Yadda za a Fitar da Rokoto na Hoda? Tsarin Inganta Rokoto na Hoda Cikakke

Summary: Yaya hanyar inganta ƙarfe dutsen ƙarfe take canza dutsen mai ƙyalli zuwa ƙara? Wannan labarin yana gabatar da cikakken tsarin aikin haɓaka ma'adanan ƙarfe...

Kayan ƙarfe na ROM (run-of-mine) da aka cire daga ma'adinai yawanci yana da ƙananan matakin inganci kuma yana ƙunshe da yawa gangue da ƙazanta masu cutarwa. Don haka, ana buƙatar matakin gyara.

Wannan labarin yana gabatar da Tsarin Gudanar da Ma'adanin Bakin Iron Mai Dacewa da Dukkanin Matakan Sarrafa Ma'adanai.

Hanyar cikakken ingantaccen ma'adanin ƙarfe mai yuli shine haɗin ayyuka na jiki da na kimiyya daban-daban, wanda babban ya ƙunshi matakai masu zuwa: murƙushewa da tantancewa, taɓa da ƙungiyawa, rarrabewa, cire ruwa daga tarin haɗaɗɗen ma'adanin, da kuma sarrafa tarkace.

Mataki na 1: Laga da Tacewa

Ƙarfen ƙwaƙwalwar ma'adinai da aka fitar daga ma'adinai tana zuwa cikin manyan ƙwai- har zuwa fiye da ɗayari guda a cikin diamita mafi girma - wanda hakan ke yiwuwa ba zai yiwuwa a shigar da shi kai tsaye cikin injin haƙora ba. Dole ne a farko ya wuce ta hanyar murƙushewa mai matakai da dama domin rage girman ƙwayoyin, yana shirya shi domin gaba ɗaya aikin haƙora da raba abubuwa.

Hana barkwanci mai kyau: Jaw crushers or gyratory crushers are utilized to break down the iron ore to below 200–300 mm. Relying on high compressive and impact forces, they accomplish the initial size reduction of the ore.

Saukar da girma da ɗanɗano: Given the high hardness of iron ore, cone crushers are used in the secondary and tertiary crushing stages to reduce the particle size to below 10–25 mm. Adopting laminated crushing principle, cone crushers feature high crushing efficiency and produce uniform product particle size distribution.

Screening: Bayan murkushewa, ana tace kayan; ƙwayoyin da suka dace da waɗannan ƙayyadaddun girma suna wucewa zuwa mataki na gaba na sarrafawa, yayin da ƙwayoyin da suka wuce girma ana mayar da su zuwa cikin na'urar murkushewa don sake murkushewa, suna ƙirƙirar tsarin kewaye. Wannan tsarin kewaye yana sarrafa girman ƙwayoyin samfur sosai kuma yana hana wulakanci fiye da kima, yayin da yake cikakken amfani da ingancin murkushewa.

Mataki na 2: Garin da Rarrabewa

Wannan mataki ne mai mahimmanci wajen sakin kyanwaƙwalwar ma'adinai a cikin aikin jintar ma'adinai na ƙarfe. Bayan makala, ƙwayoyin ma'adanin ƙarfe suna kasancewa da ƙwarai suna haɗe da ƙwayoyin gangue a cikin ma'adanin. Don cimma raba mai zuwa kai tsaye, dole ne a sare ma'adinai ta hanyar daskarewa domin samun isasshen matakin sakin monomer.

2.1 Niƙa

Gishiri is typically conducted in ball mills or semi-autogenous grinding (SAG) mills. The ore usually needs to be ground down to a particle size suitable for mineral liberation (typically 70%–95% passing -200 mesh), laying the necessary foundation for high-efficiency separation.

Gishiri is the most energy-intensive stage in the iron ore beneficiation plant, accounting for about 40–60% of the plant’s total energy consumption.

2.2 Rarrabewa

Fitar daga injin nika yana shiga kayan rarrabuwa - mafi yawan lokaci hydrocyclones - wanda ke raba kayan zuwa kayayyakin da aka yarda da su da wadanda ba a yarda da su ba bisa bambancin saurin kwanciya na kwayoyin a cikin ruwa. Ƙaramar sassa mai laushi da suka yarda da su (overflow) na ci gaba zuwa matakin rarrabuwa, yayin da ɓangaren mai ƙarfi mara ƙyama (underflow) aka mayar da shi zuwa injin don sake nika, yana ƙirƙirar wani zagaye mai ƙulle. Ingancin rarrabuwa yana da tasiri kai tsaye ga yadda aka yi nika fiye da kima da kuma yadda aka sami 'yanci' cikin kayan da aka nika, yana taka muhimmiyar rawa wajen ingancin rarrabuwa na gaba.

Mataki na 3: Raba

Wannan shi ne matakin asali na tsari mai haɓaka ƙarfe daga ma'adinai, inda ake raba ma'adinai na ƙarfe daga ma'adinai na gangue bisa bambance-bambancen fasali na jiki ko na sinadarai. Zaɓin hanyar raba da ta dace ya fi yawa ya dogara da halayen ma'adinai, musamman nau'in ma'adinai na ƙarfe, girman ƙwayoyin bazuwar cin nasara, da dangantakar haɗuwa tsakaninsu.

Sassan da ke ƙasa suna bayyana hanyoyin raba nau'ikan taƙaitaccen ƙarfe guda huɗu: magnetite, hematite, limonite, da siderite.

3.1 Magnetite - Rabewa ta Magnitik

Domin magnetite yana da ƙarfi sosai a cikin maganadisu, rabuwar maganadisu ita ce hanyar da ta fi tasiri kuma mai sauƙin ƙima wajen samun riba daga gare ta.

Wannan tsari ya fi dacewa da ma'adinai masu sauƙin sarrafawa guda ɗaya na magnetite mai sauƙi.

Continuous Gishiri – LIMS: Dangane da girman rarraba ƙwayar magnetite, aiwatarwar tana amfani da mataki ɗaya ko biyu na niƙa mai ɗorewa. Juya da thisconcrete na ruwan da aka niƙa ya kai matakin ƙare-ƙare, yana ci gaba kai tsaye zuwa LIMS.

Stage Gishiri – LIMS: Yana da kyau ga ma'adanai masu launin mwari, masu ƙananan matsayi na magnetite. Farko na gogewa yana biye da warwarewar maganetik mai kaifi don ƙin yawan sharar da aka fara samu. Sakamakon wannan tacewa mai ƙarfi shine a sanya shi cikin gogewa ta biyu kafin a tsaftacewa.

Babban Amfani na Maganin SBM: Babban manufa a cikin dukkanin jadawalin hanyoyi guda uku ita ce watsi da sharar kaya da wuri-wuri, wanda ke rage yawan aiki a ƙasa, rage yawan kuzarin da ake amfani da shi gabaɗaya, da kuma rage farashin aiki.

3.2 Raba Hematite

Hematite (Fe2O3) tana dauke da kaso har zuwa 69.94% na ƙarfe kuma ana tantance ta a matsayin ƙaramin abu mai rauni na maganadiso. A halin yanzu, hanyar warewa mafi yawa da ake amfani da ita wajen hematite sun haɗa da warewa ta nauyi, faɗuwa, da haɗin warewa.

Rabewar Nauyi

Dangane da halayen girman kwayar ƙwayar, rarrabuwar hematite ta nauyi ana raba ta zuwa cikin sarrafa ƙananan ƙwayar ƙwayar da ƙwayar ƙwayar ƙwari:

Rarrabuwa ta nauyi mai kyau Ya dace da ma'adanai na hematite masu mamaƙin ƙasa masu ƙanƙanta da kuma ƙididdigar maganadisu mai yawa. An ƙone da ƙura ma'adanin sannan a nannade shi domin samun 'yancin ma'adinai kafin a ware mai ingancin hematite mai yawa ta amfani da na'urorin rarrabewa ta nauyi (kamar teburin rawa, bututun lanƙwasa).

Rarraba Jawo Jawo Mai Girma Mafi dacewa don ma'adinai masu ɗigon jiji na hematite. Hanyar nan yawanci tana amfani da aikin murƙushewa kawai, tana amfani da kayan raba nauyi masu ɗigon jiji (misali, jiggers) domin ƙyale fatar ƙasa masu ƙyalli kai tsaye.

b) Yin tashi a ruwa

Ana amfani da shi wajen magance ma'adanan hematite masu rauni ko masu rauni sosai, tsarin juyawa yana ƙunshe da layukan guda biyu na asali: juyawa kai tsaye da juyawa mai juyawa baya. Juyawa kai tsaye yana fi dacewa da ma'adanan hematite masu sauƙi guda ɗaya, yayin da juyawa mai juyawa baya yafi dacewa da ma'adanan hematite masu grade mafi girma waɗanda ke ƙunshe da ma'adanan gangue masu sauƙin juyawa.

daban-daban haɗin gwiwa

Rarrabuwa ta haɗe an tsara ta don ma'adanai masu ƙarfi na hematite da ke haɗe da ƙananan ma'adanai masu ƙarfi sosai ko ƙari mara ƙarfe. Hanyoyin da aka saba amfani da su sun haɗa da:

• LIMS - Bangare Mai Ƙarfi Mai Ƙarfi Na Magnetic (HIMS)
• HIMS - Fitarwa
• HIMS - Rarrabuwar Nauyi
• Tsarawa Ta Wuta - Bambance-Bambancen Maganeti

3.3 Raba Limonite

Limonite yana ƙunshi babban kaso na oxide na ƙarfe mai ruwa da ƙarfe (Fe) daga 40% zuwa 60%, yana mai da shi a matsayin ƙaramin ƙarfin ƙarfe mai ƙaramin maganadisu. Hanyoyin rarrabewa na limonite sun haɗa da rarrabewa ta jijiya, rarrabewa ta maganadisu, feshi, da haɗe haɗe na rarrabewa.

Rabewar Nauyi

Mafi dacewa ga ma'adinai na limonite masu rarrabuwa mai yawa. Ana amfani da hanyoyin wanke-wanke da rarrabewa ta hanyar nauyi sosai, wanda ke amfani da injin wanke da ke wanke ma'adinai na asali don cire laka, sannan kuma kayan rarrabewa na nauyi kamar masu rarrabewa masu nauyi ko jig.

b) Rabewar Magnetik

Ko da yake limonite ba shi da ƙarfi sosai wajen jan hankali, Ana iya amfani da Tsarin Faɗaɗɗen Banƙyama mai ƙarfi (HIMS) yadda ya kamata don ƙara sarrafa ma'adanai masu ƙananan ƙari.

c) Yin ninkaya

An yi amfani da shi a cikin ma'adanan limonite masu ƙananan kwayoyi, waɗanda ke haɗe da tsarin faɗaɗa kai tsaye da kuma tsarin faɗaɗa mara kyau. Ana buƙatar cire ƙasa ko ƙara wa rarrabuwar ƙura mai laushi kafin a yin faɗaɗa don kawar da illolin rashin kyau na ƙarancin ma'adanai mai ƙarfi.

d) Raba Hadin Gwiwa

An tsara shi don masu ƙyalli na limonite masu rikitarwa waɗanda ke da girman ƙwayoyin ganinsa maras daidaito ko kuma yawan laka mai yawa. Sassan da ake amfani da su sun haɗa da:

• Rarrabuwa ta ƙarfin jiki - Rarrabuwa ta Magnitik mai ƙarfi sosai (HIMS)
• Zabiɗa Mai Zuba Ruwa - Tsarkakewa ta Dafa ruwa
• Flocculation - Rarrabuwa ta Magnit na Tsanani Mai Ƙarfi (HIMS)

3.4 Raba Siderite

Siderite (FeCO3) yana da babban ƙunshe na ferrous carbonate, tare da ƙunshe na ƙarfe na 48.2%. Hanyoyi guda huɗu na al'ada na warwarewa sune kamar haka:

Rabewar Nauyi

Ya dace da daban-daban na sassaƙaƙƙen kayayyakin ƙarfe masu ƙananan ƙwayoyi da tsaka-tsakin ƙwayoyi. Ana yawan amfani da raba mai nauyi (HMS) da jiggers don cim ma ingantaccen tarawa.

b) Raba Magnitik Mai Ƙarfi Mai Girma (HIMS)

Ya dace da ma'adinan siderite masu raunin magnetic. Amfani da masu rarraba magnetic masu ƙarfi a bisa ruwa (WHIMS) don sarrafa yadin ma'adinan da aka ƙyale, yana inganta ƙimar mai da dawo da shi sosai.

c) Yin ninkaya

Dace don sarrafa hakoran siderite masu laushi, wanda ya haɗa da sawun floata kai tsaye da kuma sawun floata na baya:

Forpishin Kai Tsaye Ya haɗa da hanyoyin tura ƙura masu酸ic da alkaline.

Tasirin Juyawa na Flotation: Yana ƙunshe da fasahar jawo maqallin anlona mai juyawa da fasahar jawo maqallin kationik mai juyawa.

d) Magnetizing Roasting - Raba Maganeti mai ƙarfi ƙasa (LIMS)

Karɓi babban buƙatar wasan kwaikwayo na mugsuwa don sauya siderite mai rauni ya zama ƙarfe mai ƙarfi (kamar magnetite), sannan kuma a yi amfani da LIMS don raba shi da inganci mai girma.

Mataki na 4: Mayar da Hankali ga Tsabtace Ruwa da Magani na Ragowar Gini

4.1 Bayar da Ruwa Mai Ruwa

Tsarin ƙarfe mai ƙarfi da aka samu bayan matakin warewa yana da ruwa mai yawa (yawanci yana da ƙarfin abubuwan ƙarfi daga 20% zuwa 30%). Dole ne a yi masa matakin shan ruwa domin cika buƙatun sufuri da kuma ƙarfe na ƙasa da ƙasa.

Kara kauri (karfafawa)

The slurry is first fed into a thickener, where gravity settling causes solid particles to migrate downward while clear water overflows from the top. This stage increases the slurry density (solids concentration) to 40%–60%.

b) Tsaftacewa ta hanyar matsa press

An zubar da ƙasan da ya tsawo zuwa kayan aikin tacewa (kamar injin tacewa na vacuum ko na faranti da frame). A ƙarƙashin vacuum ko matsin lamba na ƙaikace, ƙura mai ƙyalli tana ci gaba da kebewa don haifar da kekin tacewa mai ƙunƙarar ruwa wato kuɗa mai kusan 10%. Wannan kekin ya zama samfurin ƙarshe na ƙarfe mai mahimmanci, shiryayye don naɗa da jigilar kaya.

4.2 Gyaran Sawun Dumi

Kayan sharar gida (tailings) da ake samu yayin aiwatar da aikin inganta ma'adanan ƙarfe yakan kai sama da 50% na dukan ma'adanan ƙasƙƙarfan da aka samo daga ƙasa. Gudanar da tailings ɗin ya zama muhimmin ɓangare na aiwatar da ingantaccen aikin. A yanzu, ana amfani da manyan hanyoyi guda uku don maganin tailings na ƙarfe:

Bargar da Amafari Masu Kwanaƙwashewa

Wannan shi ne mafi al'ada sana'a, inda ruwan tarkace na tarkace ke fitarwa kai tsaye zuwa tafki na tarkace domin ajiya mai laushi. Tsarin yana da sauki kuma yana bukatar saka hannun jari mai yawa, don haka an yarda da shi sosai a farkon tsarukan fa'idantawa. Duk da haka, yana da matsalolin tsaro masu mahimmanci kuma ana rage shi a hankali.

b) Dakon Gumi Mai Daji

Wanda aka yi amfani da shi a cikin sharar mai bushewa shine al'ada ta gaba kuma shi ne tsarin da aka fi so ga sabbin wuraren haɓaka ƙarfe na ƙarfe. Tsarin yawanci yana haɗa da ƙarfi mai zurfi na roba mai lanƙwasa, sai a bi da tacewa da kuma cire ruwa, yana rage ƙunshin danshi na ragowar zuwa ƙasa da 15% don ajiye mai bushewa. Idan aka kwatanta da sharar mai ruwa, ajiye mai bushewa na ba da mafi ƙarfi na tsaro musamman, tare da cimma ƙimar dawo da ruwa mai yawa da kuma yawan kariya ga ruwa.

c) Amfani da Gabaɗaya na Ragowar Ma'adanai

Ana iya amfani da ragowar cikin ƙera kayan gine-gine, cike mashigar hakowa da aka karya, da kuma inganta ƙasa. Wannan hanya ta magance matsalar ajiyar ragowar hakowa a zahiri yayin da ta kuma ƙirƙirar yiwuwar ƙimar tattalin arziki.

Bunkasar ƙasaƙen ƙarfe na ƙarfe na da muhimmanci sosai wajen haɗa albarkatun ƙasa zuwa aikin ƙirƙirar ƙarfe. Tsari mai ilimi da hikima, tare da zaɓin kayan aiki masu dacewa, shi ne garantin asali na cimma yawan aiki da ake so, haɗa matakan inganci, da kuma kula da daidaiton aiki na dogon lokaci.

Before finalizing the beneficiation process flow, detailed process mineralogy studies must be conducted to determine the ore’s chemical composition, mineralogical composition, liberation characteristics, and particle size distribution, among other key parameters.

Domin samun ƙarin bayani game da tsarin bunkasa manƙara na ƙarfe da zaɓin kayan aiki na musamman, jin daɗin tuntuɓar SBM don shawarwari na musamman da tallafin injiniya.