./畢各莊4.0Mt/a選礦廠設計摘要本設計任務為XX畢各莊礦井型4.0Mt/a選煤廠,畢各莊是隸屬于開灤集團的礦井型選煤廠。首先根據(jù)生產(chǎn)大樣和浮沉試驗資料的分析與綜合,繪制可選性曲線；根據(jù)原煤的性質(zhì)及精煤質(zhì)量要求等,評定原煤為難選煤。在進行選煤方案比較的基礎(chǔ)上,確定采用重介-浮選聯(lián)合流程的選煤方法,并制定了工藝流程；然后經(jīng)過工藝流程計算、設備選型,對主廠房和總平面進行布置,并進行了圖紙的繪制。同時做出了該廠的經(jīng)濟技術(shù)分析,可知該設計實用性較高。關(guān)鍵字：難選煤；重介-浮選；設備選型；工藝布置BigeVillageAbstractThis

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themine-model

coalpreparationplantofKailuaGroup.Firstofall,accordingtotheproductiondetailsandanalysisandsynthesisoffugitivedusttestdata,drawthewashabilitycurves,Washabilitycurvedrawing;Accordingtothenatureoftherawcoalandplantqualityrequirements,etc.,toevaluatetherawcoalincoal.OnthebasisofcoalpreparationschemecomparisonKeywords:difficultseparationcoal;Theheavy–flotation;Equipmentselection;Processarrangement.目錄TOC\o"1-4"\h\z\u摘要IAbstractII第一章設計概要11.1項目背景11.2可行性研究概要11.2.1原煤資料分析11.2.2選煤產(chǎn)品組成11.2.3選煤廠設計生產(chǎn)能力11.2.4選煤廠位置與交通11.2.5選煤方案的擬定11.2.6工藝流程11.2.7設備選擇2第二章煤質(zhì)資料的分析與綜合32.1煤質(zhì)資料的審查分析32.1.1煤質(zhì)資料的審查32.1.2煤質(zhì)資料的分析9篩分資料分析9浮沉資料分析9可選性分析9第三章選煤方法與工藝流程的制定123.1選煤方法和入選方式123.2選煤方法的比較12、跳汰分選指標計算12重介〔三產(chǎn)品分選指標計算15理論與設計指標對比表18工藝流程的確定193.3工藝流程的簡述及特點193.3.1工藝流程說明193.3.2工藝流程的特點20第四章工藝流程的計算224.1準備作業(yè)的計算224.2分選作業(yè)的計算224.3工藝設備的選型與計算39工藝設備選型的原則和規(guī)定39設備選型的原則39不均衡系數(shù)的確定40設備的選型與計算404.2.2.1原煤篩分設備404.2.2.2破碎設備的選型與計算40分選設備的選型與計算40末煤及煤泥脫水設備的選型與計算424.2.3分級和濃縮設備的選型與計算444.2.4.輔助設備的選型與計算45運輸設備454.2.4.2儲煤設備484.3工藝布置圖514.4主廠房工藝布置圖514.5場地運輸52第五章生產(chǎn)輔助設施535.1設施概況53機電修理車間53空壓機車間53浮選藥劑站53介質(zhì)庫53材料庫535.2生產(chǎn)技術(shù)檢查53數(shù)量檢查54質(zhì)量檢查54化驗室及煤樣式545.3給排水54用水量及水壓54給水系統(tǒng)55排水系統(tǒng)55濃縮機555.4電氣56供配電56供配電系統(tǒng)57主要電器設備選型57防雷及接地575.4.5工藝系統(tǒng)設備的控制585.4.6自動化595.5檢測、計量、保護裝置59檢測59計量59保護裝置605.6生產(chǎn)管理系統(tǒng)及通信60行政電話60生產(chǎn)調(diào)度電話60直通電話60微機監(jiān)控與管理605.7采暖、通風及供熱60采暖60通風除塵615.7.3熱水及開水61鍋爐房61供熱管網(wǎng)61第六章環(huán)境保護636.1環(huán)境保護63主要污染源和污染物63防治措施63污染防治措施的預期效果646.2消防、工業(yè)衛(wèi)生64消防64電器設備防火措施65勞動安全65工業(yè)衛(wèi)生66第七章措施綜述687.1耗能指標及分析68項目耗能指標68節(jié)能分析687.2節(jié)能措施綜述68第八章生產(chǎn)組織和勞動定員69第九章職業(yè)安全與工業(yè)衛(wèi)生70第十章技術(shù)經(jīng)濟7110.1勞動定員及勞動生產(chǎn)率7110.2透支估算及投資籌措71投資估算71選煤廠設計主要技術(shù)經(jīng)濟指標73致謝75主要參考文獻76.第一章設計概要1.1項目背景近年來,市場對煤質(zhì)要求越來越高,焦炭的形勢看好,該公司的焦炭生產(chǎn)規(guī)模擴大,原選煤廠生產(chǎn)能力已不能滿足焦炭生產(chǎn)需要,直接購買精煤不利于企業(yè)在市場的競爭和經(jīng)濟效益的提高,因此需要新建一座年處理量為400萬噸的選煤煤廠,建設選煤廠,可以提高煤質(zhì),增強企業(yè)的競爭能力,提高企業(yè)的經(jīng)濟效益這已是勢在必行。1.2可行性研究概要原煤資料分析選煤廠主要入洗XX開灤畢各莊的原煤,資源可靠,穩(wěn)定。精煤灰分要求為10%時,其可選性為較難選煤。選煤產(chǎn)品組成推薦的產(chǎn)品結(jié)構(gòu)為精煤、中煤、矸石、煤泥。選煤廠設計生產(chǎn)能力選煤廠設計規(guī)模與焦化廠生產(chǎn)能力相配套,為年處理原煤400萬噸。選煤廠位置與交通選煤廠水源取自地下水,電源自設變電所,交通運輸便利。選煤方案的擬定為了確定適合本廠入洗原煤的合理洗選加工,本次設計分別對不同的選煤方法進行比較,為了保證生產(chǎn)出高質(zhì)量的精煤,使精煤的產(chǎn)量達到最大的回收率,滿足產(chǎn)品結(jié)構(gòu)多元化的要求,確定本次設計推薦的選煤方法為50-0mm三產(chǎn)品重介旋流器分選-洗煤泥浮選聯(lián)合工藝。工藝流程工藝流程共包括50-0mm設備選擇設備選型全采用國內(nèi)設備。全廠集控和自動化程度高,介質(zhì)密度控制手段先進,調(diào)節(jié)快捷,精確度高。.第二章煤質(zhì)資料的分析與綜合2.1煤質(zhì)資料的審查分析煤質(zhì)資料的審查礦區(qū)原始煤質(zhì)資料得表2.1：表2.1篩分總樣化驗結(jié)果化驗項目MadAdVdafSt,dQgr,d膠質(zhì)層粘結(jié)性系數(shù)煤樣%%%%Mj/KgX,mmY,mm毛煤1.9726.130.780.1696.827006凈煤0.618.4535.360.35038125表2.2原煤篩分試驗表粒級mm產(chǎn)品MkgA%占全樣%校正A%煤291.68915.473.4315.43150-100夾矸石23.76734.470.2834.43矸石59.47781.750.7081.71硫鐵礦000.000煤432.74617.195.0917.15100-50夾矸石29.50339.790.3539.75矸石177.03882.022.0881.98硫鐵礦0000>50小計〔除矸石777.70517.939.1617.8950-25煤1084.43733.6812.7733.6425-13煤1098.51633.6612.9333.626--13煤1258.2427.8214.8127.783--6煤1115.95921.7813.1421.743-0.5煤2106.83219.924.8019.860.5-0煤815.82516.899.6016.85毛煤總計8494.02926.14100.0026.1表2.3>50mm煤與夾矸煤破碎后篩分試驗粒級mmMkg占本級%占全樣%Ad%校正Ad%50-25297.72338.283.5120.7620.6625-13200.41525.772.3617.8517.7513--6121.92615.681.4417.0116.916--363.5138.170.7514.3614.263--0.575.2429.670.8912.7712.6750--0.5758.81997.578.9318.0617.960.5-018.882.430.2215.1215.0250-0777.699100.009.1617.9917.89總計8494.029.密度級kg/m3自然級破碎級綜合校正占本級%占全樣%Ad%占本級%占全樣%Ad%占本級%占全樣%Ad%占本級%占全樣%Ad%<1.317.9013.323.444.680.413.9716.4913.743.4516.4913.743.5141.9431.2110.5262.345.5210.4844.1136.7410.5144.1136.7410.5715.6811.6722.5920.451.8122.7516.1913.4922.6116.1913.4922.673.672.7334.483.440.3035.523.653.0434.583.653.0434.642.291.7045.732.950.2647.822.361.9746.012.361.9746.07>1.818.5213.7981.096.150.5466.8617.2114.3380.5517.2114.3380.61去泥小計100.0074.4325.90100.008.8618.12100.0083.2925.07100.0083.2925.13煤泥5.134.0232.510.460.0426.354.654.0632.454.654.0632.45總計100.0078.4526.24100.008.9018.15100.0087.3525.42100.0087.3525.35表2.450-0.5mm自然級與破碎級浮沉綜合表.表2.5原煤0.5-0mm自然級與破碎級篩分試驗綜合表粒級mm自然級破碎級綜合表校正占本級%占全樣%Ad%占本級%占全樣%Ad%占本級%占全樣%Ad%Ad%<0.5001.870.1816.721.850.00412.061.870.18416.6216.680.5-0.2526.152.5116.3626.530.05913.3626.152.56916.2916.3526.562.5517.5227.850.06214.0226.592.61217.4417.502.110.218.943.950.00917.42.130.20918.8718.9310.61.0216.9910.690.02414.910.631.04416.9417.00<0.04532.73.1416.4629.120.06517.6832.633.20516.4816.54總計1009.616.831000.22215.181009.82216.7916.85表2.6原煤0.5-0mm自然級與破碎級浮沉試驗綜合表密度級kg/m3自然級破碎級綜合級校正占本級%占全樣%Ad%占本級%占全樣%Ad%占本級%占全樣%Ad%Ad%<1.310.731.033.7727.270.063.4211.11.093.753.7549.174.727.536.360.087.3848.884.87.57.5151.4418.4713.640.0317.8814.971.4718.4618.4610.310.9927.664.540.0125.3210.181.0027.6427.644.380.4238.894.550.0136.274.380.4338.8338.83>1.810.421.0052.2713.630.0349.1910.491.0352.1852.18總計1009.616.861000.2215.561009.8216.8316.85表2.7原煤50-0.5mm浮沉實驗綜合表密度級kg/m3產(chǎn)率%灰分Ad累計分選密度浮物沉物產(chǎn)率%灰分Ad產(chǎn)率%灰分Ad密度級產(chǎn)率%123456789<1.316.493.5116.423.51100.0025.131.316.4944.1110.5760.608.6583.5129.401.460.3016.1922.6776.7911.6139.4050.481.519.843.6534.6480.4312.6523.2169.871.66.012.3646.0782.7913.6019.5776.441.72.36>1.817.2180.61100.0025.1317.2180.61去泥小計100.0025.13浮沉煤泥4.6532.45總計100.0025.35由表2.7中數(shù)據(jù)可繪制可選性曲線,以2、3欄繪制灰分特性λ曲線,由4、5欄繪制浮物β曲線,由6、7欄繪制沉物θ曲線,由4、8繪制密度δ曲線。由8、9欄繪制ε曲線。如圖2.1所示。.圖2.150-0.5mm粒級可選性曲線.煤質(zhì)資料的分析依據(jù)原煤總樣化驗結(jié)果表〔見表2-1對原煤的特性作如下分析：原煤水分：Mad=1.97%,屬于低水分煤。煤種：由總樣化驗表,原煤可燃體揮發(fā)分Vdaf=30.78%,在28～37%之間,最大膠質(zhì)層厚度Y=12mm,小于25mm,由此判定煤種為1/3焦煤。原煤灰分：Ad=26.10%,在20.01%～30.00%之間,屬于中灰分煤。原煤硫分：St.d=0.16%小于0.5%屬于特低硫煤,因此不必考慮脫硫。由原煤篩分試驗報告表可查出含矸率為3.41%＜5%屬于低矸煤,故不必考慮原煤入選前機械排矸的問題,在破碎前設置檢查性手選,只撿出雜物即可。篩分資料分析各粒級含量的分析：由表3-1可知,煤樣篩分為50-25,25-13,13-6,6-3,3-0.5,0.5-0六個粒級。各粒級的重量百分數(shù)相近,前四個粒級的百分含量均為13%左右,3-0.5的含量偏高,分別為24.80%。說明煤樣小粒度級的含量偏高,但總體上粒度分布均勻。各粒級質(zhì)量的分析：各粒級灰分差別較大,與總灰分有較大的差別,說明煤質(zhì)不均勻。而且灰分隨著粒度減小而降低,包括－0.5mm粒級灰分也低,可知煤質(zhì)脆易碎。隨著粒度的減小,煤的含量增大,矸石含量減小。各粒級水分含量相近,均為0.70%左右,水分含量比較均勻。浮沉資料分析各密度級的含量和灰分分析：由表3-2可知,＜1.40密度級的含量為50.48%,灰分為8.65%,＞1.80高密度級的含量為14.33%,灰分為80.61%。說明此礦高,低兩端密度級煤的含量較多,中間煤含量較低,易分選。而且低密度級精煤的質(zhì)量較高,灰分為8.65%,矸石含量不大?？蛇x性分析根據(jù)目前普遍采用的最新可選性評定標準,即分選密度+0.1含量法。該方法近似實際地反映了煤的可選性的難易程度。由于入選原煤為煉焦煤,對于冶煉產(chǎn)業(yè)的要求,精煤灰分不超過12.5%,而對其它的煉焦煤,灰分不超過16%,根據(jù)圖3-3入選原煤可選性曲線β浮物曲線,可以發(fā)現(xiàn)浮物曲線的拐點為11.0左右,根據(jù)此拐點數(shù)據(jù)選擇左右鄰居兩個數(shù)值作為灰分參考值,擬定精煤理論灰分為10.0%,11.0%,12.0%三個級別,對應的理論分選密度為1.44g/cm3、1.47g/cm3、1.53g根據(jù)可選性曲線,確定出如下方案：例如方案1取=10.0%,根據(jù)可選性曲線,可查出浮物產(chǎn)率=69.18%,臨界灰分=23.05%,沉物產(chǎn)率=30.82%,理論分選密度=1.43,取矸石灰分=80%,矸石產(chǎn)率=17.60%,所以中煤產(chǎn)率=13.22%,==31.25%。方案Ⅰ取精煤灰分為10.0%,矸石灰分為80.00%,通過可選性曲線可得,精煤產(chǎn)率為69.18%,矸石產(chǎn)率為17.6%,則中煤產(chǎn)率為100%-69.18%-17.6%=13.22%,理論分選密度為1.44g/cm3,中煤灰分為31.25%,精煤和中煤分界灰分為23.05%,通過δ±0.1曲線可知分選密度鄰近物的產(chǎn)率為40.21方案Ⅱ取精煤灰分為11.0%,矸石灰分為80.00%,通過可選性曲線可得,精煤產(chǎn)率為74.13%,矸石產(chǎn)率為17.6%,則中煤產(chǎn)率為100%-74.13%-17.6%=8.27%,理論分選密度為1.47g/cm3,中煤灰分為35.01%,精煤和中煤分界灰分為27.87%,通過δ±0.1曲線可知分選密度鄰近物的產(chǎn)率為27.64方案Ⅲ取精煤灰分為12.0%,矸石灰分為80.00%,通過可選性曲線可得,精煤產(chǎn)率為78.28%,矸石產(chǎn)率為17.6%,則中煤產(chǎn)率為100%-17.60%-4.12%=4.12%,理論分選密度為1.53g/cm3,中煤灰分為40.2%,精煤和中煤分界灰分為33.95%,通過δ±0.1曲線可知分選密度鄰近物的產(chǎn)率為14.13根據(jù)煉焦用精煤等級劃分及基本價格計算銷售收入：銷售收入=年處理量×[精煤產(chǎn)率×精煤灰分基價〔元×煤種比價〔%+中煤產(chǎn)率×中煤灰分基價〔元×煤種比價〔%]表2.10產(chǎn)品結(jié)構(gòu)及選煤方法綜合必選表方案精煤基價比價精煤收入中煤基價價比價中煤收入噸煤收入Ⅰ69.2871000010270613.2750068.854.56760.5Ⅱ74.121000987268.27250061.630.51756.5Ⅲ78.3561000947364.12%50054.4%13.5749.5由此可見方案Ⅰ即精煤灰分取10%,矸石灰分取80.00%時的利潤為最大值,因此確定Ⅰ為最終選煤方案.第三章選煤方法與工藝流程的制定3.1選煤方法和入選方式在確定煤樣的可選性及理論分選指標后,通過可選性曲線可知該選煤產(chǎn)品δ±0.1含量為40.2%,為難選,為了提高焦煤的精煤產(chǎn)率和效率,因此決定采用三產(chǎn)品重介質(zhì)旋流器—煤泥浮選聯(lián)合流程。由于本設計是針對的煉焦煤,結(jié)合三產(chǎn)品重介旋流器的主選特點,所以采用混合入選。原煤資料粒度主要集中在50mm以下,大粒級所占比例比較小,所以最后決定主選上線為50mm,大粒級破碎到50以下混合入選。針對原煤中細粒級所占比例>8%,且煤質(zhì)嬌脆,所以采用預先脫泥和無壓式給料方式入選。三產(chǎn)品重介質(zhì)旋流器是由兩臺兩產(chǎn)品重介質(zhì)旋流器串聯(lián)組裝而成,從分選原理上沒有差別。第一段為主選,采用低密度懸浮液進行分選,選出精煤和再選入料,同時由于懸浮液濃縮的結(jié)果為第二段準備了高密度懸浮液；第二段為再選,分選出中煤和矸石兩種產(chǎn)品。三產(chǎn)品重介質(zhì)旋流器的主要優(yōu)點是用一套懸浮液循環(huán)系統(tǒng),簡化了再選物料的運輸。缺點是在第二段分選時,重介質(zhì)密度的測定和控制較難。因第二段懸浮液入料是由第一段旋流器濃縮而成,由于懸浮液密度與兩段旋流器的尺寸有關(guān),所以第二段旋流器的分選密度除與第一段分選密度和兩段旋流器的溢流管直徑有關(guān),還與第二段旋流器底流口直徑有關(guān)。3.2選煤方法的比較、跳汰分選指標計算由可選性確定理論分選密度δp1°=1.68,δp2°=1.43?？蛇x性評定為極難選,確定實際分選密度δp1=1.80,δp2=1.40。按不分級跳汰選煤取矸石段I1=0.15,I2=0.17。每個密度級取密度的平均值。用跳汰近似公式計算t值,并查附表,得到分配率ε%。a.矸石段將δp1=1.80,I1=0.15代入查表得ε值密度級-1.3〔取1.2t===-6.23ε=0密度級1.3-1.4〔取1.35t==-3.717ε=0.01密度級1.4-1.5t===-2.587ε=0.48密度級1.5-1.6t===-1.685ε=4.6密度級1.6-1.8t===-0.600ε=27.43密度級+1.8〔取2.1t===1.213ε=95.39中煤段將δp1=1.40,I1=0.17代入密度級-1.3t==-2.749ε=0.30密度級1.3-1.4t==-0.529ε=29.84密度級1.4-1.5t==0.467ε=67.97密度級1.5-1.6t==1.263ε=89.68密度級1.6-1.8t==2.220ε=98.68密度級+1.8t==4.013ε=100.表3.1跳汰產(chǎn)品設計指標計算表密度級入料洗矸二段入料中煤段精煤r%Ad%e%r%Ad%r%Ad%e%r%Ad%r%Ad%12345678910111213<1.316.493.510.000.003.5116.493.510.300.053.5116.443.5144.1110.570.010.0010.5744.1110.5729.8413.1610.5730.9410.5716.1922.670.480.0822.6716.1122.6767.9710.9522.675.1622.673.6534.644.60.1734.643.4834.6489.683.1234.640.3634.642.3646.0727.430.6546.071.7146.0798.681.6946.070.0246.07>1.817.2180.6192.3915.9080.611.3180.61100.001.3180.610.0080.61合計100.0025.1316.7978.5583.2114.3530.2822.4252.939.74.重介〔三產(chǎn)品分選指標計算三產(chǎn)品重介質(zhì)旋流器一段〔主選分選粒級大于0.5mm,可能偏差E1=0.03~0.05。二段〔再選分選粒級大于0.5mm,可能偏差E2=0.05~0.07。取一段E1=0.05,二段E2=0.07。當精煤灰分要求Ad=10%時,確定理論分選密度為δp1=1.44g/cm-3,δp2=1.68g/cm-3。確定實際分選密度δp1=1.40g將"一段δp1=1.40g/cm-3,E1=密度級-1.30g/cm-3〔取1.2g/cm-3,==-2.7ε=0.35密度級1.30~1.40g/cm-3〔取1.35g==-0.675ε=24.97密度級1.40~1.50g/cm-3〔取1.45==0.675ε=75.03密度級1.50~1.60g/cm-3〔取1.==2.025ε=97.86密度級1.60~1.80g/cm-3〔取1==4.05ε=100密度級>1.8g/cm-3〔取2.10g==9.45ε=100將"二段δp2=1.80g/cm-3,E2=0.07密度級-1.30g/cm-3〔取1.2g/cm-3,==-5.78ε=0密度級1.30~1.40g/cm-3〔取1.35g==-4.34ε=0密度級1.40~1.50g/cm-3〔取1.==-3.375ε=0.04密度級1.50~1.60g/cm-3〔取1.5==-2.411ε=0.8密度級1.60~1.80g/cm-3〔取1.==-0.964ε=16.75密度級>1.8g/cm-3〔取2.10g==2.893ε=99.81..表3.2重介產(chǎn)品設計指標計算表密度級入料精煤段二段入料中煤段矸石r%Ad%e%r%Ad%r%Ad%e%r%Ad%r%Ad%12345678910111213<1.316.493.510.3516.433.510.063.510.000.063.510.003.5144.1110.5724.9733.0910.5711.0110.570.0011.0110.570.0010.5716.1922.6775.034.0422.6712.1522.670.0412.1422.670.0022.673.6534.6497.860.0834.643.5734.640.803.5434.640.0334.642.3646.071000.0046.072.3646.0716.751.9646.070.4046.07>1.817.2180.611000.0080.6117.2180.6199.810.0380.6117.1780.61合計100.0025.1353.659.3546.3543.3928.7521.1417.6079.74..3.2表3.3三產(chǎn)品重介理論與設計產(chǎn)品指標對照表產(chǎn)品名稱理論指標設計指標r%A%r%A%精煤69.181053.659.35中煤13.2231.2528.7521.14矸石17.68017.679.74小計10025.1310025.13數(shù)量效率：ηj=γj/γj0=53.65/69.18=77.5%表3.4跳汰理論與設計產(chǎn)品指標對照表產(chǎn)品名稱理論指標設計指標r%A%r%A%精煤69.181052.939.74中煤13.2231.2530.2822.42矸石17.68016.7978.55小計10025.1310025.13數(shù)量效率：ηj=γj/γj0=52.93/69.18=76.5%綜上所述,本工藝采用無壓三產(chǎn)品重介旋流器法分選是最好的。其產(chǎn)品設計平衡表如下表：表3.5重介選煤產(chǎn)品設計平衡表名稱產(chǎn)率占本級%占全樣%Ad%精煤53.6542.459.35中煤28.7522.7521.14矸石17.613.9379.74小計10079.1225.13占浮沉入料95.3579.1225.13浮沉煤泥4.654.0632.45合計10083.1825.35占全樣83.1883.1825.35原生煤泥9.829.8216.81次生煤泥7725.13合計10010025.343.2.4工藝流程的確定工藝流程基本流程為：入廠原煤在準備車間經(jīng)直徑為φ50mm的預先篩分機,將原煤分成+50mm粒級的原煤和-50mm粒級的原煤。+50mm原煤進行檢查性手選,除去大塊矸石和雜物。然后進入破碎機進行破碎,破碎后的原煤與預先篩分的篩下物混合進入脫泥篩,篩上物進入主選車間三產(chǎn)品重介質(zhì)旋流器,得到三種初產(chǎn)品：精煤、中煤和矸石。精煤、中煤和矸石分別經(jīng)過一次脫介和二次脫介后,最后得到最終合格產(chǎn)品。經(jīng)脫介篩脫除的合格介質(zhì)返回合格介質(zhì)桶作為循環(huán)介質(zhì)。經(jīng)脫介篩脫除的稀介質(zhì)經(jīng)磁選后進入濃介質(zhì)桶,最后返回合格介質(zhì)桶。磁選尾礦與脫泥篩篩下物一起進入煤泥濃縮機,然后用泵打入煤泥濃縮池,底流打入礦漿處理器。經(jīng)處理后進入浮選機進行浮選。浮選精煤經(jīng)過過濾后,溢流返回礦漿處理器。尾煤經(jīng)濃縮、過濾后最后得到浮選尾煤。濃縮機和過濾機溢流全部返回循環(huán)水池。3.3工藝流程的簡述及特點3.3.1工藝流程說明<1>、原煤準備原煤經(jīng)煤坑下給料機給入膠帶輸送機運支援煤準備車間,先經(jīng)分級篩50mm分級,+50mm原煤經(jīng)手選后破碎,與分級篩下50—0mm原煤混合,運至主廠房分選。<2>、原煤分選50—0mm原煤直接給入無壓給料三產(chǎn)品重介旋流器進行分選,以單一低密度懸浮液一次性分選出精煤、中煤和矸石三種產(chǎn)品。精煤產(chǎn)品脫介脫水后,由膠帶輸送機運至精煤儲煤廠；中煤精脫介脫水后由膠帶輸送機運至廠外落地；矸石經(jīng)脫介脫水后由汽車外運。<3>、介質(zhì)回收合格介質(zhì)用泵打至旋流器作為分選介質(zhì)。精煤與中、矸稀介系統(tǒng)彼此獨立,兩部分稀介質(zhì)分別進入各自的磁選機,選出的磁選精礦返回合格介質(zhì)桶。廠內(nèi)跑、冒、滴、漏的介質(zhì)收集后,由掃地泵打入中、矸稀介系統(tǒng)進行回收處理。<4>、介質(zhì)補加補加介質(zhì)采用合格磁鐵粉,不設分級和磨礦作業(yè)。補加磁鐵粉直接進入合格介質(zhì)桶。<5>、粗煤泥回收精煤磁選尾礦由精煤磁選尾礦桶收集后,用泵打至水力分級旋流器組,溢流進入浮選入料桶,底流經(jīng)高頻篩分級,篩下物進入浮選入料桶,篩上物經(jīng)煤泥離心機脫水后摻入精煤。離心液進入浮選入料桶。<6>、煤泥水處理煤泥經(jīng)浮選機分選出精煤和尾煤,浮選精煤采用壓濾機脫水回收,尾煤經(jīng)濃縮機濃縮,底流經(jīng)尾煤壓濾機脫水回收尾煤,溢流和壓濾機濾液作為循環(huán)水使用。3.3.2工藝流程的特點<1>、系統(tǒng)簡單：原煤不脫泥,直接進入三產(chǎn)品重介旋流器分選,使系統(tǒng)相對簡化。<2>、適應性強：重介分選精度高,對煤質(zhì)變化適應性強,尤其對于極難選煤,更加適合,適當選密度,可生產(chǎn)多級別灰分的精煤,適應市場多樣化的變化。<3>、由于采用重介分選,煤泥水量少,選用直接浮選工藝,減少了占地和投資。利用流水凈化,再生系統(tǒng),可確保流水閉路循環(huán),更加容易滿足環(huán)保要求。第四章工藝流程的計算4.1準備作業(yè)的計算1>入料數(shù)質(zhì)量的計算群礦選煤廠的工作制度：T=330,t=16h。選煤廠年生產(chǎn)能力Q0=400萬噸/年.選煤廠小時處理量Q=Q0/〔T×t=400×104/330×16=757.58t/h；根據(jù)原煤篩分試驗查出入料灰分：A0=26.1%2>篩下物數(shù)質(zhì)量計算本流程定為混合入選,預先篩分取η=90%,從篩分資料中查出理論篩下物率：γ2=γ0×η=90%Q11=γ1Q1=757.58×90%=681.82t/h；從篩分資料中查出篩下物灰份：A2=26.1%3>篩上物數(shù)質(zhì)量計算Q1=Q0-Q2=75.76t/h；γ1=γ0-γ2=10%A1=〔100A-γ2A2/〔100-γ24手選設檢查性手選,不計矸石損失,認為數(shù)質(zhì)量不變。γ3=γ1Q3=Q1A3=A5破碎：采用開路破碎作業(yè),經(jīng)破碎后,認為只有粒度的變化,而破碎前后數(shù)質(zhì)量不變。γ4=γ3Q4=Q3A4=A最終得出入選物數(shù)質(zhì)量γ5=γ0=100%Q5=Q0=757.58t/hA5=A0=26.1%4.2分選作業(yè)的計算1計算給料中的煤泥水煤泥的比重：δ0=1.5γ0=100%γ=γ原+γ次+γ浮=9.82+7+4.06=20.88%給料中煤泥量Gn=20.88%×757.58=158.18/h原煤含水指標Mt=8%原煤中的水量m3/h煤泥水體積m3/h單位體積中煤泥含量t/m3煤泥水密度各產(chǎn)品的量：Q精=γ精×Q0=42.45%×757.58=321.59t/hQ中=γ中×Q0=22.75%×757.58=172.35t/hQ矸=γ矸×Q0=13.93%×757.58=105.53t/h2計算產(chǎn)品的平均粒度及比重平均粒度為4.63mm精煤的平均比重中煤的平均比矸石的平均比重3計算外加濃介質(zhì)、性質(zhì)設濃介質(zhì)比重,濃介質(zhì)中磁性物含量〔t/m3〔t/m3〔t/m3〔t/m34確定工作介質(zhì)性質(zhì)要求分選密度δp=1.40工作介質(zhì)懸浮液的密度Δ1=1.35〔圖3-11取工作介質(zhì)中非磁性物含量〔t/m3〔t/m3〔t/m3〔t/m35>分選作業(yè)的計算先確定循環(huán)介質(zhì)量,旋流器循環(huán)懸浮液取3.7m3V2=757.58×3.7=2803.05m3工作介質(zhì)總量為V1=Vn+V2=171.33+2803.05=2974.38m3G1=g1V1=0.549×2974.38=1632.93t/hGc1=G1γc1=1632.93×0.35=571.53t/hGf1=G1γf1=1632.93×0.65=1061.40t/hW1=〔Δ1-g1V1=〔1.45-0.549×2974.38=2382.48m3求循環(huán)介質(zhì)的其他參數(shù)G2=G1-Gn=1632.93-158.18=1474.75t/hGc2=Gc1-Gn=571.53-158.18=413.35t/hGf2=Gf1=1061.40t/hW2=W1-Wn=2382.48-65.88=2316.60m3Δ2=〔G2+W2/V2=〔1474.75+2316.60/2803.05=1.35γc2=Gc2/G2=413.35/1474.75=28.03%設旋流器溢流中的懸浮液密度比工作介質(zhì)低0.1,低流密度比工作介質(zhì)密度高0.4,即Δ4=Δ1-0.1=1.45-0.1=1.25Δ3=Δ1+0.4=1.45+0.4=1.75V3=〔Δ1-Δ4V1/〔Δ3-Δ4=〔1.35-1.25×2974.38/〔1.75-1.25=594.876m3V4=V1-V3=2974.38-594.876=2379.504m3設底流中磁性物含量比工作介質(zhì)高0.1,即γf3=γf+0.1=0.65+0.1=0.75γc3=1-0.75=0.25t/m3gc3=g3γ3=1.097×0.25=0.274t/m3gf3=g3-gc3=1.097-0.311=0.823t/m3ω3=Δ3-g3=1.75-1.097=0.653t/m3G3=g3V3=1.244×594.876=652.58t/hGc3=G3γc3=652.58×0.25=163.145t/hGf3=G3-Gc3=652.58-163.145=489.435t/hW3=ω3V3=0.653×594.816=388.415m3G4=G1-G3=1632.93-652.58=980.35t/hGc4=Gc1-Gc3=571.53-163.145=408.385t/hGf4=Gf1-Gf3=1061.40-489.435=571.965t/hW4=W1-W3=2382.48-388.415=1994.065m3g4=G4/V4=980.35/2379.504=0.412t/m3gc4=Gc4/V4=408.385/2379.504=0.172t/m3gf4=g4-gc4=0.412-0.172=0.24t/m3ω4=W4/V4=1994.065/2379.504=0.83t/m3Δ4=g4+ω4=0.412+0.83=1.25與原假定值相同,證明以上計算無誤γc4=Gc4/G4=408.385/980.35=41.65%γf4=100-γc4=100-41.65=58.35%進入二段的懸浮液：設旋流器溢流的懸浮液比工作密度低0.1,底流密度比工作密度高0.4設底流中磁性物含量比工作介質(zhì)高10％γ'f3=0.75+0.1=0.85γ'c3=0.15δ'3=δfδc/<δ'f3δc3+δ'c3δf3>=5×1.5/<5×0.15+1.5×0.85>=3.704g'3=<Δ'3–1>/<δ'3-1>×δ'3=<2.25-1>/<3.704-1>×3.704=1.575t/m3g'c3=g'3γ'c3=1.575×0.15=0.236t/m3g'f3=g'3γ'f3=1.575×0.85=1.339t/m3ω'3=Δ'3–g'3=2.15-1.575=0.575t/m3G'3=g'3V'3=1.575×118.98=187.394t/hG'c3=G'3γ'c3=187.394×15%=28.11t/hG'f3=G'3γ'f3=187.394×85%=159.285t/hW'3=ω'3V'3=0.575×118.98=68.41m3G'4=G3-G'3=652.58-187.394=465.186t/hG'c4=Gc3-G'c3=163.145-28.11=135.035t/hG'f4=Gf3-G'f3=489.435-159.285=330.15t/hW'4=W3-W'3=388.415-68.41=320.005m3g'4=G'4/V'4=465.186/475.896=0.977t/m3g'c4=G'c4/V'4=135.035/475.896=0.284t/m3g'f4=G'f4/V'4=330.15/475.896=0.694t/m3ω'4=W'4/V'4=320.005/475.896=0.672t/m3Δ'4=ω'4+g'4=0.672+0.977=1.65與原假定值相同,證明以上計算無誤γ'c4=G'c4/G'4=135.035/465.186=29.03%γ'f4=100%–29.03%=70.97%6精煤脫介作業(yè)的計算取脫介篩脫出的介質(zhì)量占入料介質(zhì)量的70％,則合格介質(zhì)為：V8=70%×V4=70%×2379.504=1665.653m3G8=g4V8=0.412×1665.653=686.249t/hGc8=gc4V8=0.172×1665.653=286.492t/hGf8=gf4V8=0.24×1665.653=399.758t/hW8=ω4V8=0.83×1665.653=1382.492m3進入脫介篩的懸浮液V7=V4-V8=2379.504-1665.653=713.851m3G7=G4-G8=980.35–686.249=294.101t/hGc7=Gc4-Gc8=408.385–286.492=121.893t/hGf7=Gf4-gf8=571.965–399.758=172.207t/hW7=W4-W8=1994.065–1382.492=611.573m3由精煤帶入脫介篩稀介質(zhì)的懸浮液：Vd精=KQ精/dδ精=1×321.59/<4.63×1.31>=53.021m3Gcd精=gc4Vd精=0.172×53.021=9.120t/hGfd精=gf4Vd精=0.24×53.021=12.725t/hGd精=Gcd精+Gfd精=9.120+12.725=21.845t/hWd精==ω4V8精=0.83×53.021=44.007m3取噴水量為1.0m3V11=W11=1.0×Q精×2/3=1.0×2/3×321.59=214.493m3V12=W12=1.0×Q精×1/3=1.0×1/3×321.59=107.197m3取精煤產(chǎn)品帶走的磁性物介質(zhì)為M=0.4公斤/噸Gf16=M/1000×Q精=0.4/1000×321.59=0.129t/hG16=Gf16/γf4=0.129/58.35％=0.216t/hGc16=G16-Gf16=0.216–0.129=0.087t/h取精煤產(chǎn)品水分為ωQ16=14％,產(chǎn)品帶走的水量為：W16=ωQ16/<100-ωQ16>Q精=14/<100-14>*321.59=52.352m3V16=W16+Gf16/δf+Gc16/δc=52.352+0.129/5+0.087/1.5=52.436m3因此精煤脫介篩篩下稀介質(zhì)為：V17=Vd精+V11+V12-V16=53.021+214.493+107.197-52.436=322.275m3G17=Gd精-G16=21.845–0.216=21.629t/hGc17=Gcd精-Gc16=9.120-0.087=9.033t/hGf17=Gfd精-Gf16=12.725–0.129=12.596t/hW17=Wd精+W11+W12-W16=44.007+214.493+107.197-52.352=313.345m3精煤脫介篩篩下合格介質(zhì)為：V18=V7-Vd精=713.851-53.021=660.830m3G18=G7-Gd精=294.101-21.845=272.256t/hGc18=Gc7-Gcd精=121.893-9.120=112.773t/hGf18=Gf7-Gfd精=172.207–12.725=159.482t/hW18=W7-Wd精=611.573–44.007=567.566m37>中煤脫介作業(yè)的計算取弧形篩脫出的合格介質(zhì)占入料量的60％,因此篩下合格介質(zhì)為：V5=60％×V'4=0.6×475.896=285.538m3Gc5=g'c4V5=0.284×285.538=81.093t/hGf5=g'f4V5=0.802×285.538=198.163t/hG5=Gc5+Gf5=81.093+198.163=279.256t/hW5=ω'4V5=0.672×285.538=191.882m3進入脫介篩的懸浮液：V6=V'4–V5=475.896–285.538=190.358m3G6=G'4-G5=465.186–279.256=185.93t/hGc6=G'c4-Gc5=135.035-81.093=53.942t/hGf6=G'f4-Gf5=330.15-198.163=131.987t/hW6=W'4-W5=320.005-191.882=128.123m3由中煤帶入脫介篩稀介段的懸浮液量：Vd中=KQ中/dδ中=1×171.35/<4.63×1.44>=25.70m3Gcd中=g'c4Vd中=0.284×25.70=7.299t/hGfd中=g'f4Vd中=0.694×25.70=17.836t/hGd中=Gcd中+Gfd中=7.299+17.836=25.135t/hWd中=ω'4Vd中=0.672×25.70=17.270m3取噴水量為每噸產(chǎn)品1.5m3V9=W9=1.5×Q中×2/3=1.5×171.35×2/3=171.35m3V10=W10=1.5×Q中×1/3=1.5×171.35×1/3=85.675m3取中煤帶走的磁性介質(zhì)量為M=0.5公斤/噸Gf15=M/1000×Q中=0.5/1000×171.35=0.0857t/hG15=Gf15/γ'f4=0.0857/0.7097=0.121/hGc15=G15-Gf15=0.121-0.0875=0.0335t/h取產(chǎn)品水分WQ15=14%W15=WQ15/<100-WQ15>Q中=14/<100-14>×171.35=27.894m3V15=W15+Gf15/δf+Gc15/δc=27.894+0.0857/5+0.0335/1.5=27.933m3因此中煤脫介篩下稀介質(zhì)為：V14=Vd中+V9+V10-V15=25.70+171.35+85.675-27.933=254.792m3G14=Gd中-G15=25.135-0.121=25.014t/hGf14=Gfd中-Gf1557=17.750t/hGc14=Gcd中-Gc15=7.265t/hW14=Wd中+W9+W10-W15=17.270+171.35+85.675-27.894=246.401m3中煤脫介篩下合格介質(zhì)量為：V13=V6-Vd中=190.358–25.70=164.658m3G13=G6-Gd中=185.930–25.135=160.795t/hGc13=Gc6-Gcd中=53.942–7.299=46.643t/hGf13=Gf6-Gfd中=131.987–17.836=114.151t/hW13=W6-Wd中=128.123-17.270=110.853m38矸脫介作業(yè)的計算設弧形篩脫除介質(zhì)占入料的80％,因此篩下合格介質(zhì)為：V19=80%×V'3=0.8×118.98=95.184m3Gc19=g'c3V19=0.236×95.184=22.833t/hGf19=g'f3V19=1.339×95.184=127.451t/hG19=Gf19+Gc19=22.833+127.451=150.284t/hW19=ω'3V19=0.575×95.184=54.731m3進入脫介篩的懸浮液V20=V'3-V19=118.98-95.184=23.796m3G20=G'3-G19=187.394-150.284=37.11t/hGc20=G'c3-Gc19=28.11-22.833=5.277t/hGf20=G'f3-Gf19=159.285-127.451=31.834t/hW20=W'3-W19=68.41-54.731=13.679m3由矸石帶入脫介篩稀介段的懸浮液量Vd矸=KQ矸/dδ矸=0.6×105.53/〔4.63×2.09=6.543m3Gcd矸=g'c3Vd矸=0.236×6.543=1.544t/hGfd矸=g'f3Vd矸=1.399×6.543=9.154t/hGd矸=Gfd矸+Gcd矸=9.154+1.544=10.698t/hWd矸=ω'3Vd矸=0.575×6.543=3.762m3取噴水量為每噸產(chǎn)品1m3V21=W21=1×Q矸×2/3=105.53×2/3=70.353m3V22=W22=1×Q矸×1/3=105.53×1/3=35.177m3取矸石產(chǎn)品帶走的磁性物含量為M=0.3kg/tGf25=M/1000Q矸=0.3/1000×105.53=0.0316t/hG25=Gf25/γ'f3=0.0316/0.85=0.037t/hGc25=G25-Gf25=0.037-0.0316=0.0056t/h取產(chǎn)品水分ωQ25=10%則產(chǎn)品帶走水分：W25=ωQ25/<100-ωQ25>Q矸=10/<100-10>×105.53=11.726m3V25=W25+Gf25/δf+Gc25/δc=11.726+0.0316/5+0.0056/1.5=11.736m3因此矸石脫介篩下稀介質(zhì)量為：V24=Vd矸+V21+V22-V25=6.543+70.353+35.177-11.736=100.337m3G24=Gd矸-G25=10.698-0.037=10.661t/hGc24=Gcd矸-Gc25=1.544-0.0056=1.538t/hGf24=Gfd矸-Gf25=9.154-0.0316=9.122t/hW24=Wd矸+W21+W22-W25=3.762+70.353+35.177-11.726=97.566m3矸石脫介篩下合格質(zhì)量為：V23=V20-Vd矸=23.796-6.543=17.253m3G23=G20-Gd矸=37.11-10.698=26.412t/hGc23=Gc20-Gcd矸=5.277-4.544=3.733/hGf23=Gf20-Gfd矸=31.834-9.154=22.68t/hW23=W20-Wd矸=13.679-3.762=9.917m39計算所需分流量,補充水量及補加濃介質(zhì)量：為了保持工作質(zhì)懸浮液的質(zhì)量穩(wěn)定,工藝要求的指標必須使進出循環(huán)介質(zhì)系統(tǒng)懸浮液各項質(zhì)量在規(guī)定的指標完全達到平衡,求出所需濃介質(zhì)補加體積Vx.Vx=[Vogo<γcn-γcf>+Vdsgs<γcf-γcs>+Vds2gs2<γcf2-γcs2>]/gx<γcf-γcx>=[171.33*0.92×<1-0.4165>+25.70×0.977×<0.4165-0.2903>+6.543×1.575×<0.4165-0.15>]/1.287×<0.4165-0.05>=207.53m分流量：Vp=[Vo<Δo-1>+Vx<Δx-1>-Vds<Δs-1>-Vds2<Δs2-1>]/[Δf-1]-Vdf=[171.33×〔1.31-1+207.39×<2.0-1>-25.70×<1.65-1>-6.543×<2.15-1>]/[1.25-1]-53.021=892.07m3V26=Vp補加水量：Wv=Vds+Vds2+Vdf+Vp-Vx-Vn=25.70+6.543+53.021+892.63-207.39-171.33=598.614m3分流量確定后,可進一步求出分流量中其它參數(shù)：Gcp=Gc26=gc4Vp=0.172×892.07=153.436t/hGfp=Gf26=gf4Vp=0.24×892.07=214.097t/hGp=G26=Gcp+Gfp=153.53+214.230=367.533t/hWp=W26=ω4Vp=0.83×892.07=740.418m3精煤脫介所得合格介質(zhì)〔分流后,循環(huán)介質(zhì)桶V27=V8+V18-V26=1665.653+660.83-892.07=1434.413mG27=G8+G18-G26=686.249+272.256-367.533=590.972Gc27=Gc8+Gc18-Gc26=286.492+112.773-153.436=245.829t/hGf27=Gf8+Gf18-Gf26=399.758+159.482-214.097=345.143t/hW27=W8+W18-W26=1382.492+567.566-740.418=1209.64m310磁選作業(yè)的計算精煤離心脫水,取精煤產(chǎn)品水分為7％W'精=Mt/<100-Mt>Q精=7/<100-7>×321.59=24.206m3W'離=W16-W'精=52.352-24.206=28.146m3V'離=