CN117839793A

CN117839793A - Iron ore treatment equipment

Info

Publication number: CN117839793A
Application number: CN202311391034.3A
Authority: CN
Inventors: 沃伦·哈里斯; 丹尼尔·乔利
Original assignee: Fortescue Metals Group Ltd
Current assignee: Fortescue Ltd
Priority date: 2018-11-27
Filing date: 2019-11-27
Publication date: 2024-04-09
Also published as: AU2019387713A1; BR112021010210A2; WO2020107070A1; AU2021261897B2; AU2021261897A1; CN113286658A; AU2021221848B2; AU2021221848A1; AU2023285957A1

Abstract

An apparatus for treating iron ore comprising a primary crusher, a secondary crusher and a tertiary crusher, wherein the apparatus comprises a pair of independently operable conveyors from the primary crusher to the secondary crusher, from the secondary crusher to the tertiary crusher, and/or from the tertiary crusher to a screen, wherein the screen returns to the tertiary crusher.

Description

Iron ore treatment equipment

The present application is a divisional application of PCT patent application filed on 11/27 in 2019 with international application number PCT/AU2019/051301 (entering the national stage of china on 27 in 2021, with national stage application number 201980078094.5, entitled "apparatus and method for treating iron ores").

The entire contents of the patent specification (including the figures) of PCT/AU2019/051301, which was originally filed, are incorporated herein by reference.

Technical Field

The present invention relates generally to an apparatus and method for treating iron ore and, more particularly, but not exclusively, to an apparatus and method for treating iron ore having lower costs and lower staffing requirements during maintenance outages.

Background

The present invention implements a modular ore processing system that replicates the sub-portions of the system rather than making each sub-portion larger. This change in the form of the established awareness enables the removal of the surge bin and the buffering capacity and can reduce the height of the building in the plant, thereby reducing the cost of the plant and redundancy in the system, so that the plant can be partially shut down for maintenance while continuing to run at lower productivity.

Disclosure of Invention

According to one aspect of the present invention, there is provided an apparatus for treating iron ore having a classification breaker (sizer) as a secondary breaker for breaking up iron ore.

According to another aspect of the present invention there is provided an apparatus for treating iron ore comprising a mineral breaker (mineral breaker) as a secondary breaker for breaking up iron ore, wherein the mineral breaker comprises a breaking drum mounted within a housing for breaking up mineral into smaller pieces.

Those skilled in the art will recognize that suitable mineral crushers may be referred to as "classification crushers" (sizers), "roller crushers" (or "scroll crushers"). Although the example shown in the figures uses a twin roll crusher, other examples may use more rolls, e.g. 4 or 6 rolls.

Preferably, the mineral breaker has a pair of side-by-side breaker drums rotatably mounted in a housing. More preferably, the pair of crushing rollers rotate in opposite directions to facilitate crushing of minerals between the pair of crushing rollers. More preferably, each crushing drum is provided with circumferentially extending sets of crushing teeth that are axially spaced apart along the crushing drum, the axial spacing of each set of crushing teeth on one of the drums being staggered with the axial spacing of the sets of crushing teeth on the other drum such that the crushing teeth of one set of crushing teeth on one drum pass between adjacent two sets of crushing teeth on the other drum. The applicant has determined that the use of the mineral breaker is particularly advantageous in secondary crushing.

Preferably, the apparatus comprises a gyratory crusher (gyratory crusher) as the primary crusher. More preferably, the apparatus comprises a cone crusher as a three-stage crusher. Preferably, the classifying breaker is fed directly from the screen. In particular, unlike the screens (grizzly screens) typically found in primary crushing applications, the classification crushers may be fed directly from one or more coarse stage screens (scalping stage screen). In one example, each of the secondary classification crushers will be fed from only one screen.

According to another aspect of the present invention there is provided an apparatus for treating iron ore comprising a primary crusher, a secondary crusher and a tertiary crusher, wherein the apparatus comprises a pair of independently operable conveyors from the primary crusher to the secondary crusher (open circuit), from the secondary crusher to the tertiary crusher (open circuit), and/or from the tertiary crusher to a screen, wherein the screen is returned to the tertiary crusher (closed circuit).

According to another aspect of the present invention, there is provided an apparatus for treating iron ore, comprising a primary crusher, a secondary crusher and a tertiary crusher, wherein the apparatus comprises a pair of independently operable conveyors from the primary crusher to the secondary crusher (open circuit), a pair of independently operable conveyors from the secondary crusher to the tertiary crusher (open circuit), and three independently operable conveyors from the tertiary crusher to a screen, wherein the screen is returned to the tertiary crusher (closed circuit).

Preferably, in one example, the apparatus has a single primary crusher, a plurality of secondary crushers, and a plurality of tertiary crushers. More preferably, in one example, the apparatus has a single primary crusher, two secondary crushers and three tertiary crushers. Applicant has determined that there is an upgrade path that can easily extend the design to 2 Primary (2 x Primary), 3 Secondary (3 x Secondary) and 4 tertiary (4 x tertiary). The example shown in the figures is a factory configuration for about 30MTPA, however, it will be appreciated that the factory can be extended above this value by adding a breaker circuit. By means of parallel processing, expansion of factory configuration is facilitated.

According to another aspect of the present invention, there is provided an apparatus for treating iron ore, comprising a primary crusher and a secondary crusher, wherein the secondary crusher is arranged to be fed from the primary crusher.

Preferably, the secondary crusher is arranged to feed directly from the primary crusher. More preferably, the secondary crusher is fed directly from the primary crusher, there being no bin for accumulating material to be fed to the secondary crusher. Adjustability of the feed rate can be achieved by means of a variable speed drive on the conveyor, feeder and/or crusher to accommodate each stage of crushing and screening.

Alternatively, the secondary crusher is arranged to feed directly from a screen for filtering the material from the primary crusher, depending on the size of the material.

According to another aspect of the present invention, there is provided an apparatus for treating iron ore comprising at least one conveyor, wherein each conveyor of the apparatus has a fixed single discharge point.

According to another aspect of the present invention, there is provided an apparatus for treating iron ore, comprising a single yard belt located below a reversible stacker/reclaimer such that the single yard belt is configured to provide a direct loading function for loading iron ore onto a train, a stacking function for stacking iron ore onto a stack, and a reclaiming function for reclaiming iron ore from the stack onto the train.

According to another aspect of the present invention, there is provided an apparatus for treating iron ore, comprising a single belt for transporting iron ore from a three-stage crusher, wherein the single belt is positioned below a reversible stacker/reclaimer such that the single belt is configured to provide a direct loading function for directly loading iron ore material onto a carrier, a stacking function for stacking iron ore material onto a pile, and a reclaiming function for reclaiming iron ore material from the pile onto a train. The belt may be fed from a primary, secondary or tertiary crusher.

The belt and stacker/reclaimer may operate in unison, the belt may be loaded directly while also receiving ore from the stacker/reclaimer.

Brief description of the drawings

The invention is described by way of non-limiting example with reference to the accompanying drawings, in which:

fig. 1 (fig. 1A and 1B) shows an example of an apparatus for treating iron ore according to an example of the present invention in a process flow diagram;

FIG. 2 is an enlarged view of the left half of FIG. 1;

FIG. 3 is an enlarged view of the right half of FIG. 1;

FIG. 4 is a top perspective view showing a primary crusher of the apparatus;

FIG. 5 is a top perspective view showing a secondary crusher of the apparatus;

FIG. 6 is a top perspective view showing a three-stage crusher of the apparatus;

FIG. 7 is a top perspective view showing a yard belt of the apparatus and a train loading apparatus;

fig. 8 shows a detail of the train loading device;

FIG. 9 shows a top perspective view of the primary, secondary and tertiary crushers and the conveyor between these stations;

FIG. 10 shows a remote top perspective view of a secondary crusher, a tertiary crusher and a land crusher;

FIG. 11 shows a remote top perspective view of a secondary crusher, a tertiary crusher, an overall natural fines conveyor, and an overall resultant fines conveyor; and

Fig. 12 shows a plan view of a portion of a primary crusher, a secondary crusher, a tertiary crusher, an overall natural fines conveyor, an overall produced fines conveyor, and a land conveyor.

Detailed Description

Referring to fig. 1-12, an apparatus 10 for treating iron ore 12 is shown, the apparatus 10 having a classification breaker 14 as a secondary breaker (secondary crusher) for breaking up the iron ore 12. Advantageously, the applicant has determined that using the classification breaker 14 as a secondary breaker can avoid the use of large bins (required for cone breakers) because the classification breaker 14 does not need to supply iron ore material at a constant rate as is required for cone breakers. Furthermore, since the use of bins is avoided, which are typically large bins with a large height, the apparatus can be built at a low building height, thereby reducing costs and facilitating reliability and maintenance.

The classification crusher 14 may be in the form of a dual shaft mineral classification crusher (twin shaftmineral sizer) which is a mineral crusher 16 comprising a crushing drum 18 mounted within a housing 20 for crushing mineral into smaller pieces. More specifically, the mineral breaker 16 may have a pair of side-by-side breaker drums 18 rotatably mounted within a housing 20. In this arrangement, the pair of crushing rollers 18 rotate in opposite directions so that mineral is crushed between the pair of crushing rollers 18. Each crushing drum 18 may be provided with circumferentially extending sets of crushing teeth that are axially spaced along the crushing drum 18, with the axial spacing of the sets of crushing teeth on one drum 18 being staggered with the axial spacing of the sets of crushing teeth on the other drum 18 such that the crushing teeth of one set of crushing teeth on one drum 18 pass between adjacent two sets of crushing teeth on the other drum 18. The housing 20 may be made of steel plates that are bolted and welded together.

One end of the crushing cylinders 18 may be provided with gear means, wherein one of the crushing cylinders 18 is geared with respect to the other crushing cylinder such that they are driven from a common drive means to rotate in opposite directions. The pair of rollers 18 may rotate to direct material therebetween. The geared connection between the pair of rollers may be used to set the rotational position of the rollers 18 relative to each other. The crushing teeth on the drums 18 may be arranged to define a series of separate helical structures circumferentially spaced around each drum 18. The spiral structures extend in different directions along the axis of each drum, i.e., for the left drum, the spiral structures may extend in a counter-clockwise direction away from the nearest end wall; for the right side drum, the spiral structure may extend in a clockwise reverse direction. Each spiral structure extending along a respective roller may pass through an arc of about 90 degrees.

The shaping of the crushing teeth and their relative positions and dimensions may be configured such that during use there are two types of crushing action: the primary crushing action on larger pieces of mineral, sandwiching the mineral between opposed leading faces of crushing teeth on opposed rollers; and a secondary crushing action, sandwiching the mineral material between the trailing edge of a crushing tooth and the leading face of another crushing tooth. The arc through which the end helical structure passes ensures, for example, that a secondary crushing action takes place.

The spacing between the pairs of drums 18 may be selected so that there is sufficient clearance to avoid compacting the material as the tips of the crushing teeth on one drum 18 sweep across the slots defined between the sets of crushing teeth on the other drum 18. Thus, by appropriate selection of the spacing, fine material can be passed through the classification breaker quickly without being compacted, thereby enabling the classification breaker to break larger pieces of material by primary and/or secondary crushing.

Returning to fig. 1, the apparatus 10 may include a gyratory crusher 22 as a primary crusher. The apparatus 10 may include a cone crusher 24 as a three-stage crusher. The classification breaker 14 may be fed directly from the screen 26. Advantageously, there is no need to use a silo to feed the crusher 14, as the crusher 14 is not required to crush a constant feed rate of iron ore material. The screen 26 screens the iron ore material according to particle size, allowing the smaller particle size material to bypass the classification breaker 14 as natural fines 28, while the remainder is classified according to coarse screen midds 30 and classification breaker feed 32.

Referring to fig. 4, the primary crushing station may cut into rock instead of having a retaining wall; the gyratory crusher 22 may be mounted on a combination of steel and concrete for crushing the iron ore material 12 to a large silo or silo 70. The large bin may have a waist and a pair of leg funnels to distribute crushed iron ore between the two leg funnels from which the crushed iron ore is sent to two separate coarse screen feed conveyors 34, as shown in fig. 1.

Referring to fig. 5, the coarse screen feed device 34 includes a pair of conveyors that convey the iron ore material 12 from the gyratory crusher 22 to the coarse screen 26. Advantageously, by providing two conveyors, two coarse screens 26 and two classifying crushers 14, one of the conveyors may be shut down for maintenance while the other conveyor is operated, enabling on-line maintenance of the entire apparatus 10. This is important because it means that the equipment does not require a lot of personnel for maintenance, which means that the skills of the maintenance crews can be optimized to avoid errors that may occur due to lack of skill (realization of a lot of labor) and/or due to the fact that maintenance is done in a busy state while the equipment is offline. Applicant foresees that with the present invention, shut-down crew will be reduced from 700 to 200 for a given plant size. In the example shown in fig. 1-12, the plant is a plant with an annual production of 1-3 tens of millions of tons.

Referring to fig. 1-3, and referring to the apparatus 10 in the upper half of the process flow diagram, the apparatus 10 includes a primary crusher 22, a secondary crusher 14, and a tertiary crusher 24, the apparatus 10 including a pair of independently operable conveyors from the primary crusher 22 to the secondary crusher 14, and from the secondary crusher 14 to the tertiary crusher 24; and three conveyors from the tertiary crusher 24 to the screen 40, wherein the screen 40 is returned to the tertiary crusher 24. In the example of the invention shown in the figures, the apparatus 10 comprises two conveyors from the primary crusher 22 to the secondary crusher 14, two conveyors from the secondary crusher 14 to the tertiary crusher 24 and three conveyors from the tertiary crusher 24 to the screen 40, wherein the screen 40 is returned to the tertiary crusher 24. Furthermore, the apparatus 10 has a single primary crusher in the form of a single gyratory crusher 22, a plurality of secondary crushers in the form of two classification crushers 14 and a plurality of tertiary crushers in the form of three cone crushers 24. Thus, in the preferred example of the invention shown in the figures, the apparatus 10 has a single primary crusher, two secondary crushers and three tertiary crushers.

As will be appreciated by those skilled in the art, the secondary crusher 14 is arranged to be fed from the primary crusher 22; more specifically, the secondary crusher 14 is arranged to feed directly from the primary crusher, there being no bin for iron ore material accumulation/conditioning between the primary crusher 22 and the secondary crusher 14. As described above, this is achieved because the applicant has determined that the classification breaker 14 does not require a constant rate of supply of iron ore material, thereby being able to accommodate a potentially intermittent supply of iron ore material from the primary breaker 22. Furthermore, this has the advantage that no large accumulation silos are required, and since such silos are typically large, the building height can be greatly reduced. Although the silos are used in the form of tertiary crushing silos 36 to feed the cone crushers 24 of the tertiary crushing station, the tertiary crushing silos 36 are duplicated into three parallel silos (see fig. 1) so that the silos are smaller and the building is correspondingly lower as shown in fig. 6. By repeating and replicating the assembly rather than making individual components larger, applicants achieve an efficient modular design, thereby reducing inventory.

Advantageously, the apparatus 10 comprises at least one conveyor, wherein each conveyor of the apparatus 10 has a fixed single discharge point. This is in contrast to typical conveyors having moving conveying sections, moving sections, and/or moving shuttles (moving shuttles). The applicant has determined that by eliminating the bin of the secondary crushing station and reducing the size of the bin of the tertiary crushing station, the advantage of direct feeding is facilitated, thereby eliminating the need for conveyor movement to convey the material to a series of locations. A pair of conveyors terminate at positions corresponding to the abutting sides of adjacent tertiary crushing bins 36 such that the iron ore material falls over the upper edges of the abutting sides and is thereby distributed among the three bins. In this way, without the use of a mobile conveyor, the feed from two separate conveyors is split into three different feeds. Each of the three tertiary crushing bins 36 is fed to a separate cone crusher 24, and each cone crusher 24 is fed to a different one of the three product screen feed conveyors 38.

As shown in detail in fig. 2, the secondary crusher 14 is arranged to feed directly from the screen 26, wherein the screen 26 is used to filter the iron ore material 12 from the primary crusher 22 according to the material size.

The product screen feed conveyor 38 delivers the iron ore material 12 to three separate screens 40, the three screens 40 determining whether to direct the iron ore material 12 to a total fines generation conveyor 42 or return the iron ore material 12 along a tertiary crusher feed conveyor 44 for further tertiary crushing by return.

The iron ore material on the total natural fines conveyor 46 and the total produced fines conveyor 42 is then sent to the land conveyor 50, which in turn sends it to the yard conveyor 52 (stockyard conveyor). As shown in fig. 12, the overall natural fines conveyor 46 and the overall resultant fines conveyor 42 run perpendicular to the conveyors between the primary, secondary and tertiary crushing stations. And, the total natural fines conveyor 46 and the total resultant fines conveyor 42 run perpendicular to the land conveyor 50. Fig. 12 also shows that the three conveyors feeding from the three-stage crusher to the screen 40 alternate between the two three-stage crusher feeding conveyors feeding from the two-stage crusher 14 to the three-stage crusher 24. In this way, the feed direction is turned back 180 degrees at the three stage crushing station in order to return the material to itself and minimize the footprint and size of the plant.

The yard conveyor 52 is in the form of a single yard belt (yardbelt) located below the reversible stacker (reversible stacker)/reclaimer (reclaimer) 54 such that the single yard belt is configured to provide a direct loading (through load) function of loading iron ore onto the train 58, a stacking function of stacking iron ore onto the stacking pile 56 (which may be carried to additional stacking piles 56 by additional pile conveyors, as shown in fig. 1 and 3), and a reclaiming function of receiving iron ore from the stacking pile 56 onto the train 58. The yard conveyor 52 includes a bypass chute for bypassing the stacker/reclaimer 54 and is capable of selectively routing the iron ore material to the stacker conveyor 62 or bypass chute 60 (in the event that the iron ore material is to be routed directly to the train 58). The stacking conveyor 62 delivers the iron ore material to the reversible conveyor 64, which when the reversible conveyor 64 is driven forward delivers the iron ore material to the pile conveyor (stockpiling conveyor), and thus to the stacking pile 56. The stacker/reclaimer is capable of being driven to take iron ore material from the stacking stockpile 56 and send it to a reclaiming chute 66 by a reversible conveyor 64, through which the iron ore material is sent to a single yard belt, which in turn sends the iron ore material to a Train Loading (TLO) facility 68.

The crushing stage refers to reducing the size of the material or mineral in a single process carried out by one or more units of the apparatus.

The primary stage may be any of the following:

1x gyratory crusher

1x jaw crusher

2x classification crushers (primary and secondary for producing typical primary crusher ore)

The secondary stage may be any of the following (for each process stream):

1x cone crusher

1x classifying crusher

1x double-roller crusher

The tertiary stage may be any of the following (for each process stream):

1x cone crusher

1x HPGR

1x grinder (mill)

Particle Size Distribution (PSD):

crushing at a first stage: feeding-1500 mm, product-270 mm

And (3) crushing in a second stage: feeding 270mm and 100mm

Crushing in three stages: feeding-100 mm, product-8 mm

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above-described exemplary embodiments.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment, admission, or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

In the description and claims, unless the context requires otherwise, the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

List of reference numerals

10-apparatus for treating iron ore

12-iron ore

14-stage crusher

16-mineral breaker

18-crushing roller

20-shell

22-gyratory crusher

24-cone crusher

26-Screen

28-Natural fines

30-coarse Sieve midds

32-classification breaker feed arrangement

34-coarse-stage sieve feeding device

36-three-stage crushing bin

38-product screen feed conveyor

40-screen

42-Total production fines conveyor

44-three-stage crusher feeding conveyor

46-total natural fine particle conveyor

50-land conveyor

52-stock yard conveyor

54-stacker/reclaimer

56-stacking stockpile

58-train

60-bypass chute

62-stacker conveyor

64-reversible conveyor

66-material taking chute

68-Train Loading (TLO) equipment

70-large bin

72-produced granules or produced granules

74-ultra-large product screen

76-pile conveyor

78-Train Loading (TLO)

80-direct Train Loading (TLO)

82-take out

84-double terminal

86-door

88- (clam shell type) flip bucket (clamshell)

90-Port (port)

92-reversible

94-150m ³

96-track ring (track loop)

Claims

1. An apparatus for treating iron ore comprising a primary crusher, a secondary crusher and a tertiary crusher, wherein the apparatus comprises a pair of independently operable conveyors from the primary crusher to the secondary crusher, from the secondary crusher to the tertiary crusher, and/or from the tertiary crusher to a screen, wherein the screen is returned to the tertiary crusher.

2. An apparatus for treating iron ore according to claim 1, wherein the apparatus has a single primary crusher, a plurality of secondary crushers and a plurality of tertiary crushers.

3. An apparatus for treating iron ore according to claim 2, wherein the apparatus has a single primary crusher, two secondary crushers and three tertiary crushers.

4. A plant for treating iron ores according to any of claims 1-3, wherein each of the conveyors of the plant has a fixed single discharge point.

5. An apparatus for treating iron ore according to claim 1, wherein the secondary crusher is arranged to be fed from the primary crusher.

6. An apparatus for treating iron ore according to claim 5, wherein the secondary crusher is arranged to feed directly from the primary crusher.

7. An apparatus for treating iron ore according to claim 6, wherein the secondary crusher is fed directly from the primary crusher, there being no bin for accumulating material to be fed to the secondary crusher.

8. An apparatus for treating iron ore according to claim 5, wherein the secondary crusher is arranged to feed directly from a screen for filtering material from the primary crusher, depending on the size of the material.

9. An apparatus for treating iron ore according to claim 1, comprising a mineral breaker as the secondary breaker for breaking the iron ore, wherein the mineral breaker comprises a breaking drum mounted within a housing for breaking primary coarse mineral into smaller pieces suitable for tertiary breaking.

10. An apparatus for treating iron ore comprising a primary crusher, a secondary crusher and a tertiary crusher, wherein the apparatus comprises a plurality of independently operable secondary screening, crushing and conveying circuits from the primary crusher to the tertiary crusher, and a plurality of independently operable tertiary screening, crushing and conveying circuits from the secondary crusher to a product grade; thereby, the apparatus also allows each loop to be cross fed between parallel loops.

11. An apparatus for treating iron ore according to claim 10, comprising at least one conveyor, wherein all conveyors of the apparatus have a fixed single discharge point.

12. An apparatus for treating iron ore according to claim 10 or 11, comprising a primary crusher and a secondary crusher, wherein the secondary crusher is arranged to feed from the primary crusher without material storage between the primary crusher and the secondary crusher.