重介旋流器運(yùn)行手冊(cè)

1、重介旋流器操作手冊(cè)客戶訂單號(hào):IMA09250036旋流器型號(hào):MAX800-20-1/AB宏測(cè)項(xiàng)目 北京華德創(chuàng)業(yè)環(huán)保設(shè)備有限公司MULTOTEC 過程設(shè)備公司FP/ALL/-DENSEINDEX目 錄 1.0 Introduction簡(jiǎn)介 2.0 General Description綜述 3.0 Installation安裝 4.0 Operation操作 5.0 Predicted Performance性能預(yù)測(cè) 6.0 Inspection and Maintenance檢測(cè)維修 7.0 Recommended Operating Spares運(yùn)行備件推薦 8.0 GA Drawing

2、 and Brochure總圖和手冊(cè) 9.0 Handling and Storage運(yùn)輸與存儲(chǔ)IDX/ALL/-ALL1.0 INTRODUCTION簡(jiǎn)介Thank you for purchasing a Multotec cyclone, which was wholly designed and manufactured by Multotec Process Equipment. Our cyclone designs are constantly under review and new process ideas are continually investigated to e

3、nsure that we offer our customers: i) State of the art technology and performanceii) A quality product iii) A cost effective productiv) A product which is robust in operationThis manual provides a brief description of the cyclone that you have purchased and offers other information in the following

4、areas:感謝您購買MULTOTEC生產(chǎn)的旋流器，該旋流器的生產(chǎn)及設(shè)計(jì)均在南非由MULTOTEC過程設(shè)備公司進(jìn)行。我們?cè)趯?shí)踐中不斷的摸索改善旋流器來滿足我們的客戶：）技術(shù)和性能的概述）高質(zhì)量iii）成本效率高iv) 產(chǎn)品結(jié)實(shí)耐用該手冊(cè)對(duì)您所購買的旋流器提供簡(jiǎn)介及以下信息：InstallationOperationPerformanceMaintenanceSpares安裝操作性能維護(hù)備件DrawingsAncillary Products圖紙附屬產(chǎn)品Whilst this manual can only provide limited information, further assista

5、nce in any area can be obtained by contacting Multotec directly and speaking to one of their cyclone engineers.該手冊(cè)提供的信息有限，進(jìn)一步的咨詢請(qǐng)與MULTOTEC工廠的旋流器工程師聯(lián)系，或者與北京華德創(chuàng)業(yè)環(huán)保設(shè)備有限公司聯(lián)系。1/ALL/-ALL 2.0 DESCRIPTION 綜述Our dense medium cyclones are available in the following wear materials:(i) High Chrome Cast Iron(ii)

6、 Mild Steel with Alumina Tiles(iii) Mild Steel with Silicon Carbide Liners(iv) Polyurethane我們的重介旋流器有以下材質(zhì)可選(v) 高鉻鑄鐵(vi) 低碳鋼，內(nèi)襯高鋁陶瓷(vii) 低碳鋼，內(nèi)襯碳化硅(viii) 聚氨酯Your cyclone material has been chosen to most cost effectively match your particular wear characteristics.The modular design of the cyclone is sho

7、wn in the figure over page, and you should have received a detailed drawing with a spares list with your purchase. If you did not or would like an update, please contact us. When re-ordering please pay particular attention to the part numbers given and quote in as much detail as possible to avoid de

8、lays and misunderstanding.根據(jù)您自己的磨損特性，我們將為您選擇最合適的材質(zhì)。下頁中，可以看到旋流器的模塊式設(shè)計(jì)。您將看到為您采購的產(chǎn)品提供的詳細(xì)備件清單。當(dāng)續(xù)訂這些備件時(shí)，請(qǐng)您特別注意備件型號(hào)等詳細(xì)信息，以避免延誤或者誤解。2/MAX/-DENSE (1) 2/MAX/-DENSE (1)THE MAX RANGE OF MILD STEEL ALUMINA TILED CYCLONESMAX系列高鋁陶瓷內(nèi)襯旋流器The MAX range of alumina cyclones comprises the following models:510mm, 610mm,

9、 660mm, 710mm, 800mm, 900mm, 1000mm, 1150mm, 1300mm and 1450mm.They incorporate the following design features: MAX 系列高鋁陶瓷內(nèi)襯旋流器具有下述直徑可選：510mm, 610mm, 660mm, 710mm, 800mm, 900mm, 1000mm, 1150mm, 1300mm and 1450mm.主要設(shè)計(jì)特點(diǎn)有：1.SCROLLED EVOLUTE ENTRYThe inlet head does not have a tangential inlet as does t

10、he standard D.S.M. cyclone, but a scrolled evolute inlet. The advantage of the scrolled evolute inlet is fourfold:a)By allowing the particles to follow their natural downward spiral as a result of the scroll on the inlet, both wear and turbulence are reduced thereby increasing the wear life of the i

11、nlet.b)Due to the lower turbulence in and lower pressure drop across the inlet head, the cyclone has a higher capacity than a tangential inlet.c)The smooth evolute entry into the inlet allows the particles to align themselves as they move into the cyclone before being subjected to the centrifugal ac

12、tion of the cyclone. This alignment results in a more efficient separation process within the cyclone. d)With the scrolled evolute inlet, the feed entering the cyclone does not impact directly on the vortex finder, as is the case for the tangential design. Wear on the vortex finder is considerably r

13、educed thereby extending the efficiency over the life of the cyclone. The vortex finder normally has the same life as the inlet head.Please note that the combination of the above features results in our cyclones having a higher differential and thus a higher relative cutpoint. Therefore, the circula

14、ting medium density must be lower to maintain the same cutpoint. 1、渦形漸開線入料設(shè)計(jì)一般的旋流器都采用切線入口設(shè)計(jì)，MULTOTEC 公司采用了專利技術(shù)渦形漸開線設(shè)計(jì)，主要有以下優(yōu)點(diǎn)：a) 作為入口處渦形的結(jié)果，顆粒自然螺旋狀下落，減少了湍流和磨損，從而提高了入口的使用壽命b) 在入口處，由于較低的紊流和較小的壓降，渦形漸開線入口旋流器比切線型入口型旋流器具有更大的處理量c) 渦形漸開線入口平滑，顆粒在受到離心力之前即開始集結(jié)，從而使得旋流器具有更好的分離效率。d) 由于渦形漸開線入料設(shè)計(jì)，入料并不像切線入口那樣直接沖擊溢流口

15、，大大減少了溢流口的磨損，提高了旋流器的分選效率。一般來講，溢流口的使用壽命與入料口相同由于渦形漸開線入料設(shè)計(jì)，入料并不像切線入口那樣直接沖擊溢流口，大大減少了溢流口的磨損，提高了旋流器的分選效率。一般來講，溢流口的使用壽命與入料口相同2/MAX/-DENSE (2) 2.INLET HEAD CAPACITYThe inlet head can be custom designed to meet the capacity requirements of customers. The standard design (B Inlet) provides a capacity of about

16、 15% higher than an equivalent “DSM cyclone”. The high capacity design (A Inlet) provides a capacity of approximately 50% greater than the standard design (B Inlet).A square inlet nozzle is used in these inlet heads to cater for a larger top size.2、入料頭部 入料頭部可以客戶的要求定制，滿足客戶的處理量等要求。標(biāo)準(zhǔn)入料頭部設(shè)計(jì)為B型，與同等DSM旋流

17、器相比，處理量大約提高15%，A型入口設(shè)計(jì)為高處理量型，處理量比B型大約提高50 使用A型入口，主要是為了獲得更大的處理粒度。3.BARREL SECTIONBarrel sections are generally recommended to increase the residence time within the cyclone and therefore improve the overall efficiency of separation and in particular, improve the recovery of fines. 3、桶體部分一般推薦使用桶體部分，以增大

18、漿液在旋流器中的逗留時(shí)間，提高整體分離效率，尤其可以提高精煤的回收。4.VORTEX FINDERThe MAX cyclones are available either with a standard ( 0.43 x Diameter ) or High Capacity ( 0.5 x Diameter ) vortex finder.4、溢流口MAX系列旋流器有兩種溢流口可選：標(biāo)準(zhǔn)型( 0.43 x D )和高處理量( 0.5 x D)型5.PARALLEL THROAT SPIGOTSThe parallel throat design eliminates the initial

19、 high wear rate and maintains the spigot size for a longer period despite the “flowering” wear at the discharge. This is of special importance if cyclones are operated in parallel, as the cut density is dependant on the spigot size. Three different sizes of spigot, namely Standard, High Capacity and

20、 Extra High Capacity.5、平行喉底流口平行喉設(shè)計(jì)減少了高磨損，即使在卸料口開花磨損的情況下，仍然能夠長(zhǎng)時(shí)間保持底流口尺寸。因?yàn)榍蟹置芏仁桥c底流口尺寸密切相關(guān)的，所以保持底流口尺寸是非常重要的。6.OVERSIZE SPIGOTSOversize spigots are available. These spigots, which have a larger than normal diameter at the top to cater for the increase in diameter of a worn cone, can extend cyclone life

21、 by up to 50%, if installed timeously.6、大尺寸底流口MULTOTEC公司提供大尺寸底流口。這些底流口直徑大與普通底流口直徑，以配合錐體磨損后直徑的增大，如果更換及時(shí)，可以延長(zhǎng)旋流器的壽命達(dá)50。7. INTERCHANGEABLE CONESThe MAX cyclones have been designed to allow for replacement of the Alumina tiled cone sections with 27 % High Chrome cast iron cones, for operations where tra

22、mp iron becomes a problem.7、錐體互換當(dāng)出現(xiàn)含鐵廢料問題的時(shí)候，MAX系列旋流器可以更換27 %的高鉻鑄鐵。2/MAX/-DENSE (2)8.OVERFLOW DESIGNIn a conventional overflow hood design, any hole in the inlet head roof cannot be detected immediately, which causes a loss of the cyclone feed to the overflow. With the Multotec overflow elbow any le

23、ak can be noticed immediately, as the pulp will discharge to atmosphere. The potential for loss of for example diamonds to the overflow, is therefore eliminated.In addition to the overflow elbow, a cyclone can also be equipped with a vortex extension. The material of construction consists of a mild

24、steel shell, which is ceramic lined with 25mm thick alumina tiles. The major advantages of this design include: light weight, ease of removal of the vortex finder and ease of inspection to determine internal wear within the cyclone.8、溢流設(shè)計(jì)在傳統(tǒng)的溢流設(shè)計(jì)中，無法檢測(cè)到入料頭部的任何孔洞，引起旋流器入料對(duì)溢流的損失。使用MULTOTEC的溢流彎管時(shí)，由于漿液是排

25、放到周圍環(huán)境中，所以立即能檢測(cè)到泄漏，減少了溢流產(chǎn)品的潛在損失。除了溢流彎管，旋流器還可以配備溢流延長(zhǎng)管，采用低碳鋼本體，內(nèi)襯25mm厚的高鋁陶瓷。溢流設(shè)計(jì)的只要優(yōu)點(diǎn)有：質(zhì)量輕，便于溢流口的拆卸，并且便于檢測(cè)旋流器內(nèi)部的的磨損情況9.FLANGED JOINTSA deliberate outward step is built into the design at the housing joints. This ensures that no inward steps, with attendant efficiency losses, are possible.All wetted jo

26、ints are sealed with epoxy. The problem of gaskets protruding into the cyclone body is thus avoided. Any possible areas of turbulence are minimized and a more efficient separation with less misplaced material is achieved.9法蘭連接在流動(dòng)方向的接口處刻意做成向外的臺(tái)階，確保不會(huì)因?yàn)橄騼?nèi)臺(tái)階發(fā)生效率損失。所有的潤(rùn)濕部分采用環(huán)氧樹脂密封，避免了橡膠墊圈的向內(nèi)彎曲。最大限度的降低蝸流

27、的發(fā)生，減少錯(cuò)配物的可能，獲得更高的分選效率。2/MAX/-DENSE (2)10.PRE-ENGINEERED TILESTile design is of critical importance in terms of preventing lining failure and maximising the wear life of the cyclone. Narrow chamfered tiles, with staggered joints across flow, provide the smoothest internal surface and maximum wear li

28、fe. However, for a scrolled evolute inlet head, tiling design considerations become complicated. Fortunately, as a result of the diverse business activities of the Multotec Group of Companies, the MAX range of cyclones reflect the expertise of a company that specialises in both cyclone design and ce

29、ramic wear lining design. After years of experience and development, the MAX range of cyclones is lined throughout with pre-engineered alumina tiles. Each tile is specifically designed for and allocated a place in the cyclone. Such careful design, coupled with years of operating experience results i

30、n a lining with maximum strength and abrasion resistance.Tile thickness is predominantly 25 mm.10、工程陶瓷對(duì)于防止內(nèi)襯失敗和最大化旋流器的耐磨壽命，內(nèi)襯的設(shè)計(jì)是一個(gè)非常關(guān)鍵的因素。窄斜切面陶瓷，交錯(cuò)排列的連接，確保旋流器內(nèi)部最光滑的內(nèi)表面，使用壽命最大化。然而，對(duì)于渦形漸開線設(shè)計(jì)的入料頭部，陶瓷內(nèi)襯設(shè)計(jì)變得非常復(fù)雜，幸運(yùn)的是，MULTOTEC集團(tuán)公司具有經(jīng)營(yíng)的多樣性，MAX系列的旋流器設(shè)計(jì)和高鋁陶瓷內(nèi)襯的設(shè)計(jì)，都反應(yīng)了公司的專業(yè)性。隨著多年的經(jīng)驗(yàn)和發(fā)展，MAX系列旋流器全部采用工程陶瓷內(nèi)襯，每塊內(nèi)

31、襯都是專門設(shè)計(jì)并安放在指定的位置。精心的設(shè)計(jì)和多年的操作經(jīng)驗(yàn)，使MULTOTEC內(nèi)襯具有最大的強(qiáng)度和防磨損性。高鋁陶瓷內(nèi)襯的厚度主要是25mm。11.EXTENSIVE EXPERIENCEIn addition to the design features incorporated into the cyclone, Multotec also provides technical backup. The knowledge that is available has resulted from years of experience with both low (1.3) an high

32、(4.0) gravity separations and from supplying cyclones to treat ore with up to 70% (± 0.1) near density material. 11、廣泛的經(jīng)驗(yàn)多年的技術(shù)實(shí)踐使重介旋流器的分選密度在1.3與4.0之間，并且能夠處理接近密度達(dá)到70% (± 0.1)的礦石。2/MA/-DENSE (2)3.0 INSTALLATION安裝3.1Inspection after Delivery交貨后檢驗(yàn)We would recommend an inspection upon receiving

33、 the cyclone. Aspects to note are:(i) Check the exterior for any serious defects that may have resulted through transit and inform us as soon as possible, should these exist. (ii) If possible, check the inside of the cyclone to ensure that no interior damage has occurred and that no foreign objects

34、have entered the cyclone during transit. On large diameter cyclones, these checks may be carried out by looking up through the spigot.旋流器到達(dá)現(xiàn)場(chǎng)后我們推薦您參考下面的描述對(duì)旋流器進(jìn)行檢驗(yàn)：（i） 檢查旋流器的外觀在運(yùn)輸途中是否產(chǎn)品嚴(yán)重的損壞，如果發(fā)現(xiàn)有問題，盡快和我們聯(lián)系。（ii） 如果可能，檢查旋流器內(nèi)部，以確保沒有發(fā)生損壞，并且在運(yùn)輸過程中沒有其他雜物進(jìn)入旋流器，對(duì)于大直徑旋流器，可以通過底流口向內(nèi)觀察。 Caution:Under no circums

35、tances should the cyclone be dissembled for inspection. These cyclones are carefully assembled by Multotec personnel to ensure correct housing alignment and housing joints are then sealed with an epoxy compound.注意：在任何情況下都不要拆卸旋流器進(jìn)行檢測(cè)！MULTOTEC公司的專業(yè)人員小心認(rèn)真地進(jìn)行組裝以保證合適的殼體以及連接，然后用環(huán)氧化合物膠密封。3.2Installation安裝S

36、ome aspects to consider with plant installation are:(i) Cyclones installed on dense medium circuits are normally installed at 15 20 degrees to the horizontal in order to minimise any short-circuiting that may occur due to the hydrostatic head of a vertical cyclone and the high slurry density. (ii) F

37、or best results a straight feed pipe of at least nine pipe diameters is recommended to ensure no unnecessary turbulence. Diagrams showing correct feed pipe design are appended to this section.(iii) The overflow elbow must be fitted with a breather pipe if the overflow discharge is below the feed pip

38、e entry to the cyclone.(iv) Strong attention must be given to feeding the cyclone at a constant volumetric flowrate.(v) We recommend the installation of a pressure gauge to measure steady performance.現(xiàn)場(chǎng)安裝需要考慮的因素有：（i） 由于豎直旋流器和入料漿液密度產(chǎn)生的流體動(dòng)力學(xué)壓力可能引起短路，為了將這種影響降低到最小，用于重介分選的旋流器一般都安裝在與水平成15-20度角的位置。（ii） 為了獲

39、得良好的分選效果，推薦入料管到至少要有9倍旋流器直徑長(zhǎng)的豎直距離，以保證沒有不必要的渦流，請(qǐng)參考所附的入料管到的正確設(shè)計(jì)圖。（iii） 如果溢流卸料端在入料管道進(jìn)入旋流器點(diǎn)的下方，溢流彎管則必須安裝有透氣管。（iv） 強(qiáng)烈提醒您注意保持旋流器恒定的體積入料量（v） 為了檢測(cè)穩(wěn)定的性能，我們推薦您安裝壓力表。3/C/CE/HY/MA/MAXA/SD/-DENSE3.0 INSTALLATION安裝Note:New cyclones may leak slightly upon water-testing the circuit. Providing that the leakage is onl

40、y minor, there is no need for corrective action, as the cyclone will seal itself once fed with slurry.提示：在用清水測(cè)試的時(shí)候，新的旋流器可能會(huì)有輕微的泄漏現(xiàn)象，如果泄漏比較小，則不需要糾正，因?yàn)闈{液入料的時(shí)候旋流器會(huì)自行封閉泄漏情況。Caution:Under no circumstances should the cyclone bolts be tightened. These cyclones are rigid assemblies, sealed with an epoxy com

41、pound. Tightening of any of the cyclone bolts is likely to result in the irreparable cracking of the cyclone components.注意： 在任何情況下都不要試圖擰緊旋流器螺栓。旋流器是非常堅(jiān)固的，使用了環(huán)氧膠，試圖擰緊旋流器螺栓的任何部分，都可能引起旋流器部件的開裂，而且無法維修。3/C/CE/HY/MA/MAXA/SD/-DENSEFeed Pipe Designs for Horizontal Cyclone水平旋流器的入料管線設(shè)計(jì)þ The feed-pipe must

42、 come from vertically above or below the cyclone.入料管必須是垂直于旋流器的上部或者下部。þ The internal diameter of the feed-pipe may not be greater than that of the cyclone inlet as this will cause turbulence and excessive wear on equipment.入料管的內(nèi)徑不能大于旋流器入料口直徑，否則會(huì)引起紊流，并容易對(duì)設(shè)備產(chǎn)生額外磨損。þ The feed-pipe must be self

43、-supporting. This prevents excessive loading on the cyclone.入料管要自帶支撐，避免對(duì)旋流器產(chǎn)生額外負(fù)荷。þ The feed-pipe must be straight for at least 9 feed-pipe diameters before reaching the cyclone inlet.入料管在到達(dá)旋流器之前必須有不小于9倍旋流器直徑的直立部分。If a bend is necessary, use these diagrams as a guide:如果需要有彎曲部分，請(qǐng)參考下面的指導(dǎo)。3/C/CE/H

44、Y/MA/MAXA/SD/-DENSE4.0 DENSE MEDIUM CIRCUIT OPERATION重介流程運(yùn)行The most important factor in obtaining a consistently high yield at a good separation efficiency is the operation of the dense medium circuit.Listed below is a recommended list of critical operating parameters and the frequency with which th

45、ey should be monitored.在某一分選效率條件下，獲得連續(xù)高產(chǎn)的一個(gè)最重要因素就是重介流程的運(yùn)行。下面列出了關(guān)鍵的運(yùn)行參數(shù)，以及我們應(yīng)該以多大的頻率進(jìn)行檢測(cè)。§ Accurate feed density control and calibration (± 0.005)準(zhǔn)確的入料密度控制和校準(zhǔn)(± 0.005)。§ Daily sample of media:介質(zhì)的每日取樣a) % - 45 microns （45um的百分含量）b) Non magnetics %（非磁性物百分含量）c) Non magnetics size dis

46、tribution（非磁性物粒度分布）§ Two hourly samples of：每?jī)蓚€(gè)小時(shí)一次的采樣a) Overflow density （溢流密度）b) Underflow density（底流密度）§ Accurate feed rate control準(zhǔn)確的入料控制§ Accurate spigot rate control準(zhǔn)確的底流量控制§ Weekly inspection of cyclones旋流器的周檢測(cè)§ Accurate steady head control 準(zhǔn)確的穩(wěn)定壓頭控制§ Weekly effic

47、iency determinations (instantaneous)分選效率周檢查（即時(shí)的）§ Single density misplaced material determination on shift cumulative sample§ Demagnetising spools should be used at lower density separations§ Clean media continuously連續(xù)的干凈介質(zhì)4/SD/C/CE/HY/MA/VV/-DENSEPage 1 of 104.1 CYCLONE PERFORMANCE旋流

48、器性能The most effective way to determine cyclone efficiency is by setting up a partition curve.Not only does the partition curve give the cut density, Ep 75/25 and Ep 90/10, but it is also an invaluable aid in troubleshooting a cyclone, which will be covered in more detail in the following section.檢測(cè)旋

49、流器分選效率的最有效辦法是繪制分配曲線：分配曲線不僅僅可以顯示分配密度、Ep 75/25 和 Ep 90/10，對(duì)于解決旋流器可能出現(xiàn)的問題，還具有無法估測(cè)的幫助，這些在下面的部分將會(huì)詳細(xì)描述：影響旋流器性能的因素如下：A list of factors, which can affect cyclone performance, follows:§ Size of cyclone旋流器尺寸§ Size of spigot底流口尺寸§ Design of cyclone旋流器設(shè)計(jì)§ Steps or grooves inside cyclone旋流器內(nèi)部

50、§ Feedrate入料量§ Yield產(chǎn)率§ Media stability and viscosity介質(zhì)穩(wěn)定性和粘度§ % non magnetics非磁性物含量§ Slime in media介質(zhì)中的粘土量§ Particle size distribution of ore煤的粒徑分布§ Particle size distribution of medium solids介質(zhì)固體的粒度分布§ Operating head操作壓力§ Density control密度控制§ Sampl

51、ing and analyses errors采樣和分析誤差4/SD/C/CE/HY/MA/VV/-DENSEPage 2 of 104.2 TROUBLE SHOOTING問題解決Although most problems resulting from a dense medium circuit operation are assigned to the cyclone, 99% of the problems are normally found to be extraneous to the cyclone.A correctly designed and properly main

52、tained cyclone will at all times provide the potential for obtaining a consistent, high efficiency separation.Some of the extraneous factors that can result in problems are the following:重介流程中很多問題看起來都和旋流器的操作有關(guān)，但是往往99% 的問題都和旋流器本身沒有關(guān)系。旋流器設(shè)計(jì)出色，維護(hù)良好，則意味著獲得穩(wěn)定高效的分選效果。§ Feed Design (Pump Feed and Grav

53、ity Operation)入料設(shè)計(jì)（泵入料和重力操作）A cyclone is a constant volume device and it is critical that the cyclone receives a constant medium feed and a constant feed of ore, i.e. no surges.Furthermore, the level within either the feed sump or steady head arrangement must remain constant.Any surges in feed to th

54、e cyclone or changes in operating levels will result in reduced efficiencies and in extreme cases overloaded spigots. (Coal operations).旋流器的體積是固定的，因此維持旋流器入料的穩(wěn)定是非常關(guān)鍵的， 包括介質(zhì)入料和煤入料，不要有涌動(dòng)現(xiàn)象。此外，必須保證穩(wěn)定的入料池液位和恒定的壓力安排任何旋流器入料的涌動(dòng)或者是操作液位的變化都會(huì)引起分選效率的下降，在極端的情況下，可能引起底流口超負(fù)荷。§ Medium Properties介質(zhì)性能Medium selec

55、tion is critical to the successful operation of a dense medium cyclone.There are two basic problems that can arise from incorrect media, i.e. stability and viscosity.成功的運(yùn)行重介旋流器，介質(zhì)的選擇是非常關(guān)鍵的。介質(zhì)不合格可能引起兩個(gè)基本的問題：穩(wěn)定性和粘度。a) Stability穩(wěn)定性Stability problems arise when the medium solids are too coarse and the cyclone classifies the medium to a large degree resulting in an unstable cyclone