金川镍矿柱式短流程分选研究
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摘要
镍是我国国民经济建设和发展高新技术的重要有色金属原材料,被称为“工业维生素”。近些年,随着我国矿产工业的发展,镍矿资源开发力度逐步加大,易选富矿石逐年减少,贫细杂难处理的镍矿石比例不断增加。金川镍矿是我国最大的硫化镍矿床,其硫化镍矿石的选矿工艺是以浮选机为主体的“阶段磨浮”工艺,长期以来浮选机暴露出细粒回收能力不足,分选选择性差的弊端,因而限制了贫细镍矿资源的进一步高效开发和利用。浮选柱与浮选机相比具有细粒分选效果好、精矿品位高的特点,因而它在国内外硫化镍矿选厂的精选作业提高精矿品位方面获得了成功的应用,但是在贫细难选矿回收及粗选和扫选作业上应用的较少,究其原因是目前的浮选柱大多缺乏强化分选回收手段,总体回收率难以得到有效的保证。因此,采用先进高效的分选方法、设备和工艺来开发利用贫细硫化镍矿,提高硫化镍矿的回收率和分选效率是镍矿选矿行业十分迫切与重要的研究课题。
为了实现对贫细难选硫化镍矿的高效分选,本文系统的开展了硫化镍矿的基础理论与可浮性的研究,并结合金川镍矿石的工艺矿物学性质,分析了微细难选镍矿的难选原因。金川硫化镍矿石中以镍黄铁矿和紫硫镍铁矿最为普遍,部分镍黄铁矿的粒度细小,此外还有少量镍黄铁矿呈细小粒状或脉状嵌布于脉石矿物中,细粒嵌布的镍黄铁矿在磨矿过程中难于单体解离,造成磁黄铁矿和脉石矿物中含镍,且直接影响选矿指标。紫硫镍铁矿化学成分波动大,易氧化,易过粉碎,因此可浮性十分复杂。矿石中各种硫化矿物嵌布粒度极不均匀,磨矿后总体粒度和镍铜金属分布呈“哑铃型”,难于浮选。金川镍矿石中含有大量的蛇纹石,蛇纹石是一种硬度低、密度小的含镁脉石矿物,在磨矿过程中易碎、易泥化,沉降困难,在浮选过程中易与气泡粘附一起进入泡沫产品,因此蛇纹石对选矿工艺的影响较大,蛇纹石矿泥的存在影响矿浆粘度,包裹细粒硫化矿粒并对粗颗粒硫化矿表面形成强的矿泥覆盖,从而破坏浮选过程的选择性,致使精矿中氧化镁的含量超标。
基于金川硫化镍矿石的工艺矿物学特点,本论文针对性地进行了硫化镍矿的可浮性特征研究,在此基础上开展了金川镍矿气泡矿化及矿化后气絮团在旋流力场下的分离研究,通过研究提出了基于矿物物理特性和可浮性综合效应的旋流分离。表明在旋流力场下镍黄铁矿经过药剂作用与气泡接触矿化后,可以更多的富集于旋流中矿,实现镍黄铁矿与脉石矿物的有效分离和多重循环高效回收。针对金川镍矿“哑铃型”的粒度组成和金属分布,为实现短流程高效分选,论文针对金川难选镍矿的细度控制强化浮选进行了研究,利用细磨改善粒度组成和金属分布,使入浮矿物粒度组成和金属分布更接近于精矿的粒度组成和金属分布,通过细粒高效的分选设备和工艺来浮出更多的镍黄铁矿,进而提高镍精矿的总体回收率,并根据研究提出了匹配高效浮选的粒度分布曲线和回收率曲线。
在金川硫化镍矿浮选特性和分选过程研究的基础上,本论文进行了详细的柱式分选过程强化研究,通过旋流-静态微泡浮选柱多重矿化分选方式强化和营造适于细粒难选镍矿分选过程的流体分选环境,来强化细粒贫镍矿的气泡碰撞矿化和矿化气泡的选择性升浮。论文详细研究和论证了微泡、旋流力场、管流矿化紊流度等对细粒分离分选的影响,合理的确定了微泡强化方式、循环旋流分选压力、逆流碰撞高度等影响镍矿分选的设备参数和理论模型。
论文最后进行了金川镍矿柱式分选研究,针对金川细粒硫化镍矿难选的特点,逐步进行了基于金川镍尾矿的浮选柱强化分选、基于二段作业的浮选柱强化分选和基于一段二段作业联合的柱式强化分选研究。通过各种方式的柱式分选,采用强化的分选条件与柱式分选过程,回收率和精矿品位等工艺指标在浮选机分选的基础上都获得了明显的提升,表明柱式分选设备和工艺适于细粒难选贫镍矿的分选。通过不同强化分选研究,最终确定应用了强化细磨条件下的基于二段作业的柱式短流程高效分选,为细粒难选镍矿的高效开发利用奠定了基础。
通过合理的分选研究,半工业试验的连续运行,细磨-机-柱联合分选工艺与原有生产系统同期相比精矿品位提高3个百分点,回收率提高3个百分点,实现了柱式分选设备和工艺的在微细难选硫化镍矿分选的应用。通过对细磨-机-柱联合分选工艺的矿物学分析和比较,表明机-柱联合工艺强化了微细镍黄铁矿的富集与回收,并有效的控制了含镁硅酸盐类脉石的上浮,明显提高了金川镍矿的选矿效率。在半工业的基础上,进行了工业的设计,通过半工业的应用结果和工业设计表明,细粒难选镍矿柱式分选工艺可大大缩减工艺流程,降低能耗,节约生产成本。
细粒难选镍矿的柱式分选设备和工艺克服了常规浮选设备矿化方式单一、缺乏细粒强化分选机制等弊端,在提高矿物浮选效率的同时,简化浮选工艺配置、节约生产成本,为我国细粒难选矿的高效开发利用提供了有利的支撑。
Nickel, also called“Vitamin for Industry,”is a very important nonferrous metal for China's national economic and high-tech development. In recent years, with the development of China’s minerals industry, the exploration of nickel resources has been gradually enhanced, however, easy-to-separate ores have been decreasing year by year while the proportion of poor quality and difficult-to-separate nickel ores is rising steadily. The laregest nickel reserve in China is called Jinchuan nickel sulfide ore, and cell-type flotation technology has been used for nickel separation at Jinchuan. Due to the inherent inefficiencies associated with traditional flotation machines including the single mineralized separation and low mineralization efficiency, the separation technology of nickel sulfide using flotation machine has its problems such as complex process and high processing cost. Compared with flotation machine, flotation column has many advantages including simple structure, energy saving, high efficiency, and efficient separation of micro-fine mineral, etc. Thus, it is applied in cleaning flotation to improve the concentrate grade in nickel sulfide ore dressing plants; however it has been rarely used in hard-to-separate ores, rough and scavenging operations due to the lack of an intensified separation mechanism in most present flotation columns, which cannot guarantee high efficient recovery rate. Consequently, using highly efficient separation methods, equipment and technologies to explore nickel sulfide ores and improve their recovery rate and separation efficiency is a very urgent and important research project in nickel separating industry.
In order to achieve the highly efficient separation of nickel sulfide ores, the basic theory and flotation characteristics of nickel sulfide ores were systematically investigated in this dissertation, combined with the mineralogical characterization of Jinchuan nickel ores. The reasons of poor floatability of this ultra-fine nickel ores were analyzed and an improved separation process was designed. Mineralogical analysis indicated that the Jinchuan nickel sulfide ores consist of mostly pentlandite and violarite and the particle size of some pentlandite is quite small; in addition, there is also little pentlandite inlayed in gangue minerals in the form of fine particles or nervation. In the two parts the small size of pentlandite makes dissociation difficult in grinding, which results in some nickel residues in pyrrhotite and veinstone minerals and this directly affects the mineral separation performance. Violarite has high volatility and is easy to be oxidized and overgrinded, so its floation nature is quite complicated. The inlaid degree of all kinds of sulfide minerals in ores forms irregularly. After grinding the whole grade size and distribution of nickel and copper are in the form of“dumbbell-shaped”and the separation is difficult. The Jinchuan nickel ores contain large amount of ophiolite which has great effects on separation and mainly leads to the above-norm level of magnesium oxide in flotation concentrate. In addition, ophiolite is a kind of veinstone mineral containing of low hardness and density magnesium; it is easy to break down into fine clay particles and hard to settle down; ophiolite slime also can easily adhere to air bubbles and enter into froth pulp. In the same time, ophiolite has greater superficial free ability, and easily adheres to the bubble generator in flotation; the existence of ophiolite slime affects the viscosity of ore pulp, packs the fine grain sulfide ores and forms strong cover of slime to the surface of rough grain sulfide ores, which in turn adversely affect the selectivity of flotation process.
Base on the technological mineralogy characteristics of Jinchuan nickel sulfide ores, the flotation characteristics of nickel sulfide ores were studied in this dissertation. The bubble mineralization of Jinchuan nickel ores and the separation of mineralized floccules under centrifugal force field enviroment were investigated. And it has found that the centrifugal force field separation does not separate with the particles and density of ores but with the density of mineralized air floccules. In order to obtain better separation efficiency, based on previous studies this dissertation in further forms grade composition in the form of“dumbbell-shaped”and ores separation theory of metal distribution--fineness controlled optimized floatation theory of the hard-to-separate nickel ores. In this theory, it uses fine grinding to improve the grade composition and metal distribution. The floating grade composition and the distribution should be closer to the grade composition and metal distribution of concentrate not tailing, which is useful to the flotation recovery of nickel concentrate. After fine grinding, the grade distribution transmits to fine grade distribution, so highly efficient fine floatation and separation methods shall be employed to realize the effective recovery of fine particle. Highly efficient separation equipment and technology shall be used to improve the overall separation performance and based on the research put forward matched highly efficient floatation grade distribution curve and recovery rate curve. Aiming at the hard separation characteristics of fine grade nickel ores and analysis of the floatation process of nickel sulfide ores, this dissertation studied column separation theory in details. Using cyclonic static micro-bubble flotation column multi-mineralization separation method to strengthen and create suitable fluid separation environment for separation process of the fine grade hard-to-separate nickel ores to strengthen the bubble collision and mineralization of the fine poor nickel ores and the selective floation of mineralized bubbles.
The dissertation studied and demonstrated that micro-bubble, centrifugal force field and the pipe flow mineralized turbulence degree have significant effects of on fine particle separation. Based on detailed research, this dissertation reasonably demonstrates some parameters which affect nickel ore separation such as strengthening means of micro-bubble, circular separation pressure, and the height of flotation column and theoretical model.
The existing problems of the separation of Jinchuan nickel ores were identified. To efficiently separate the difficult-to-separate Jinchuan nickel sulfide ores, nickel tailing re-separation column separation and the second-stage highly efficient column separation and two-stages united Column separation was developed. Under fortified separation condition, through proper technological adjustments, separation performance indicators such as recovery rate and concentrate grade, etc. have been measurably increased compared with floatation machine separation. And that justifies the application of column separation equipment and technology in the separation of fine grade hard-to-separate nickel ores. Comparison and optimized different technology finally demonstrate the most proper the second-stage column flotation column under optimized fine grinding condition, which lays a fundamental base to the highly efficient exploration and utilization of fine grade hard-to-separate poor nickel ores.
Through technological development and pilot-scale testing, a combined process using fine grinding + flotation machine + column flotation has increased 3% of concentrate grade compared with original process, and the recovery rate has also increased 3%. This new process strengthened the gathering and recovery of micro-fine pentlandite, effectively controlled the floatation of magnesium silicate gangue, and measurably improved the mineral separation efficiency of Jinchuan nickel ores. Based on pilot testing, industrial-scale flotation columns were designed, and the application results indicate that column separation technology of fine grade hard-to-separate nickel ore can greatly simplify the separation process circuit, reduce energy consumption and save processing cost.
The column separation equipment and technology proposed in this research for fine hard-to-separate nickel ores treatment overcomes the shortcomings of conventional flotation equipment including single means of bubble mineralization and the lack of intense separation mechanism. Application of the proposed technology also resulted in simplified flotation process, lower processing cost, and improved the flotation efficiency, which lays a strong base for our country’s highly efficient exploration and utilization of finely sized hard-to-separate ores.
为了实现对贫细难选硫化镍矿的高效分选,本文系统的开展了硫化镍矿的基础理论与可浮性的研究,并结合金川镍矿石的工艺矿物学性质,分析了微细难选镍矿的难选原因。金川硫化镍矿石中以镍黄铁矿和紫硫镍铁矿最为普遍,部分镍黄铁矿的粒度细小,此外还有少量镍黄铁矿呈细小粒状或脉状嵌布于脉石矿物中,细粒嵌布的镍黄铁矿在磨矿过程中难于单体解离,造成磁黄铁矿和脉石矿物中含镍,且直接影响选矿指标。紫硫镍铁矿化学成分波动大,易氧化,易过粉碎,因此可浮性十分复杂。矿石中各种硫化矿物嵌布粒度极不均匀,磨矿后总体粒度和镍铜金属分布呈“哑铃型”,难于浮选。金川镍矿石中含有大量的蛇纹石,蛇纹石是一种硬度低、密度小的含镁脉石矿物,在磨矿过程中易碎、易泥化,沉降困难,在浮选过程中易与气泡粘附一起进入泡沫产品,因此蛇纹石对选矿工艺的影响较大,蛇纹石矿泥的存在影响矿浆粘度,包裹细粒硫化矿粒并对粗颗粒硫化矿表面形成强的矿泥覆盖,从而破坏浮选过程的选择性,致使精矿中氧化镁的含量超标。
基于金川硫化镍矿石的工艺矿物学特点,本论文针对性地进行了硫化镍矿的可浮性特征研究,在此基础上开展了金川镍矿气泡矿化及矿化后气絮团在旋流力场下的分离研究,通过研究提出了基于矿物物理特性和可浮性综合效应的旋流分离。表明在旋流力场下镍黄铁矿经过药剂作用与气泡接触矿化后,可以更多的富集于旋流中矿,实现镍黄铁矿与脉石矿物的有效分离和多重循环高效回收。针对金川镍矿“哑铃型”的粒度组成和金属分布,为实现短流程高效分选,论文针对金川难选镍矿的细度控制强化浮选进行了研究,利用细磨改善粒度组成和金属分布,使入浮矿物粒度组成和金属分布更接近于精矿的粒度组成和金属分布,通过细粒高效的分选设备和工艺来浮出更多的镍黄铁矿,进而提高镍精矿的总体回收率,并根据研究提出了匹配高效浮选的粒度分布曲线和回收率曲线。
在金川硫化镍矿浮选特性和分选过程研究的基础上,本论文进行了详细的柱式分选过程强化研究,通过旋流-静态微泡浮选柱多重矿化分选方式强化和营造适于细粒难选镍矿分选过程的流体分选环境,来强化细粒贫镍矿的气泡碰撞矿化和矿化气泡的选择性升浮。论文详细研究和论证了微泡、旋流力场、管流矿化紊流度等对细粒分离分选的影响,合理的确定了微泡强化方式、循环旋流分选压力、逆流碰撞高度等影响镍矿分选的设备参数和理论模型。
论文最后进行了金川镍矿柱式分选研究,针对金川细粒硫化镍矿难选的特点,逐步进行了基于金川镍尾矿的浮选柱强化分选、基于二段作业的浮选柱强化分选和基于一段二段作业联合的柱式强化分选研究。通过各种方式的柱式分选,采用强化的分选条件与柱式分选过程,回收率和精矿品位等工艺指标在浮选机分选的基础上都获得了明显的提升,表明柱式分选设备和工艺适于细粒难选贫镍矿的分选。通过不同强化分选研究,最终确定应用了强化细磨条件下的基于二段作业的柱式短流程高效分选,为细粒难选镍矿的高效开发利用奠定了基础。
通过合理的分选研究,半工业试验的连续运行,细磨-机-柱联合分选工艺与原有生产系统同期相比精矿品位提高3个百分点,回收率提高3个百分点,实现了柱式分选设备和工艺的在微细难选硫化镍矿分选的应用。通过对细磨-机-柱联合分选工艺的矿物学分析和比较,表明机-柱联合工艺强化了微细镍黄铁矿的富集与回收,并有效的控制了含镁硅酸盐类脉石的上浮,明显提高了金川镍矿的选矿效率。在半工业的基础上,进行了工业的设计,通过半工业的应用结果和工业设计表明,细粒难选镍矿柱式分选工艺可大大缩减工艺流程,降低能耗,节约生产成本。
细粒难选镍矿的柱式分选设备和工艺克服了常规浮选设备矿化方式单一、缺乏细粒强化分选机制等弊端,在提高矿物浮选效率的同时,简化浮选工艺配置、节约生产成本,为我国细粒难选矿的高效开发利用提供了有利的支撑。
Nickel, also called“Vitamin for Industry,”is a very important nonferrous metal for China's national economic and high-tech development. In recent years, with the development of China’s minerals industry, the exploration of nickel resources has been gradually enhanced, however, easy-to-separate ores have been decreasing year by year while the proportion of poor quality and difficult-to-separate nickel ores is rising steadily. The laregest nickel reserve in China is called Jinchuan nickel sulfide ore, and cell-type flotation technology has been used for nickel separation at Jinchuan. Due to the inherent inefficiencies associated with traditional flotation machines including the single mineralized separation and low mineralization efficiency, the separation technology of nickel sulfide using flotation machine has its problems such as complex process and high processing cost. Compared with flotation machine, flotation column has many advantages including simple structure, energy saving, high efficiency, and efficient separation of micro-fine mineral, etc. Thus, it is applied in cleaning flotation to improve the concentrate grade in nickel sulfide ore dressing plants; however it has been rarely used in hard-to-separate ores, rough and scavenging operations due to the lack of an intensified separation mechanism in most present flotation columns, which cannot guarantee high efficient recovery rate. Consequently, using highly efficient separation methods, equipment and technologies to explore nickel sulfide ores and improve their recovery rate and separation efficiency is a very urgent and important research project in nickel separating industry.
In order to achieve the highly efficient separation of nickel sulfide ores, the basic theory and flotation characteristics of nickel sulfide ores were systematically investigated in this dissertation, combined with the mineralogical characterization of Jinchuan nickel ores. The reasons of poor floatability of this ultra-fine nickel ores were analyzed and an improved separation process was designed. Mineralogical analysis indicated that the Jinchuan nickel sulfide ores consist of mostly pentlandite and violarite and the particle size of some pentlandite is quite small; in addition, there is also little pentlandite inlayed in gangue minerals in the form of fine particles or nervation. In the two parts the small size of pentlandite makes dissociation difficult in grinding, which results in some nickel residues in pyrrhotite and veinstone minerals and this directly affects the mineral separation performance. Violarite has high volatility and is easy to be oxidized and overgrinded, so its floation nature is quite complicated. The inlaid degree of all kinds of sulfide minerals in ores forms irregularly. After grinding the whole grade size and distribution of nickel and copper are in the form of“dumbbell-shaped”and the separation is difficult. The Jinchuan nickel ores contain large amount of ophiolite which has great effects on separation and mainly leads to the above-norm level of magnesium oxide in flotation concentrate. In addition, ophiolite is a kind of veinstone mineral containing of low hardness and density magnesium; it is easy to break down into fine clay particles and hard to settle down; ophiolite slime also can easily adhere to air bubbles and enter into froth pulp. In the same time, ophiolite has greater superficial free ability, and easily adheres to the bubble generator in flotation; the existence of ophiolite slime affects the viscosity of ore pulp, packs the fine grain sulfide ores and forms strong cover of slime to the surface of rough grain sulfide ores, which in turn adversely affect the selectivity of flotation process.
Base on the technological mineralogy characteristics of Jinchuan nickel sulfide ores, the flotation characteristics of nickel sulfide ores were studied in this dissertation. The bubble mineralization of Jinchuan nickel ores and the separation of mineralized floccules under centrifugal force field enviroment were investigated. And it has found that the centrifugal force field separation does not separate with the particles and density of ores but with the density of mineralized air floccules. In order to obtain better separation efficiency, based on previous studies this dissertation in further forms grade composition in the form of“dumbbell-shaped”and ores separation theory of metal distribution--fineness controlled optimized floatation theory of the hard-to-separate nickel ores. In this theory, it uses fine grinding to improve the grade composition and metal distribution. The floating grade composition and the distribution should be closer to the grade composition and metal distribution of concentrate not tailing, which is useful to the flotation recovery of nickel concentrate. After fine grinding, the grade distribution transmits to fine grade distribution, so highly efficient fine floatation and separation methods shall be employed to realize the effective recovery of fine particle. Highly efficient separation equipment and technology shall be used to improve the overall separation performance and based on the research put forward matched highly efficient floatation grade distribution curve and recovery rate curve. Aiming at the hard separation characteristics of fine grade nickel ores and analysis of the floatation process of nickel sulfide ores, this dissertation studied column separation theory in details. Using cyclonic static micro-bubble flotation column multi-mineralization separation method to strengthen and create suitable fluid separation environment for separation process of the fine grade hard-to-separate nickel ores to strengthen the bubble collision and mineralization of the fine poor nickel ores and the selective floation of mineralized bubbles.
The dissertation studied and demonstrated that micro-bubble, centrifugal force field and the pipe flow mineralized turbulence degree have significant effects of on fine particle separation. Based on detailed research, this dissertation reasonably demonstrates some parameters which affect nickel ore separation such as strengthening means of micro-bubble, circular separation pressure, and the height of flotation column and theoretical model.
The existing problems of the separation of Jinchuan nickel ores were identified. To efficiently separate the difficult-to-separate Jinchuan nickel sulfide ores, nickel tailing re-separation column separation and the second-stage highly efficient column separation and two-stages united Column separation was developed. Under fortified separation condition, through proper technological adjustments, separation performance indicators such as recovery rate and concentrate grade, etc. have been measurably increased compared with floatation machine separation. And that justifies the application of column separation equipment and technology in the separation of fine grade hard-to-separate nickel ores. Comparison and optimized different technology finally demonstrate the most proper the second-stage column flotation column under optimized fine grinding condition, which lays a fundamental base to the highly efficient exploration and utilization of fine grade hard-to-separate poor nickel ores.
Through technological development and pilot-scale testing, a combined process using fine grinding + flotation machine + column flotation has increased 3% of concentrate grade compared with original process, and the recovery rate has also increased 3%. This new process strengthened the gathering and recovery of micro-fine pentlandite, effectively controlled the floatation of magnesium silicate gangue, and measurably improved the mineral separation efficiency of Jinchuan nickel ores. Based on pilot testing, industrial-scale flotation columns were designed, and the application results indicate that column separation technology of fine grade hard-to-separate nickel ore can greatly simplify the separation process circuit, reduce energy consumption and save processing cost.
The column separation equipment and technology proposed in this research for fine hard-to-separate nickel ores treatment overcomes the shortcomings of conventional flotation equipment including single means of bubble mineralization and the lack of intense separation mechanism. Application of the proposed technology also resulted in simplified flotation process, lower processing cost, and improved the flotation efficiency, which lays a strong base for our country’s highly efficient exploration and utilization of finely sized hard-to-separate ores.
引文
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