Classifications

• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
  • G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
  • G01N27/22—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance
  • G01N27/223—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance for determining moisture content, e.g. humidity
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B1/00—Preliminary treatment of ores or scrap
  • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
  • C22B1/24—Binding; Briquetting ; Granulating
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B1/00—Preliminary treatment of ores or scrap
  • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
  • C22B1/24—Binding; Briquetting ; Granulating
  • C22B1/2406—Binding; Briquetting ; Granulating pelletizing
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B1/00—Preliminary treatment of ores or scrap
  • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
  • C22B1/24—Binding; Briquetting ; Granulating
  • C22B1/242—Binding; Briquetting ; Granulating with binders
• • G—PHYSICS
  • G05—CONTROLLING; REGULATING
  • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
  • G05D22/00—Control of humidity
  • G05D22/02—Control of humidity characterised by the use of electric means

Definitions

• the present invention relates to a method and equip ⁇ ment for preparing ore concentrate for pelletizing.
• the dewatered mixture is then conveyed on a first conveyor to a buffer bin wherein the mixture is buffer stored.
• the mixture is con ⁇ veyed to a mixer on a second conveyor while adding ad ⁇ ditives from additive bins.
• the mixture and the additives are mixed. If needed, an amount of water is fed to the mixer.
• the water is fed to the mixer via a pipeline having a control valve by which the amount of water to be fed can be regulated.
• a transfer means transfers the mixture from the mixer to a pelletizing device wherein the mixture is pelletized to form green pellets for subsequent indurating which can be made by a sintering/indurating process.
• the green pellets are formed gradually by a snow-ball effect wherein the concen ⁇ trate particles are bound together by the moisture re- siding between the particles holding them together.
• the size and strength of the green pellets mainly de ⁇ pends on the grain size and the moisture content of the mixture from which the green pellets are formed of.
• the grain size is normally adjusted to constant in the grinder. Thereafter the pellet size can only be regulated by regulating the moisture content of the mixture. If the moisture content of the mixture is too low, the green pellets are not formed properly or their size is too small. If the moisture content of the mixture is too high, the size of the green pellets will be too large. It is known that the optimal mois ⁇ ture content to obtain an optimal pellet size and strength for example for chromite concentrate mixture before pelletizing is 9 - 10 w-% by which the optimal pellet diameter about 12 mm can be obtained.
• the method of regulating the moisture content of the mixture before pelletizing is based on manual sampling of the mixture and measurement of the moisture content of the sample is performed in a la ⁇ boratory.
• a sample has been taken from the same place from the pelletizing feed.
• the amount of water to be fed to the mixer has been regulated on the basis of these results obtained in the laboratory analysis.
• the interval between consecutive samplings has typically been two hours and the laboratory analysis takes sev ⁇ eral minutes.
• the long response time for regulating the moisture content of the mixture causes problems and the moisture content of the mixture in the process can vary substantially within such a period before ad ⁇ justment of the moisture content can take place.
• Manu ⁇ al sampling may lead to unreliable measurement results due to dynamic nature of the process, long sampling intervals, disturbances and other failure. Sampled moisture data always includes some random variation, inaccuracy and errors that cannot be eliminated from the results. Manual sampling and laboratory analysis also requires costly human work input and working time of the process operators.
• the objective of the invention is to alleviate the disadvantages mentioned above.
• the present invention provides a method for preparing ore concentrate for pelletizing, the method comprising
• the mois ⁇ ture content of the mixture is continuously measured by an online measurement method during at least one of said method steps d) to j ) , and the amount of water to be fed into the mixer (8) in the mixing step h) is continuously regulated on the basis of said measured moisture content value to ensure that the mixture has a predetermined moisture content to produce green pel ⁇ lets having a predetermined pellet size and/or strength.
• the moisture content to be measured includes the water on the surface of the concentrate particles and be ⁇ tween the particles, hygroscopic water, capillary wa- ter, pore water and added water.
• measurement of the moisture content means measuring of the content of residual water and added water.
• the present invention provides an equipment to prepare ore concentrate for pelletizing, the equipment comprising - a concentrate bin for feeding the concentrate,
• a grinder to receive the concentrate from the concentrate bin and for grinding the concentrate to a predetermined grain size together with an amount of water, if needed, and possibly added additives to a mixture ,
• a filter to receive the mixture from the slurry mixer for filtering the mixture to a dewatered mixture
• a transfer means to receive the mixture from the mixer for transferring
• the equipment comprises one or more online moisture content sensors arranged to measure moisture content of the mixture, said sen ⁇ sor being disposed in connection with one or more of the devices including the filter, the first conveyor, the buffer bin, the second conveyor, the mixer and/or the transfer means; and a control unit arranged to continuously control the first control valve to regu- late the amount of water to be fed to the mixer on the basis of the moisture content measurement results ob ⁇ tained from the one or more online moisture content sensors to ensure that the mixture has a predetermined moisture content to produce green pellets having a predetermined pellet size and/or strength.
• the invention has many advantages.
• the process for preparing ore concentrate for pelletizing can be monitored online and adjusted in real time.
• the measure- ment of the moisture content can be made continuously and the measurement results can be immediately used as a feedback to continuously regulate the moisture con ⁇ tent of the mixture to ensure that the mixture has a predetermined moisture content to produce green pel- lets having a predetermined pellet size and/or strength.
• the response time to control the process is remarkably shortened. Proper moisture control further produces significant cost savings; for instance pelletizing (agglomeration) process becomes more sta- ble and thus good green pellet quality is secured.
• process operator will have more time for performing other tasks when moisture content is controlled automatically. Manual sampling can be reduced or even avoided.
• the moisture content of the concentrate is measured in at least one of the method steps a) to b) , and that the an amount of water to be fed to the grinder is regulated continuously on the basis of said measured moisture content value.
• the moisture content of the concentrate and/or the mixture is measured by a high-frequency capacitive measurement method.
• the moisture content of the concentrate and/or the mixture is measured by a non-contact high-frequency capacitive measurement sen ⁇ sor which has no direct contact to the material sub ⁇ ject to measurement.
• the amount of water to be fed into the mixer in the mixing step h) is calcu ⁇ lated by the difference between the measured moisture content value and a target value known to produce op- timal size and/or strength for the green pellets.
• the moisture content of the concentrate is measured with a moisture content sensor placed in and/or after the filter.
• the filtration effect of the filter is regulated on the basis of said meas ⁇ ured moisture content value.
• the moisture content of the mixture is measured during conveying the con- centrate on the conveyor.
• the first conveyor and/or the second conveyor being a belt conveyor having a moving belt on which the mixture is placed as a material bed the moisture content of the material bed lying on the belt is measured in a contact or non- contact manner by a high-frequency capacitive measure ⁇ ment sensor which is placed above or underneath the moving belt.
• a high-frequency ca ⁇ pacitive measurement sensor being placed above the moving belt, the sensor is arranged to direct constant contact with the upper surface of the material bed.
• the high-frequency ca ⁇ pacitive measurement sensor being placed underneath the moving belt, the sensor is arranged to direct con ⁇ stant contact with the underside of the moving belt.
• the moisture content of the mixture is measured while storing the concen ⁇ trate in the intermediate bin.
• the moisture content of the mixture is measured in at least one measurement point located after the mixing step h) and before the pelletizing step k) .
• the moisture content of the mixture is measured during the transferring step j ) .
• an additional amount of water is fed to the mixture just before feeding the mixture to the pelletizing device or directly to the pelletizing device if the measured moisture content value of the mixture is below the target value, and the amount of additional water to be fed is regulated on the basis of said moisture content value of the mixture measured in said at least one measurement point located after the mixing step h) and before the pelletizing step k) .
• the moisture content of the mixture is meas ⁇ ured during conveying the concentrate on a third con- veyor.
• the third conveyor is a belt conveyor having a moving belt on which the mixture is placed as a material bed; and the moisture content of the material bed lying on the belt is meas ⁇ ured in a contact or non-contact manner by a high- frequency capacitive measurement sensor which is placed above or underneath the moving belt.
• a high-frequency ca ⁇ pacitive measurement sensor being placed above the moving belt, the sensor is arranged to direct constant contact with the upper surface of the material bed.
• the high-frequency ca ⁇ pacitive measurement sensor being placed underneath the moving belt, the sensor is arranged to direct con ⁇ stant contact with the underside of the moving belt.
• the type of grinder in the grinding step b) being a ball mill
• the amount of grinding media to be fed into the ball mill is regu ⁇ lated on the basis of the moisture measured in at least one of the method steps a) to b) .
• the ore concentrate is chromite or iron or manganese or ilmenite or nickel or niobium concentrate or any combination thereof.
• the equipment com ⁇ prises a second pipeline for feeding water to the grinder and a second control valve in the second pipe ⁇ line for regulating of the amount of water to be fed to the grinder; that a moisture content sensor is dis- posed in the concentrate bin and/or in the grinder; and that the control unit is arranged to continuously control the second control valve to regulate the amount of water to be fed to the grinder on the basis of the moisture content measurement results obtained from said moisture content sensor disposed in the con ⁇ centrate bin and/or in the grinder.
• the first conveyor and/or the second conveyor is a belt conveyor includ- ing an endless moving belt having an upper side on which the mixture is lying as a material bed and an underside .
• the transfer device is a third belt conveyor arranged between the mixer and the pelletizing device, said third belt conveyor having a moving belt having an upper side on which the mixture is lying as a material bed and an underside.
• the equipment com ⁇ prises a third pipeline for spraying water onto the mixture bed travelling on the third belt conveyor at a water spraying point, and a third control valve in the third pipeline for regulating of the amount of water; and a moisture content sensor is disposed before and/or after said water spraying point; and that the control unit to control the first third control valve to regulate the amount of water to be fed to the mix ⁇ ture bed.
• the equipment com- prises a fourth pipeline for feeding water to the pelletizing device, and a fourth control valve in the second pipeline for regulating of the amount of water to be fed to the pelletizing device; and that the con ⁇ trol unit is arranged to continuously control the fourth control valve to regulate the amount of water to be fed into the pelletizing device on the basis of the moisture content measurement results obtained from a moisture content sensor disposed to measure the moisture content of the mixture bed travelling on the moving belt of the third belt conveyor.
• the moisture con ⁇ tent sensor is arranged to direct constant contact with the upper surface of the material bed travelling on the upper side of the moving belt.
• the moisture con ⁇ tent sensor is placed underneath the moving belt, and that the sensor is arranged to direct constant contact with the underside of the moving belt.
• the moisture con ⁇ tent sensor is a high-frequency capacitive measurement sensor which senses the dielectricity of the concen- trate and/or mixture subject to measurement, and that the control unit is arranged to calculate the moisture content on the basis of the measured dielectricity.
• control unit is arranged to calculate the amount of water to be fed to the grinder and/or to the mixer and/or to the mixture material bed on the third conveyor and/or to the pelletizing device by the difference between the meas ⁇ ured moisture content and a target value, said target value being known to produce an optimal size or strength for the green pellets.
• control unit is arranged to adjust the filtration effect of the filter for controlling the moisture content of the filtration cake on the basis of the moisture content value meas- ured by said one or more moisture content sensors.
• the type of grinder is a ball mill
• the control unit is arranged regulate the amount of grinding media to be fed into the ball mill on the basis of the moisture measured in the concentrate bin and/or in the ball mill.
• the equipment com ⁇ prises a mechanical level control device, such as a ski, a scraper, a plough or like, which is disposed at a height above the moving belt and upstream in rela ⁇ tion to the moisture content sensor to control the thickness of least the part of the material bed which passes the moisture content sensor.
• a moisture content sensor is connected to the mechanical level control device and arranged to direct contact with the upper surface of the mixture bed travelling on the moving belt.
• Figure 1 shows a schematic flow chart of a process and process equipment of a first embodiment of the inven ⁇ tion for preparing ore concentrate for pelletizing
• Figure 2 shows a a schematic flow chart of a process and process equipment of a second embodiment of the invention for preparing ore concentrate for pelletizing
• Figure 3 is a cross-section III - III of the second conveyor of the equipment of Figure 1
• Figure 4 is a cross-section IV - IV of Figure 3
• Figure 5 shows a first alternative embodiment for the embodiment of Figure 3
• Figure 6 shows a cross-section VI - VI of Figure 5
• Figure 7 shows a second alternative embodiment for the embodiment of Figure 3.
• Figure 8 shows a cross-section VIII - VIII of Figure 7.
• the raw material is obtained from a mine.
• the raw material, coarse ore concentrate is stored and initially fed to the process from a con ⁇ centrate bin 1.
• the equipment and method is suitable for any ore concentrate such as chromite or iron or manganese or ilmenite or nickel or niobium concentrate or any combination thereof.
• the equipment further comprises a wet or dry grinder 2 for grinding the coarse ore concentrate to a suitable grain size.
• Dry grinder is a grinder which is more closely disclosed in WO2012/172174 Al .
• the grinder 2 receives the concentrate from the concentrate bin 1 and grinds the concentrate to a predetermined grain size together with an amount of water and possibly added additives to a mixture.
• the grinder 2 may be a ball mill, whereto the material to be ground is fed together with the addition of water if the grinder is a wet grinder.
• a ball mill 2 is a rotating drum which is partially filled with the material to be ground and grinding medium. Different materials are used as grinding media, including ceramic balls, flint pebbles and steel balls.
• the grinder 2 is followed by a slurry mixer 3 which is arranged to mix the slurry discharged from the grinder 2.
• the mixture mixed in the slurry mixer 3 is then led to a filter 4, which can be a pressure filter or a capillary-effect ceramic disc filter.
• the filter 4 is ar ⁇ ranged to dewater the mixture by filtering to form a dewatered mixture.
• the mixture is conveyed by a first conveyor 5 to a buffer bin 6a.
• additives solid fuel (coke fine which acts as a fuel in the sub- sequent sintering/indurating process), process dust and binding agent are stored in additive bins 6 b, c, d.
• the mixture from the buffer bin 6a and additives from the additive bins 6 b, c, d are distributed onto a second conveyor 7 which conveys these materials to a mixer 8.
• the mixer 8 mixes the mixture with solid fuel, process dust and binder to form a homogenous mixture of these.
• An amount of water is added, if needed, via a first pipeline 12 and regulated by a control valve 13 into the mixer 8 to ensure that the mixture has predeter ⁇ mined moisture content for pelletizing.
• a third belt conveyor 11 receives the mixture from the mixer 8 for transferring it to a pelletizing device 9 for pelletizing the mixture to green pellets.
• One or more online moisture content sensors 10 are ar- ranged to measure moisture content of the mixture.
• the sensor 10 or sensors 10 is/are disposed in connection with one or more of the devices including the filter 4, the first conveyor 5, the buffer bin 6a, the second conveyor 7, and/or the mixer 8.
• the equipment compris ⁇ es a control unit 14.
• the control unit 14 is arranged to continuously control the first control valve 13 to regulate the amount of water to be fed to the mixer 8 on the basis of the moisture content measurement re ⁇ sults obtained from the one or more online moisture content sensors 10.
• the control unit 14 calculates the amount of water to be fed into the mixer 8 by the dif- ference between the measured moisture content value and a target value known to produce optimal size and/or strength for the green pellets.
• the control unit 14 controls the first control valve 13 to feed a calculated amount of water into the mixer 8. If the measured moisture con ⁇ tent value is the same or greater than predetermined target value, the control unit 14 shuts off the first control valve 13, so that no water is fed into the mixer 8. This ensures that the mixture has a predeter ⁇ mined moisture content to produce green pellets having a predetermined pellet size and/or strength.
• Figure 1 shows an embodiment which is shown to include all the above-mentioned moisture content sensors 10, it should be understood that less or more sensors 10 (but at least one sensor 10) may be used in other embodiments.
• the moisture content of the mixture is continuously measured by an online measurement method during
• the amount of water to be fed into the mixer 8 via the first pipeline 12 during mixing in the mixer 8 is continuously regulated on the basis of said measured moisture content. This is to ensure that the mixture has a predetermined moisture content to produce green pellets having a predetermined pellet size and/or strength.
• the first conveyor 5 and the second conveyor 7 are belt conveyors including an endless moving belt 17 having an upper side 18 on which the mixture is lying as a material bed and an underside 19. Also the trans- fer device 11 between the mixer 8 and the pelletizing device 9 is a third belt conveyor 11. The third belt conveyor 11 also has a moving belt 17 having an upper side 18 on which the mixture is lying as a material bed and an underside 19.
• the arrangement of moisture content sensors 10 in connection with the belt convey ⁇ ors is more closely disclosed in connection with Fig ⁇ ures 3 - 9.
• Figure 2 shows a further modification of the equipment shown in Figure 1 having the common features as dis ⁇ closed in connection with Figure 1.
• the equipment comprises a second pipeline 15 for feeding water to the grinder 2 and a second control valve 16 in the second pipeline for regulating of the amount of water to be fed to the grinder 2.
• One or more moisture content sensors 10 are disposed in the concentrate bin 1 and/or in the grinder 2.
• the control unit 14 is arranged to continuously control the second control valve 16 to regulate the amount of water to be fed to the grinder 2 on the basis of the moisture content measurement results obtained from said moisture content sensor 10 disposed in the con ⁇ centrate bin 1 and/or in the grinder 2.
• Figure 2 also schematically shows that the filtration effect of the filter 4 can be regulated by the control unit 14 on the basis of a moisture content value meas ⁇ ured by a moisture content sensor 10 arranged in or after the filter 4.
• Figure 2 shows that the equipment may com ⁇ prise a third pipeline 20 for spraying water onto the mixture bed travelling on the third belt conveyor 11 at a water spraying point, and a third control valve 21 in the third pipeline for regulating of the amount of water.
• the moisture content sensor 10 is disposed before and after said water spraying point.
• control unit 14 controls the first third control valve 21 to regulate the amount of water to be fed to the mix ⁇ ture bed.
• the equipment may comprise a fourth pipeline 22 for feeding water to the pelletizing device 9.
• a fourth control valve 23 is in the second pipeline 22 for regulating of the amount of water to be fed to the pelletizing device 9,
• the con- trol unit 14 is arranged to continuously control the fourth control valve 23 to regulate the amount of wa ⁇ ter to be fed into the pelletizing device 9 on the ba ⁇ sis of the moisture content measurement results ob- tained from a moisture content sensor 10 disposed to measure the moisture content of the mixture bed trav ⁇ elling on the moving belt 17 of the third belt convey ⁇ or 11.
• control unit 14 may also regulate the amount of grinding media to be fed into the ball mill on the basis of the mois ⁇ ture measured in the concentrate bin 1 and/or in the ball mill 2. By this way also the grain size of the concentrate may be adjusted.
• the additional moisture content measuring sensors 10 arranged in the concentrate bin 1, in the grinder 2 and in connection with the third belt conveyor 11 may be used separately in different embodiments or in com ⁇ bination in one embodiment.
• the additional water feeding to the grinder 2, on the third belt conveyor 11 or into the pelletizing drum 9 may be used separately in different embodiments or in combination in one embodiment.
• Figures 3 to 6 show two alternative embodiments of ar ⁇ ranging the moisture content sensor 10 in connection with a conveyor belt when the sensor 10 is placed un- derneath the moving belt 17 of the conveyor.
• the sensor 10 is arranged to direct constant contact with the underside 19 of the moving belt 17.
• the moving belt 17 is typically an endless loop of rubber belt. This kind of arrangement wherein the sensor 10 is out of contact to the mixture to be measured is especially advanta ⁇ geous when the particles in the material to be meas ⁇ ured are very hard, sharp-edged and abrasive, like in the case of chromite concentrate.
• the moisture content sensor 10 cannot be arranged to direct constant contact with the material bed travel ⁇ ling on the moving belt since the particles tend to adhere rapidly to the sensor 10 and the mechanical level control device 26.
• the abrasive material also causes rapid wear of the sensor head.
• the moisture content sensor 10 is preferably a high- frequency capacitive measurement sensor which senses the dielectricity of the concentrate and/or mixture subject to measurement.
• the control unit 14 is arranged to calculate the moisture content on the basis of the measured dielectricity.
• a mounting frame 24 is arranged below the moving belt 17.
• the high-frequency capacitive measurement sensor 10 is mounted to the frame 24.
• An adjustment means 25 is ar ⁇ ranged for adjusting the height position of the sensor 10 in relation to the moving belt 17 and for pressing the sensor 10 against the underside 19 of the moving belt for non-contact measurement of the moisture con ⁇ tent of the mixture travelling on the upper side 18 of the moving belt.
• a mechanical level control device 26 such as a ski, a scraper, a plough or like, is dis- posed at a height above the moving belt 17 and up ⁇ stream in relation to the moisture content sensor 10 to control the thickness s of least the part of the material bed which passes the moisture content sensor 10.
• the adjustment means 25 is mechani ⁇ cal and implemented with springs to produce the press ⁇ ing effect.
• desired action of the adjustment means 25 is implemented with a parallelogram and a hy ⁇ draulic cylinder.
• Figures 8 and 9 show that the moisture content sensor 10 may be arranged to direct constant contact with the upper surface of the material bed travelling on the upper side 18 of the moving belt 17.
• a mechanical lev ⁇ el control device 26, such as a ski, a scraper, a plough or like, is disposed at a height above the mov ⁇ ing belt 17 and upstream in relation to the moisture content sensor 10 to control the thickness s of least the part of the material bed which passes the moisture content sensor 10.
• the moisture content sensor 10 is connected to the mechanical level control device 26, such as a ski, arranged to direct contact with the up ⁇ per surface of the mixture bed travelling on the mov- ing belt 17.

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• 2013
  • 2013-12-17 FI FI20136277A patent/FI126553B/sv active IP Right Grant
• 2014
  • 2014-12-16 CN CN201480073271.8A patent/CN105917010A/zh active Pending
  • 2014-12-16 WO PCT/FI2014/051013 patent/WO2015092137A1/en active Application Filing
• 2016
  • 2016-06-23 ZA ZA2016/04264A patent/ZA201604264B/en unknown

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