Optimization of Barrel Liner Modification of Ball Mill Based on Discrete Element Method
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摘要:
针对球磨机内能量利用率低、磨矿钢耗高的问题，基于离散元法（DEM）仿真分析了不同衬板结构及衬板高度时钢球在磨机内的运动状态及碰撞能量分布。研究结果表明：衬板结构及高度会显著影响磨机内颗粒的运动状态和能量分布；不平滑衬板（筋波衬板和双筋衬板）提升载荷的作用强于平滑型衬板（单波衬板和双波衬板），但不平滑型衬板的球磨机内钢球对衬板的冲击作用较强，会增加衬板的磨损；平滑型衬板中，双波衬板能量分布最合理，其钢球−钢球的碰撞能量最低，为52.10%，能量利用率（钢球−矿石和矿石−矿石的碰撞能量之和在磨机碰撞总能量中的占比）最高，为21.10%。随着衬板高度逐渐增加，高速运动的钢球数量增多，大量的钢球冲击裸露衬板会加快衬板的磨损；磨机内的碰撞总能量随着衬板高度的升高而增加，且钢球−衬板和矿石−衬板的碰撞能量也在增加，能量利用率在衬板高度为60 mm时最高，为21.10%，说明衬板高度在60 mm时最佳。因此，选择适宜的衬板结构和衬板高度，能优化磨机的能量利用率，改善磨矿环境、降低钢耗和节约磨矿成本。
Abstract:Aiming at the problems of low energy utilization rate and high grinding steel consumption in the ball mill, the motion state and collision energy distribution of steel balls under different liner structures and liner heights were analyzed based on discrete element method (DEM). The results showed that the structure and height of the liner significantly affected the motion state and energy distribution of particles in the mill. The effect of rough liners (rib liners and double rib liners) on load lifting was stronger than that of smooth liners (single wave liners and double wave liners), but leaving profound impact of steel balls on the liners in the ball mill of rough liners and increasing the wear. Among the smooth liners, the double wave liner had the most reasonable energy distribution, with the lowest 52.10% steel ball−steel ball collision energy, and the highest 21.10% energy utilization rate (the sum of the collision energy of steel ball−ore and ore−ore in the total collision energy of the mill). With the gradual increase of the liner height, the number of steel balls moving at high speed may increase, and the impact of a large number of steel balls on the exposed liner would accelerate the wear. The total collision energy in the mill increased with the expansion of liner height, with the incremental collision energy of steel ball−liner and ore−liner, bringing the highest 21.10% energy utilization rate at 60 mm liner height, indicating that the best liner height at 60 mm. Therefore, the selection of the appropriate liner structure and liner height could optimize the energy utilization of the mill, improve the grinding environment, reduce steel consumption and save grinding costs.
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Key words:
- ball mill /
- liner shape /
- liner height /
- collision energy distribution /
- DEM
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表 1 Φ3.6 m×4.5 m球磨机工作参数
Table 1. Working parameters of Φ3.6 m×4.5 m ball mill
参数 Value 球磨机直径/m 3.6 球磨机参数/m 4.5 钢球充填率/% 41 最大钢球直径/mm 70 转速率/(r·min−1) 17.29 
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表 2 离散元模拟仿真参数
Table 2. Discrete element simulation parameters
参数 数值 矿石密度/（kg·m−3） 3250 钢球密度/（kg·m−3） 7800 矿石泊松比 0.16 钢球泊松比 0.30 矿石杨氏模量/Pa 2.07×1010 钢球杨氏模量/Pa 7.00×1010 恢复系数（矿石−矿石） 0.35 恢复系数（矿石−钢球） 0.40 恢复系数（钢球−钢球） 0.70 静摩擦系数（矿石−矿石） 0.68 静摩擦系数（矿石−钢球） 0.50 静摩擦系数（钢球−钢球） 0.25 滚动摩擦系数（矿石−矿石） 0.30 滚动摩擦系数（矿石−钢球） 0.05 滚动摩擦系数（钢球−钢球） 0.03
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