WO2020107070A1 - Appareil et procédé pour traiter un minerai de fer - Google Patents

Appareil et procédé pour traiter un minerai de fer Download PDF

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Publication number
WO2020107070A1
WO2020107070A1 PCT/AU2019/051301 AU2019051301W WO2020107070A1 WO 2020107070 A1 WO2020107070 A1 WO 2020107070A1 AU 2019051301 W AU2019051301 W AU 2019051301W WO 2020107070 A1 WO2020107070 A1 WO 2020107070A1
Authority
WO
WIPO (PCT)
Prior art keywords
crusher
iron ore
tertiary
primary
stage
Prior art date
Application number
PCT/AU2019/051301
Other languages
English (en)
Inventor
Warren Harris
Daniel JOLLEY
Original Assignee
Fortescue Metals Group Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2018904512A external-priority patent/AU2018904512A0/en
Application filed by Fortescue Metals Group Ltd filed Critical Fortescue Metals Group Ltd
Priority to BR112021010210-8A priority Critical patent/BR112021010210A2/pt
Priority to CN202311391034.3A priority patent/CN117839793A/zh
Priority to AU2019387713A priority patent/AU2019387713A1/en
Priority to CN201980078094.5A priority patent/CN113286658A/zh
Publication of WO2020107070A1 publication Critical patent/WO2020107070A1/fr
Priority to AU2021221848A priority patent/AU2021221848B2/en
Priority to AU2021261897A priority patent/AU2021261897B2/en
Priority to AU2023285957A priority patent/AU2023285957A1/en
Priority to AU2024100020A priority patent/AU2024100020A4/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C4/00—Crushing or disintegrating by roller mills
    • B02C4/02—Crushing or disintegrating by roller mills with two or more rollers
    • B02C4/08—Crushing or disintegrating by roller mills with two or more rollers with co-operating corrugated or toothed crushing-rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C4/00—Crushing or disintegrating by roller mills
    • B02C4/02—Crushing or disintegrating by roller mills with two or more rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C2/00—Crushing or disintegrating by gyratory or cone crushers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C21/00—Disintegrating plant with or without drying of the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
    • B02C23/02—Feeding devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
    • B02C23/08—Separating or sorting of material, associated with crushing or disintegrating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
    • B02C23/08—Separating or sorting of material, associated with crushing or disintegrating
    • B02C23/10—Separating or sorting of material, associated with crushing or disintegrating with separator arranged in discharge path of crushing or disintegrating zone
    • B02C23/12—Separating or sorting of material, associated with crushing or disintegrating with separator arranged in discharge path of crushing or disintegrating zone with return of oversize material to crushing or disintegrating zone

Definitions

  • the present invention relates generally to an apparatus and method for processing iron ore and more specifically, but not exclusively, to an apparatus and method for processing iron ore with lower cost and lower manning requirements during maintenance shutdown.
  • the present invention enables an ore processing system which is modular in that it replicates sub parts of the system rather than making each subpart larger.
  • This change in established ideology enables the removal of surge bins and surge capacity as well as lower buildings in the plant resulting in lower plant costs as well as redundancy in the system such that the plant is able to be partially shut down for maintenance while still operating at reduced capacity.
  • an apparatus for processing iron ore having a sizer as a secondary crusher for crushing the iron ore.
  • an apparatus for processing iron ore including a mineral breaker as a secondary crusher for crushing the iron ore, wherein the mineral breaker includes a breaker drum mounted in a housing for breaking minerals into smaller pieces.
  • the mineral breaker has a pair of side by side breaker drums rotatably mounted in a housing. More preferably, the pair of breaker drums rotate in opposite directions to facilitate crushing of the minerals between the breaker drums.
  • each breaker drum is provided with circumferentially extending groups of breaker teeth, the groups being spaced axially along the breaker drum, the axial spacing of groups on one drum being staggered to that on the other drum so that the teeth in a group on one drum pass between an adjacent pair of groups on the other drum.
  • the apparatus includes a gyratory crusher as a primary crusher. More preferably, the apparatus includes a cone crusher as a tertiary crusher.
  • the sizer is fed directly from a screen.
  • the sizer may be fed directly from one or more scalping stage screens, as opposed to a grizzly screen that would commonly be seen in a primary crushing application.
  • the secondary sizers will each be fed from one screen only.
  • an apparatus for processing iron ore including a primary crusher, a secondary crusher and a tertiary crusher, wherein the apparatus includes 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 which feeds back to the tertiary crusher (closed circuit).
  • an apparatus for processing iron ore including a primary crusher, a secondary crusher and a tertiary crusher, wherein the apparatus includes 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 from three independently operable conveyors from the tertiary crusher to a screen which feeds back to the tertiary crusher (closed circuit).
  • the apparatus has a single primary crusher, multiple secondary crushers and multiple tertiary crushers. More preferably, in one example, the apparatus has a single primary crusher, two secondary crushers and three tertiary crushers.
  • an apparatus for processing iron ore including a primary crusher and a secondary crusher, wherein the secondary crusher is arranged to be fed from the primary crusher.
  • the secondary crusher is arranged to be fed directly from the primary crusher. More preferably, the secondary crusher is fed directly from the primary crusher in that there is no bin to accumulate material to be fed to the secondary crusher. Adjustability of feed rate to suit each stage of crushing and screening may be achieved with variable speed drives on conveyors, feeders and/or crushers.
  • the secondary crusher is arranged to be fed directly from a screen used to filter material from the primary crusher according to material size.
  • an apparatus for processing iron ore including at least one conveyor, wherein each conveyor of the apparatus has a fixed single discharge point.
  • an apparatus for processing iron ore including a single yard belt located beneath a reversible stacker/reclaimer such that the single yard belt is configured to provide throughload functionality for loading the iron ore on a train, stacking functionality for stacking the iron ore on a stockpile, and reclaiming functionality for reclaiming iron ore from the stockpile to the train.
  • an apparatus for processing iron ore including a single belt arranged to transport iron ore material from a tertiary crusher, wherein the single belt is located beneath a reversible stacker/reclaimer such that the single belt is configured to provide throughload functionality for directly loading the iron ore material on a transport, stacking functionality for stacking the iron ore material on a stockpile, and reclaiming functionality for reclaiming iron ore material from the stockpile to the train.
  • the belt may be fed from either primary, secondary or tertiary crusher.
  • the belt and stacker/reclaimer may operate in unison where the belt can through- load while also receiving ore from the stacker/reclaimer.
  • Figure 1 shows in a process flow diagram an example of an apparatus for processing iron ore in accordance with an example of the present invention
  • Figure 2 is an enlargement of the left half of Figure 1;
  • Figure 3 is an enlargement of the right half of Figure 1;
  • Figure 4 is a top perspective view showing a primary crusher of the apparatus
  • Figure 5 is a top perspective view showing a secondary crusher of the apparatus
  • Figure 6 is a top perspective view showing a tertiary crusher of the apparatus
  • Figure 7 is a top perspective view of a yard belt and a train loadout facility of the apparatus
  • FIG. 8 shows detail of the train loadout facility
  • Figure 9 shows a distant top perspective overview of the primary, secondary and tertiary crushers, as well as conveyors between these stations;
  • Figure 10 shows a distant top perspective view of the secondary crusher, the tertiary crusher, and an over land conveyor;
  • Figure 11 shows a distant top perspective view of the secondary crusher, the tertiary crusher, a total natural fines conveyor and a total generated fines conveyor;
  • Figure 12 shows a plan view of the primary crusher, the secondary crusher, the tertiary crusher, the total natural fines conveyor, the total generated fines conveyor and part of the over land conveyor.
  • a sizer 14 as a secondary crusher enables large feed bins (of the type required for a cone crusher) to be obviated, as the sizer 14 does not require a constant rate of supply of iron ore material as does a cone crusher.
  • the bins are obviated and are typically large bins of great height, this enable the apparatus to be built with a low building height which reduces costs and facilitates reliability and maintenance.
  • the sizer 14 may be in the form of a twin shaft mineral sizer, being a mineral breaker 16 including a breaker drum 18 mounted in a housing 20 for breaking minerals into smaller pieces. More specifically, the mineral breaker 16 may have a pair of side by side breaker drums 18 rotatably mounted in the housing 20. In such an arrangement, the pair of breaker drums 18 rotate in opposite directions to facilitate crushing of the minerals between the breaker drums 18.
  • Each breaker drum 18 may be provided with circumferentially extending groups of breaker teeth, the groups being spaced axially along the breaker drum 18, the axial spacing of groups on one drum 18 being staggered to that on the other drum 18 so that the teeth in a group on one drum 18 pass between an adjacent pair of groups on the other drum 18.
  • the housing 20 may be fabricated from steel plate panels which are bolted and welded together.
  • the breaker drums 18 may be geared at one end, one drum 18 geared relative to the other, so that they are driven from a common drive to be rotated in opposite directions.
  • the drums 18 may be rotated so as to direct material between them.
  • a gear connection between the drums may serve to set rotary positions of the drums 18 relative to one another.
  • Teeth on the drums 18 may be arranged to define a series of discrete helical formations which are spaced circumferentially about each drum 18. The helical formations extend along the axis of each drum in a different sense, i.e.
  • the helical formations may extend away from the nearest end wall in an anti-clockwise sense and for a right hand drum the helical formations may extend in a clockwise sense.
  • Each helical formation in extending along its respective drum may pass through an arc of about 90°.
  • Shaping of the teeth and their relative positions and size may be configured such that during use, two types of breaking actions are present - a primary breaking action on larger pieces of mineral where the mineral is gripped between opposing leading faces of teeth on opposite drums and a secondary breaking action wherein mineral material is trapped between the rear edges of teeth and the leading face of another tooth.
  • the arc through which end helical formation passes is such as to ensure that a secondary breaking action occurs.
  • Spacing between the drums 18 may be chosen so that when the tips of teeth on one drum 18 sweep past the trough defined between groups of teeth on the other drum 18, there is sufficient clearance so that compaction of material is avoided. As such, with a suitable choice of spacing, it is possible for fine material to quickly pass through the sizer without compaction, thus leaving the sizer to break down larger pieces of material either by the primary and/or secondary breaking action.
  • the apparatus 10 may include a gyratory crusher 22 as a primary crusher.
  • the apparatus 10 may include a cone crusher 24 as a tertiary crusher.
  • the sizer 14 may be fed directly from a screen 26.
  • no bin is required to feed the sizer 14 as the sizer does not require a constant rate of feed of iron ore material to be crushed.
  • the screen 26 screens the iron ore material according to particle size, allowing smaller particle size material to bypass the sizer 14 as natural fines 28, whereas the remainder is then sorted according to scalping screen midds 30 and sizer feed 32.
  • the primary crushing station may be cut into rock rather than having a retaining wall, and the gyratory crusher 22 may be mounted on a combination of steel and concrete, arranged to crush the iron ore material 12 into a large bin or bin 70.
  • the large bin may have a waist and a pair of trouser leg funnels so as to divide the crushed ore between the two trouser leg funnels from which the crushed ore is fed to two separate scalping screen feed conveyors 34, as shown in Figure 1.
  • the scalping screen feed 34 comprises a pair of conveyors which transport the iron ore material 12 from the gyratory crusher 22 to the scalping screens 26.
  • this enables one of the conveyors to be shut down for maintenance while the other conveyor operates such that the entire apparatus 10 is able to function for online maintenance.
  • This is significant as it means that the apparatus does not require such a large number of personnel to carry out the maintenance, meaning that it possible to optimise the skills of the maintenance force and to avoid mistakes which may otherwise occur owing to lack of skills (to achieve a large work force) and/or rushing to complete maintenance while the apparatus is offline.
  • the applicant fore sees that, by virtue of the present invention, shutdown manning will be reduced from 700 people to 200 people for a given plant size. In the example shown in Figures 1 to 12, the plant is a 10 to 30 million tonne per annum plant.
  • 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, from the secondary crusher 14 to the tertiary crusher 24, and three conveyors from the tertiary crusher 24 to the screen 40 which feeds back to the tertiary crusher 24.
  • the apparatus 10 includes 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 which feeds back to the tertiary crusher 24.
  • the apparatus 10 has a single primary crusher in the form of the single gyratory crusher 22, multiple secondary crushers in the form of the two sizers 14 and multiple tertiary crushers in the form of the three cone crushers 24. Accordingly, in the preferred example of the invention shown, the apparatus 10 has a single primary crusher, two secondary crushers and three tertiary crushers.
  • the secondary crusher 14 is arranged to be fed from the primary crusher 22 and, more particularly, the secondary crusher 14 is arranged to be fed directly from the primary crusher in the sense that there is no bin for accumulation/regulation of iron ore material between the primary crusher 22 and the secondary crusher 14.
  • this is achieved by virtue of the applicant identifying that the sizer 14 does not require a constant rate of feed of iron ore material such that it is able to accommodate a potentially sporadic supply of iron ore material from the primary crusher 22.
  • this has the advantage that large accumulation bins are not required, and because such bins are typically large, this results in a significant reduction in building height.
  • bins are used in the form of tertiary crushing bins 36 to feed the cone crushers 24 of the tertiary crushing station
  • the tertiary crushing bins 36 are replicated as three bins in parallel (see Figure 1) such that the bins are smaller and the building is also correspondingly lower, as shown in Figure 6.
  • Figure 1 By replicating and duplicating components rather than making single components larger, the applicant has achieved an efficient modular design resulting in a reduction in inventory.
  • the apparatus 10 includes 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 conveyor parts, moving parts, and/or moving shuttles.
  • the applicant has determined that by eliminating bins at the secondary crushing station and by reducing the size of bins at the tertiary crushing station, this promotes direct feed assets whereby the conveyors are not required to move to deliver material to a range of locations.
  • a pair of conveyors terminate at locations corresponding to adjoining sides of the adjacent tertiary crushing bins 36 such that the iron ore material falls over the upper edges of the adjoining sides and is distributed between the three bins accordingly. In this way, feed from two separate conveyors is separated into three different feeds without the use of moving conveyors.
  • Each of the three tertiary crushing bins 36 is fed to a separate cone crusher 24, and each cone crusher 24 feeds to a different one of the three product screen feed conveyors 38.
  • the secondary crusher 14 is arranged to be fed directly from the screen 26 used to filter the iron ore material 12 from the primary crusher 22 according to material size.
  • the product screen feed conveyors 38 feed the iron ore material 12 to three separate screens 40 which determine whether the iron ore material 12 is to be directed to the total generated fines conveyor 42 or to be returned by feedback along the tertiary crusher feed conveyors 44 for further tertiary crushing.
  • the iron ore material on a total natural fines conveyor 46 and a total generated fines conveyor 42 are then fed to an over land conveyor 50 which, in turn, feeds to a stockyard conveyor 52.
  • the total natural fines conveyor 46 and the total generated fines conveyor 42 run perpendicular to the conveyors between the primary, secondary and tertiary crushing stations.
  • the total natural fines conveyor 46 and the total generated fines conveyor 42 run perpendicular to the over land conveyor 50.
  • Figure 12 also shows that the three conveyors feeding from the tertiary crushers to the screens 40 run between and alternately to the two tertiary crusher feed conveyors feeding from the secondary crushers 14 to the tertiary crushers 24. In this way, the feed direction is fed back 180 degrees at the tertiary crushing station so as to feed back onto itself and to minimise the footprint and size of the plant.
  • the stockyard conveyor 52 is in the form of a single yard belt located beneath a reversible stacker/reclaimer 54 such that the single yard belt is configured to provide throughload functionality for loading the iron ore on a train 58, stacking functionality for stacking the iron ore on a stacking stockpile 56 (possibly by way of an additional stock piling conveyor to an additional stacking stockpile 56 as shown in Figure 1 and Figure 3), and reclaiming functionality for reclaiming iron ore from the stacking stockpile 56 to the train 58.
  • the stockyard conveyor 52 includes a bypass chute 60 for bypassing the stacker/reclaimer 54 and is able to selectively feed iron ore material to a stacking conveyor 62 or to the bypass chute 60 in the event that the iron ore material to be fed directly to the train 58.
  • the stacking conveyor 62 feeds iron ore material to a reversible conveyor 64 which, when driven forwards, feeds the iron ore material to a stock piling conveyor and thereby to the stacking stockpile 56.
  • the stacker/reclaimer is able to be driven to take iron ore material from the stacking stockpile 56 and to feed it via the reversible conveyor 64 (driven in reverse) to the reclaim chute 66 through which the material is fed to the single yard belt which, in turn, feeds to the train loadout (TLO) facility 68.
  • TLO train loadout
  • Stage of crushing refers to the reduction of material or mineral size in a single process completed by one or more units of equipment.
  • Primary Stage could be either:
  • Tertiary Stage could be either per process stream:
  • Particle Size Distribution (PSD):

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  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Crushing And Grinding (AREA)

Abstract

La présente invention concerne un appareil pour traiter un minerai de fer, qui comprend un broyeur primaire, un broyeur secondaire et un broyeur tertiaire, l'appareil comprenant une paire de transporteurs actionnables indépendamment depuis le broyeur primaire jusqu'au broyeur secondaire, depuis le broyeur secondaire jusqu'au broyeur tertiaire, et/ou depuis le broyeur tertiaire jusqu'à un tamis qui renvoie au broyeur tertiaire.
PCT/AU2019/051301 2018-11-27 2019-11-27 Appareil et procédé pour traiter un minerai de fer WO2020107070A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
BR112021010210-8A BR112021010210A2 (pt) 2018-11-27 2019-11-27 aparelho e método para processamento de minério de ferro
CN202311391034.3A CN117839793A (zh) 2018-11-27 2019-11-27 处理铁矿的设备
AU2019387713A AU2019387713A1 (en) 2018-11-27 2019-11-27 Apparatus and method for processing iron ore
CN201980078094.5A CN113286658A (zh) 2018-11-27 2019-11-27 处理铁矿的设备和方法
AU2021221848A AU2021221848B2 (en) 2018-11-27 2021-08-25 Apparatus and method for processing iron ore
AU2021261897A AU2021261897B2 (en) 2018-11-27 2021-11-03 Apparatus and method for processing iron ore
AU2023285957A AU2023285957A1 (en) 2018-11-27 2023-12-22 Apparatus and method for processing iron ore
AU2024100020A AU2024100020A4 (en) 2018-11-27 2024-05-14 Apparatus and method for processing iron ore

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2018904512 2018-11-27
AU2018904512A AU2018904512A0 (en) 2018-11-27 Apparatus and method for processing iron ore

Publications (1)

Publication Number Publication Date
WO2020107070A1 true WO2020107070A1 (fr) 2020-06-04

Family

ID=70854741

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2019/051301 WO2020107070A1 (fr) 2018-11-27 2019-11-27 Appareil et procédé pour traiter un minerai de fer

Country Status (4)

Country Link
CN (2) CN113286658A (fr)
AU (5) AU2019387713A1 (fr)
BR (1) BR112021010210A2 (fr)
WO (1) WO2020107070A1 (fr)

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