What Chemical Additives Enhance Efficiency in Primary Iron Ore Crushing Processes?
Tijd:
6 May 2021
Efficiency in primary iron ore crushing processes can be enhanced through the use of chemical additives that improve the mechanical and physicochemical properties of the ore during comminution. These additives primarily focus on reducing energy consumption, improving particle size distribution, and increasing throughput. Here are some common categories of chemical additives that are used in the iron ore crushing process:
1.Surfactants
- Function: Surfactants can reduce the surface energy of particles, aiding in better disintegration and crack propagation during crushing.
- Voorbeelden: Polyethylene glycols, fatty acids, or organic surfactants that improve ore wettability and flow within the crusher.
2.Grinding Aids
- Function: Grinding aids prevent particle agglomeration, which can improve ore breakage by reducing recirculation and clogging within cone crushers or jaw crushers.
- Voorbeelden: Amines, glycols, or alcohol-based compounds that optimize grindability and particle dispersion.
3.Binder Agents
- Function: Binders are used to prevent excessive fines generation or dust formation, helping to maintain a balanced proportion of coarse and fine particles during crushing.
- Voorbeelden: Bentonite, organic polymers, or synthetic binders that stabilize particle interactions during comminution.
4.Flocculants
- Function: Flocculants can improve the separation of fines during crushing processes, ensuring higher selectivity and better flowability of ore into secondary crushing or beneficiation stages.
- Voorbeelden: Polyacrylamides or lignosulfonates used in slurry systems.
5.Corrosion Inhibitors
- Function: Corrosion inhibitors prevent equipment wear and prolong the life of machinery in acidic or harsh conditions, indirectly improving throughput by reducing maintenance downtime.
- Voorbeelden: Phosphates, silicates, or nitrites used in crusher systems.
6.Dust Suppressants
- Function: Chemicals that prevent airborne dust formation during crushing increase efficiency by improving environmental conditions and minimizing losses due to dust escape.
- Voorbeelden: Water-based foams or chemical sealants containing surfactants and binders, such as calcium lignosulfonates.
7.pH Regulators
- Function: Certain processes benefit from controlling the ore’s surface chemistry during crushing, making it more amenable for secondary beneficiation operations.
- Voorbeelden: Lime or caustic soda for pH adjustment in ores containing acidic impurities.
8.Viscosity Modifiers
- Function: These additives reduce slurry viscosity for ores with high clay content, ensuring smoother flow in handling and crushing systems.
- Voorbeelden: Specialty polymers or dispersants.
Application of Additives:
The selection of chemical additives depends on:
- The mineralogical composition of the ore (e.g., hematite, magnetite, goethite).
- Crushing equipment and operational parameters.
- Downstream processing requirements (e.g., whether magnetic separation or flotation is used).
It is critical to conduct lab-scale and pilot-scale testing to assess the impact of the chemical additive on specific ore types and crushing systems before implementation.
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