来自内蒙古一家大型矿业集团，该集团在包头、巴彦淖尔市分别新建了400t/h、500t/h、1000t/h磁铁矿破碎选矿生产线，基于对世邦品牌的认同，该集团三条生产线设备全部选择了世邦集团。

400t/h磁铁矿破碎选矿项目升级改造

该客户基于历史原因，在包头的400t/h生产线建设之时曾尝试过各种厂家的各种破碎设备，哪怕是国际知名品牌，但效果却远远达不到预期，这让客户既疑惑又苦恼。

2020年8月，客户既有生产线因工艺设计问题，出现三段破碎作业不甚匹配，颚破、圆锥破单机更是时而出现机械故障，加之厂家售后服务不到位，严重影响生产线的稳定运行，后该公司致电世邦，希望能对其400t/h磁铁矿生产线进行技术诊断、升级改造。

世邦经实地勘察，详细了解生产线设备的运行情况，技术工程师为客户制定了全方位系统升级改造方案。

改造后，粗碎阶段使用PEW860欧版颚破替代了原有颚破，解决了粗碎原有的卡料问题，后又增加了HST250圆锥破替代原有单缸液压圆锥破，从而提高了中碎的破碎比，进而减轻了细碎压力和筛分作业压力，优化了生产线的破碎比分配。

改造后的生产线运行稳定，降低了成品粒度，减轻了筛分压力，持续好的产出。

 

 

一、原料特性与加工难点分析

    原料特征：
   主要类型：磁铁矿（Fe3O4）、赤铁矿（Fe2O3）、褐铁矿（2Fe2O3·3H2O）
    典型成分：TFe 30-65%，SiO2 5-35%，Al2O3 1-8%
    物理特性：普氏硬度f=12-16，堆积密度2.5 3.5t/m³

    核心加工难题：

    嵌布粒度不均：0.02-5mm不等
    矿物解离困难：与石英等脉石紧密共生
    设备磨损严重：衬板寿命仅300-800小时
    能耗瓶颈：破碎能耗占全流程35-50%

二、现代化加工工艺流程

    破碎筛分系统
    （1）三段一闭路流程：

    粗碎：颚式破碎机（入料≤1000mm，出料≤250mm）
    中碎：单缸液压圆锥破（出料≤60mm）
    细碎：多缸液压圆锥破（出料≤12mm）
    筛分：多层重型振动筛（筛分效率≥90%）

（2）关键技术参数：

    总破碎比控制在30-50:1
    循环负荷率35-45%
    设备作业率≥92%

    磨矿分级系统

    一段磨矿：溢流型球磨机+螺旋分级机
    二段磨矿：格子型球磨机+水力旋流器
    技术指标：
        磨矿细度-200目≥85%
        分级效率η≥65%
        吨矿电耗18-22kWh

    选矿系统优化
    （1）磁铁矿选别：

    弱磁选：磁选机场强1200-1500Gs
    精选：高频振动细筛（筛孔0.1mm）
    扫选：梯度磁场磁选机

（2）赤铁矿选别：

    强磁选：1.0-1.2T高梯度磁选
    浮选：阴离子反浮选（pH=11-12）
    重选：螺旋溜槽+摇床组合

三、技术创新方向

    好的破碎装备

    超重型颚破（900×1200mm以上）
    智能圆锥破（液压+电控双调节）

    预选抛废技术
    干式磁滑轮预选（抛废率15-25%）

    智能化控制系统

    在线粒度分析仪（测量误差≤3%）
    专家优化控制系统（产能提升8-12%）
    数字孪生平台（故障预警准确率85%）

四、经济效益分析

    典型选矿厂指标：

    处理规模：200万吨/年
    精矿品位：65±1%TFe
    金属回收率：磁铁矿82-88%，赤铁矿75-80%
    加工成本：120-180元/吨原矿

    成本构成：

    破碎筛分：18-25%
    磨矿分级：35-45%
    选别作业：15-20%
    尾矿处理：10-15%

    节能降耗措施：

    多碎少磨工艺（节电15-20%）
    高频筛取代螺旋分级机（效率提升30%）
    尾矿干排技术（回水率≥90%）

五、发展趋势展望

    短流程工艺：
    超细碎+粗粒抛尾

    绿色矿山建设：

    粉尘浓度≤10mg/m³
    噪声控制≤80dB(A)
    废水零排放系统

 

本报告基于国内30个典型铁矿石选矿厂运行数据，各项技术指标均经过工业验证。最新实践表明，采用现代加工技术可使铁精矿综合成本降低15-25%，资源利用率提高8-12个百分点。建议新建项目优先考虑短流程方案，改造项目重点优化破碎筛分和预选抛废环节。

Henan LIMING Heavy Industry Science and Technology Co. LTD which mainly manufacture large and medium-sized crushing and grinding equipments was founded in 1987. It is a modern joint-stock corporation with research, manufacturing and sales together. The Headquarter is located in HI-TECH Industry Development Zone of Zhengzhou and covers 80000 m ². Another workshop in Shangjie Industry Park covers 67000 m ². Over the more than 30 years, our company adheres to modern scientific management system, precision manufacturing, pioneering and innovation. Now LIMING has become the leader in domestic and oversea machinery manufacturing industry.

LIMING brings a large number of high-qualification talents together. Bai Yinghui, general research and development engineer, is a well-known expert in crushing and grinding area who won the youth medal of technology of the state council and receives special government allowance. LIMING owns an experienced service team, offering the customer free design and professional skill training and live guide for installation and debugging. The company's service networks have spread all over the country. Established client files, and mix the traditional door-to-door service with online service together, complementary the advantages. LIMING has won high recognition from clients.

The company mainly manufactures mobile crushers, stationary crushers, sand-making machines, grinding mills and complete plants that are widely used in mining, construction, highway, bridge, coal, chemical, metallurgy, refractory matter, etc. Product quality is life, and scientific innovation is motive power. LIMING got ISO international quality system certification, European Union CE certification and Russian GOST certification. The company has strong research and development strength and innovation.

LIMING machinery research institute was founded in 2005 which is the most powerful comprehensive technological research institute in the domestic mining machinery industry and provides top scientific research platform for professional personnel. Up to now, LIMING has won 10 national patents, 24 national utility model patents and 3 provincial science and technology achievement awards. The company products remain the international leading level by strengthening international exchanges and cooperation all the time, and has won a wide range of international market, such as Russian, Azerbaijan, Kazakhstan, Turkey, Kuwait, South Africa, Egypt, Vietnam, Malaysia, India, Australia, Korea, Canada and European Union,etc. Through more than 30 years' hard work, LIMING's staff built supremacy of credibility, excellent quality, service "LIMING" brand, and has made outstanding contributions to the development of mechanical manufacturing industry for China and the whole world.

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