永磁盘式强磁选机磁场分布优化设计及钾长石除铁试验研究
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摘要
与电磁选机相比,永磁选机具有结构简单,耗能少等诸多优点,目前工业上大多数电磁弱磁选机已被永磁选机代替,永磁强磁选机因存在分选空间内磁场分布不合理或处理量低等一系列问题,工业上应用的强磁场磁选机仍然以电磁选机为主。永磁强磁选机的分选性能与磁场分布密切相关,磁场分布是否合理对磁选机分选的效果起决定性作用。对永磁强磁选机磁场分布进行优化设计,提高其单位时间处理量和分选效果,有利于促进强磁选机在工业上的永磁化。因此,本文研究磁场分布,对永磁强磁选机的发展具有重要意义。
本研究从以下几方面进行研究和分析,对PH型永磁盘式强磁选机磁场分布进行优化设计,得到如下结论：
(1)介绍PH型永磁盘式强磁选机的结构与分选原理,分析影响尖齿形、半圆形、矩齿形和平面磁极对磁场分布的主要因素,指出永磁盘式磁选机在实际应用中存在的问题。
(2)采用复变函数数学理论方法求解半圆形、尖齿形和矩齿形几种磁极的磁场分布,推导出分选空间内磁场强度和磁场力理论计算公式。
(3)运用数学计算分析软件Matlab对分选空间内磁场强度和磁场力公式进行计算,得出分选空间内磁场强度和磁场力的计算数值。与实测值进行对比,结果表明,计算值与实际测量值相近,在允许误差范围内。说明推导的磁场强度和磁场力计算公式能正确反映分选空间内磁场分布规律。本研究将数学计算分析软件Matlab与复变函数推导相结合,简化了磁场分布运算过程,为磁选机磁场分布的数值计算开辟了新途径。
(4)分别调整尖齿形、半圆形和矩齿形三种磁极对尺寸结构参数,计算不同结构参数条件下磁场分布情况,通过对比分析,对磁场分布进行优化设计。在最佳尺寸参数条件下,尖齿形、半圆形和矩齿形三种磁极对磁极顶点处磁场力大小分别为48.32×108Oe2/cm、42.74×108Oe2/cm和40.01×108Oe2/cm,比较而言,尖齿形磁极对磁选机分选空间内磁场力最高。结合选矿工艺技术要求,采用尖齿形磁极对制造出结构合理的PL型永磁盘式强磁选机试验样机。
(5)应用PL型永磁盘式强磁选机样机进行钾长石除铁试验研究。根据矿石性质,通过正交试验和条件试验探索背景磁场强度、磁盘转速、矿浆浓度、磁性矿物冲洗水量和磁选时间等各个因素对除铁效果的影响。在最佳试验条件下,进行一段磨矿闭路试验和中矿再磨闭路试验,最终获得较好的除铁效果。原矿中Fe203含量从0.52%下降到0.19%,精矿产率83.32%,除铁率68.29%。将这一试验结果与PH型永磁盘式强磁选机进行对比,结果表明PL型永磁盘式强磁选机样机选别指标和除铁效果更好,且磁盘间距比原磁选机增大2mm,提高了处理能力。从实践上证明了本课题所设计的磁极对结构是合理的。
(6)运用有限元分析软件ANSYS对尖齿形、半圆形、矩齿形和平面磁极对构成的磁选机分选空间内的磁场分布进行仿真模拟,将微观的磁场分布转化为可视的磁力线分布图、磁通密度矢量图和磁感应强度等值图。结果表明,尖齿形、半圆形、矩齿形和平面磁极对构成的磁选机分选空间内的最高磁场强度分别为2.13T、2.34T、1.96T和1.78T,半圆形磁极对磁极表面磁场强度高于尖齿形磁极对磁极表面的磁场强度。通过对比四种磁极对之间磁力线分布图表明,半圆形磁极对分选空间内磁场梯度低于尖齿形磁极对分选空间内的磁场梯度,所以半圆形磁极对分选空间内磁场力低于尖齿形磁极对分选空间内的磁场力。这一结论与计算结果一致,从理论上揭示了尖齿形磁极对结构的永磁盘式磁选机具有较好分选效果的根本原因。
Comparing with the electromagnetic separator, permanent magnetic separator has some advantages such as simple structure, low energy consumption and so on. In industry, most of the low intensity magnetic electromagnetic separators have been replaced by permanent magnetic separator nowadays.
High intensity permanent magnetic separator existed a series of problems, for instance, unreasonable magnetic field distribution in separation space and lower work capacity, so high intensity permanent magnetic electromagnetic separators remain primary in actual application. High intensity permanent magnetic separator performance is closely related to magnetic field distribution.
The optimization design for high intensity permanent magnetic separator magnetic field distribution and improving the processing capacity per unit time and the separation effect are profitable to propel and accelerate high intensity permanent magnetic separator industrialization. This study is important for the development of permanent magnetic separator.
The following aspects were studied and analyzed in this paper to optimize the magnetic field distribution of high intensity permanent magnetic separator developed by Professor Peng Huiqing.
1) Tthe high intensity permanent magnetic separator structure and separation principle developed by Professor Peng Huiqing were introduced in the paper. The main factors that impact magnetic field distribution of tooth shape, half round, rectangular profile and plane pole were analyzed. Meanwhile, the problems of the application were also pointed out.
2) The magnetic field distribution of semicircular, teeth shape and moment profile was studied with the complex variable function and other physical mathematical means. The calculation formula of separation space magnetic field intensity and magnetic force was obtained.
3) The separation space magnetic field intensity and magnetic force numerical values was obtained by analyzing the separation space magnetic field intensity and magnetic force calculation formula with the mathematical calculation and analysis software Matlab. The calculation results were similar to the actual measured value compared with the measured value, and it shows that magnetic field intensity and magnetic force formula can correctly reflect the distribution of magnetic field in the separation space. The calculation and analysis software Matlab combined with complex function mathematical derivation, simplified the operation process of distribution of magnetic field, and laid the theoretical foundation for the numerical calculation of magnetic field distribution in magnetic separator.
4) The calculation of magnetic field distribution under conditions of different structural parameters was processed with adjusting the teeth shape, semi-circular and serrate three poles on the size structure parameters through comparative analysis, the distribution of magnetic field optimization design. The results show that the magnetic force of the magnetic pole teeth shape high magnetic separator space. Combined with the technology requirement of mineral processing, sharp teeth-shaped pole to produce permanent disk type strong magnetic separator with the advantages of reasonable structure was adopted in this paper.
5) The test research of new type high intensity permanent magnetic separator prototype of potash feldspar deforestation was applied. According to the character of the ore, the disk speed, slurry concentration, magnetic minerals of flushing water and magnetic separation time and other factors on the iron removal effect through orthogonal experiments and condition tests to explore the background magnetic field intensity. Under the optimum conditions, a grinding circuit and middling regrinding closed-circuit test was presented for obtaining a better effect of removing iron.Fe2O3content in ore decreased from0.52%to0.19%. The concentrate yield reached83.32%and the iron removal rate reached68.29%. The test results were compared with the original permanent disk type strong magnetic separator, which show that the new high intensity permanent magnetic separator classification index and iron removal effect is better.
6) The advanced finite element analysis software ANSYS was used to analyze the tooth shape, half round, rectangular profile and plane distribution of the magnetic separator magnetic separation space formed by the magnetic field simulation. The microscopic distribution of magnetic field was changed into visible distribution of magnetic line of force, the magnetic flux density vector, and the magnetic induction intensity contour map. The simulation results through comparative analysis, to reveal the fundamental reason of tooth shape magnetic with high magnetic field.
本研究从以下几方面进行研究和分析,对PH型永磁盘式强磁选机磁场分布进行优化设计,得到如下结论：
(1)介绍PH型永磁盘式强磁选机的结构与分选原理,分析影响尖齿形、半圆形、矩齿形和平面磁极对磁场分布的主要因素,指出永磁盘式磁选机在实际应用中存在的问题。
(2)采用复变函数数学理论方法求解半圆形、尖齿形和矩齿形几种磁极的磁场分布,推导出分选空间内磁场强度和磁场力理论计算公式。
(3)运用数学计算分析软件Matlab对分选空间内磁场强度和磁场力公式进行计算,得出分选空间内磁场强度和磁场力的计算数值。与实测值进行对比,结果表明,计算值与实际测量值相近,在允许误差范围内。说明推导的磁场强度和磁场力计算公式能正确反映分选空间内磁场分布规律。本研究将数学计算分析软件Matlab与复变函数推导相结合,简化了磁场分布运算过程,为磁选机磁场分布的数值计算开辟了新途径。
(4)分别调整尖齿形、半圆形和矩齿形三种磁极对尺寸结构参数,计算不同结构参数条件下磁场分布情况,通过对比分析,对磁场分布进行优化设计。在最佳尺寸参数条件下,尖齿形、半圆形和矩齿形三种磁极对磁极顶点处磁场力大小分别为48.32×108Oe2/cm、42.74×108Oe2/cm和40.01×108Oe2/cm,比较而言,尖齿形磁极对磁选机分选空间内磁场力最高。结合选矿工艺技术要求,采用尖齿形磁极对制造出结构合理的PL型永磁盘式强磁选机试验样机。
(5)应用PL型永磁盘式强磁选机样机进行钾长石除铁试验研究。根据矿石性质,通过正交试验和条件试验探索背景磁场强度、磁盘转速、矿浆浓度、磁性矿物冲洗水量和磁选时间等各个因素对除铁效果的影响。在最佳试验条件下,进行一段磨矿闭路试验和中矿再磨闭路试验,最终获得较好的除铁效果。原矿中Fe203含量从0.52%下降到0.19%,精矿产率83.32%,除铁率68.29%。将这一试验结果与PH型永磁盘式强磁选机进行对比,结果表明PL型永磁盘式强磁选机样机选别指标和除铁效果更好,且磁盘间距比原磁选机增大2mm,提高了处理能力。从实践上证明了本课题所设计的磁极对结构是合理的。
(6)运用有限元分析软件ANSYS对尖齿形、半圆形、矩齿形和平面磁极对构成的磁选机分选空间内的磁场分布进行仿真模拟,将微观的磁场分布转化为可视的磁力线分布图、磁通密度矢量图和磁感应强度等值图。结果表明,尖齿形、半圆形、矩齿形和平面磁极对构成的磁选机分选空间内的最高磁场强度分别为2.13T、2.34T、1.96T和1.78T,半圆形磁极对磁极表面磁场强度高于尖齿形磁极对磁极表面的磁场强度。通过对比四种磁极对之间磁力线分布图表明,半圆形磁极对分选空间内磁场梯度低于尖齿形磁极对分选空间内的磁场梯度,所以半圆形磁极对分选空间内磁场力低于尖齿形磁极对分选空间内的磁场力。这一结论与计算结果一致,从理论上揭示了尖齿形磁极对结构的永磁盘式磁选机具有较好分选效果的根本原因。
Comparing with the electromagnetic separator, permanent magnetic separator has some advantages such as simple structure, low energy consumption and so on. In industry, most of the low intensity magnetic electromagnetic separators have been replaced by permanent magnetic separator nowadays.
High intensity permanent magnetic separator existed a series of problems, for instance, unreasonable magnetic field distribution in separation space and lower work capacity, so high intensity permanent magnetic electromagnetic separators remain primary in actual application. High intensity permanent magnetic separator performance is closely related to magnetic field distribution.
The optimization design for high intensity permanent magnetic separator magnetic field distribution and improving the processing capacity per unit time and the separation effect are profitable to propel and accelerate high intensity permanent magnetic separator industrialization. This study is important for the development of permanent magnetic separator.
The following aspects were studied and analyzed in this paper to optimize the magnetic field distribution of high intensity permanent magnetic separator developed by Professor Peng Huiqing.
1) Tthe high intensity permanent magnetic separator structure and separation principle developed by Professor Peng Huiqing were introduced in the paper. The main factors that impact magnetic field distribution of tooth shape, half round, rectangular profile and plane pole were analyzed. Meanwhile, the problems of the application were also pointed out.
2) The magnetic field distribution of semicircular, teeth shape and moment profile was studied with the complex variable function and other physical mathematical means. The calculation formula of separation space magnetic field intensity and magnetic force was obtained.
3) The separation space magnetic field intensity and magnetic force numerical values was obtained by analyzing the separation space magnetic field intensity and magnetic force calculation formula with the mathematical calculation and analysis software Matlab. The calculation results were similar to the actual measured value compared with the measured value, and it shows that magnetic field intensity and magnetic force formula can correctly reflect the distribution of magnetic field in the separation space. The calculation and analysis software Matlab combined with complex function mathematical derivation, simplified the operation process of distribution of magnetic field, and laid the theoretical foundation for the numerical calculation of magnetic field distribution in magnetic separator.
4) The calculation of magnetic field distribution under conditions of different structural parameters was processed with adjusting the teeth shape, semi-circular and serrate three poles on the size structure parameters through comparative analysis, the distribution of magnetic field optimization design. The results show that the magnetic force of the magnetic pole teeth shape high magnetic separator space. Combined with the technology requirement of mineral processing, sharp teeth-shaped pole to produce permanent disk type strong magnetic separator with the advantages of reasonable structure was adopted in this paper.
5) The test research of new type high intensity permanent magnetic separator prototype of potash feldspar deforestation was applied. According to the character of the ore, the disk speed, slurry concentration, magnetic minerals of flushing water and magnetic separation time and other factors on the iron removal effect through orthogonal experiments and condition tests to explore the background magnetic field intensity. Under the optimum conditions, a grinding circuit and middling regrinding closed-circuit test was presented for obtaining a better effect of removing iron.Fe2O3content in ore decreased from0.52%to0.19%. The concentrate yield reached83.32%and the iron removal rate reached68.29%. The test results were compared with the original permanent disk type strong magnetic separator, which show that the new high intensity permanent magnetic separator classification index and iron removal effect is better.
6) The advanced finite element analysis software ANSYS was used to analyze the tooth shape, half round, rectangular profile and plane distribution of the magnetic separator magnetic separation space formed by the magnetic field simulation. The microscopic distribution of magnetic field was changed into visible distribution of magnetic line of force, the magnetic flux density vector, and the magnetic induction intensity contour map. The simulation results through comparative analysis, to reveal the fundamental reason of tooth shape magnetic with high magnetic field.
引文
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