	0.245	52.43
	平均						0.121	67.80		0.260	50.41
M4	1	28.26	3.70	1.20	67.7	7.60	0.061	106.22	3.00	0.160	80.36
	2	28.26	3.20	1.20	90.2	8.08	0.071	98.00	3.00	0.167	77.02
	3	28.26	3.40	1.25	79.0	8.00	0.068	100.10	3.00	0.164	78.20
	4	28.26	3.50	1.30	68.0	7.90	0.063	107.26	3.00	0.155	83.16
	平均						0.066	102.89		0.161	79.68
M5	1	28.26	4.50	6.50	11.4	5.16	0.058	76.22	3.50	0.402	31.98
	2	28.26	4.00	6.60	22.6	7.40	0.104	61.09	3.50	0.306	41.99
	3	28.26	2.50	5.50	13.5	4.53	0.032	120.20	3.50	0.361	35.65
	4	28.26	4.00	6.00	11.3	4.96	0.047	90.08	3.50	0.372	34.59
	平均						0.060	86.89		0.360	36.05
M6	1	28.26	1.20	6.40	45.1	4.19	0.060	59.58	3.50	1.004	12.80
	2	28.26	1.20	6.40	56.6	4.62	0.076	52.35	3.50	0.777	16.55
	3	28.26	1.20	6.40	67.7	4.74	0.090	44.90	3.50	0.839	15.32
	4	28.26	1.20	6.40	79.0	5.01	0.106	40.67	3.50	0.804	15.99
	平均						0.083	49.38		0.856	15.17

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