高压辊磨机HPGR及其应用

高压辊磨机及其应用

High Pressure Grinding Roll and Its Application

赵 德 君Dejun Zhao

摘要：

高压辊磨机在世界工业先进国家的冶金矿山工业中，己经得到了广泛的推广应用，而在我国的应用才刚刚起步。本文简要介绍了高压辊磨机结构、工作机理和高效、节能、环保等先进性能以及磨碎铁矿石的试验研究。

Abstract:

High pressure grinding roll has been widely popularized and applied in metallurgical industry and mining industry in the industry-advanced countries around the world. However, its application in our country is still in infancy. This paper is going to briefly introduce the structure and working principle of high pressure grinding roll, its advantages such as high efficiency, energy conservation and environmental protection, and the reach study of grinding iron ore.

关键词：

粒群、层压破碎、压力峰值、微裂纹、抗磨料垫。

Key words:

Particle flow, inter-particle breakage, pressure peak, micro-cracking, anti-wear layer

高压辊磨机简介

高压辊磨机（也称辊压机）是十九世纪八十年代，由德国科学家研制开发的一种先进磨碎设备。由于该产品的结构简单、生产效率高、环保节能和工作机理先进等优点，很快被推广应用到美国、德国、俄罗斯、巴西、智利、澳大利亚等工业先进国家。我们国家于1988年，由德国洪堡公司引进高压辊磨机的许可证制造生产技术，首先应用在水泥熟料的磨碎生产中，收到了显著的效果，并得到了广泛的推广应用。图1即是国内生产的高压辊磨机主机。

Introduction of high pressure grinding roll (HPGR)

High pressure grinding roll is a kind of advanced grinding equipment developed by Germany scientists in the 1980s. It was popularized soon in USA, German, Russian, Brazil, Chile, Australia and other advanced industrial counties because of simple structure, high production efficiency, environmental protection and energy-saving and advanced working principle. Our

country introduced the manufacturing technology of HPGR from KHD, a Germany Company. It was firstly applied in the grinding of cement clinker which achieved obvious effects. So, the machine was widely promoted and applied. Figure 1 is the main frame of HPGR produced in

domestic.

图1 高压辊磨机 Figure 1 High Pressure Grinding Roll (HPGR)

经过二十几年的生产实践，在吸收消化引进技术的基础上，先后开发设计了多种规格的高压辊磨机，装备于国内各大中型水泥企业，用于磨碎水泥熟料的生产中，并已形成了产品系列。经过长期的生产实践证明，我国自己生产制造的高压辊磨机完全能够替代进口的设备。在冶金工业中，近几年来在烧结厂的磨细铁精粉制备球团给料生产中，也已经成功的应用国产的高压辊磨机，并取得了很好的效果。但在矿山选矿工业领域内，利用国产的高压辊磨机细碎金属矿石，目前还没有成功的先例。

After more than twenty years of production practice and learning from introduced technology, high pressure grinding roll has formed product seriation and been applied in national large-medium size cement enterprises for grinding cement clinker. It has been proved that HPGR manufactured in domestic can replace imported ones completely after years of production practice. In metallurgical industry, high pressure grinding roll has been successfully used in the pelletizing feed production of grinding fine iron in sintering plant for recent years which also achieves very good results. However, it is still no successful examples to use domestic high pressure grinding roll for comminuting metallic ore in the area of mineral separation.

1. 高压辊磨机机理及结构 Mechanism and structure of HPGR

1.1. 高压辊磨机机理：Mechanism

高压辊磨机是利用高挤压力作用使粒群层压破碎原理而设计的。挤压力是通过两个直径相等、转速相同且相向旋转的辊子压力而产生的。其中一个辊子为定辊，另一个为可以前后水平小幅度移动的动辊，压力通过高压油缸加在动辊两端的轴承座上。高压辊磨机工作时，物料由料柱仓靠自重力压入料腔，同时被两个相向旋转的辊子咬入并在辊面作用下受到加速进入压实腔，由于两辊间距的逐渐减小挤压力由小增大，此时物料颗粒除了受到辊面的直接压力外，物料颗粒之间也产生相互挤压作用（见图2），

图2 颗粒间的受力 Figure 2 Forces from other particles

导致物料粒群被压实和预粉碎，当辊子旋转至水平中心线时压力达到峰值，各颗粒之间遭到不同程度的粉碎，并随着辊子的转动以压片形式排出机外。图3即是辊间物料粉碎过程的示意图。

High pressure grinding roll is designed according to the principle of inter-particle breakage by huge pressures. The pressure is from a pair of counter-rotating rolls with the same diameter and rotary speed. One is fixed while the other is allowed to shift front and back slightly. Pressures are worked on the bearing supports at the both ends of floating roll through high pressure cylinder. While HPGR is operating, materials are entering into the crushing cavity by its gravity from stock column bin, and then are bitten by the two counter-rotating rolls, forced into compacting cavity. Duo to the gap reduction between two rolls, compression force increases. Material particles are compressed by roll surfaces directly but also other particles, leading to material particles compacted and pre-crushed. When rolls are rotated to the horizontal center line, pressures reach to peak. Particles are crushed in different degrees. With the rotation of rolls, materials are discharged in the form of tablets. Figure 3 displays the grinding process of material between rolls.

物料压力 material pressure

辊面 roll surface 加速区 accelerating zone 压实区 compacting zone 膨胀区expansion zone

图3 辊间粉碎过程 Figure 3 grinding process between rolls

1.2 高压辊磨机结构Structure of HPGR

高压辊磨机的组成如下：给料装置安装在主机机架上部，挤压辊装置安装在机架的机座上，由轴承装置支撑，每个辊子都有单独的传动系统，并通过万向联轴节、安全离合器及行星齿轮减速器，将能量传递给挤压辊；中央润滑系统向各轴承装置提供润滑油和润滑脂。高压辊磨采用PLC 智能控制，设置有现场控制、中控室控制、手动控制和自动控制，并通过中央自控室进行自动监控所有的工作程序和机器的运转数据（见图4）。

The following is the composition of HPGR. Feed device is mounted on the rack of frame. Compression rolls are mounted on the rack bed supported by bearings. Each roll has independent drive system. Energy is delivered to compressing rolls through universal coupling, safety clutch and planetary gear reducer. Centro-lubricating system supplies lubricating oil and grease to all bearings. HPGR adopts PLC smart control designed with field control, central control chamber control, hand control and automatic control, watching all work procedures and machine operating dates automatically through the central control chamber. (See figure 4).

图4 （换结杨构图）figure 4 structure

高压辊磨机的主要易损件为挤压辊的带柱钉辊套。辊套采用耐磨合金钢制造，柱钉为碳化钨硬质合金材料（见图5）

Wear parts of HPGR is mainly tyre with stud around the compressing rolls. Tyres are

manufactured by wear-resistant alloy steel. Studs adopt tungsten carbide material. (See figure 5)

图5 带柱钉辊面 Figure 5 studded roll surface

当高压辊磨机工作时，辊子的抗磨性能主要靠柱钉间嵌满物料时形成的自生式抗磨料垫与矿石接触磨损，而辊面不直接接触矿石并受到保护（见图6）。

While HPGR is working, wear-resistant performances of rolls depend on the formation of auto-genous wear protection layer when materials are fulfilling the zones among studs. Roll surfaces are protected without contact with ores directly (see figure 6).

图6自生式料垫 Picture 6 auto-genous wear protection layer

因此，可有效的延长了辊套的使用寿命。硬质合金碳化钨柱钉的硬度和耐磨性能很高，但韧性较差，因此，在工作时难免有折断损坏现象。进口设备的柱钉与辊面的装配形式采用过盈配合，因此，柱钉折断后没办法修补，只能等大面积折断后更换新辊皮。我们经过研究开发了新的配合方式，当柱钉折断后可以随意更换新的柱钉，极大的延长辊套服役寿命。

Therefore, tyres’ service life can be extended effectively. Tungsten carbide studs have high hardness and great abrasion-resistant performance but are brittle and easily chipped or broken. Hence, it is inevitable to be broken or damaged during operation. The assembly of studs and roll surfaces of imported machines adopts interference fit so that studs can be repaired if broken.

2、 高压辊磨机的优点 The benefits of HPRG

2.1 高压辊磨机工作时与一般同类设备相比单位粉碎能耗低。从该机的工作机理可知，由于是粒群间的层压破碎，使充满粉料腔的物料颗粒接触点多，作用力大，能量利用率髙。因此，使粉碎能耗比其它常规单颗粒粉碎或磨碎设备显著降低。据国内外的生产实践，多数矿石的单位粉碎能耗为0.8-3kwh/t，如果同后续设备共同装机时，其总磨碎能耗可节约40%以上。

2.1 compared to the same kind of equipments, high pressure grinding roll is lower energy-consumption because of its working principle that inter-particle breakage makes particles contact more and interact much to utilize energy in high ratio. Therefore, its breaking energy-consumption is apparently lower than common single particle breaking equipments ’ or milling equipments’. According to the production practice at home and broad, for most of ores, their breaking energy consumption is 0.8-3kwh/t. if the machine are mounted with the following-up equipments, the total grinding energy consumption can reduce by more than 40%.

2.2 能处理水分含量较高的物料。髙压辊磨机工作时给料中希望含有一定的水分，这

样有利于形成较坚固的自生式料垫，改善辊磨机的工况和辊面使用寿命。如磨碎铁矿石制备球团给料时，其水分可高达10%；磨碎铁矿石或贵金属矿石时，国外推荐水分不高于8%。

2.2 It can process materials with relatively high moisture. HPGR expects the feed can contain some moisture during operation so that would be better to form the sturdy auto-genous wear layer to improve its working condition and roll surfaces ’ service life. For instance, feed moisture content can be up to 10% when grinding iron ore for briquetting. When grinding iron ore or precious metal ore, the foreigner recommended moisture content should be no more than 8%.

2.3 提高后续作业产品的回收率、可磨性和产量。从照片6可看出，经高压辊磨机加工的物料，其颗粒内部或矿物与周围废岩的界面之间，存在许多微观或宏观裂纹，而沒有产生裂纹的颗粒内部，也由于承受压力而产生较大的内应力。因此，当这些颗粒进入后续作业如磨机等设备进行再加工时，可磨度大幅度提高，很容易被磨碎磨细，提高后续作业的生产效率；

2.3 It can improve the recovery rate, grindability and capacity of products in the following-up process. Based on the picture 6, particles processed by HPGR, have a lot of micro-cracking. Particles without micro-cracking are having internal stress due to undertaking pressure. Therefore, these particles re-processed in next step such as entering into ball mill can be grinded and levigated easily, improving grindability greatly and productivity of following-up process.

2.4 机器占地面积小，土建投资少。高压辊磨机结构紧凑、重量轻，外形尺寸小；由于该机的破碎粉磨作用，主要发生在两个辊子之间的相互静压力，而产生的静压力全部由机架承载吸收，对基础的作用力很小甚至没有，因此同磨机等设备装机相比，不需要打很坚固的地基，可节省大量的土建投资。

2.4 The machine has less occupation and less civil engineering investment. HPGR has compact structure, less weight, small outline size; its grinding and crushing are occurred between two rolls. Produced static pressure are absorbed totally by the rack with less force on the foundation even none. So, compared to the same kinds of grinding equipments, HPGR does not need very sturdy foundation which can save a lot of civil engineering investment.

2.5 机器振动小、噪音低、粉尘小。高压辊磨机工作时物料主要靠静压力粉碎，粉碎时物料被封闭在辊子和给料装置之间的密闭料腔内。因此，不会产生冲击和物料飞溅现象，故振动和噪音较低，粉尘很少。

2.5 The machine has less vibration, lower noises and less dust. During its working, grinding relies on the static pressure. When grinding, materials are in a closed cavity between rolls and

feed device. Therefore, there is no any impacting phenomenon and material splashing phenomenon. That is why vibration, noises and dust are less.

2.6 机器的作业率高，可在95％以上。高压辊磨机釆用先进的自动控制和自动检测系统，对设备的主要部分如温度、辊缝、压力、给料量、功率等进行监测和控制。保证主机能正常可靠的工作；同时由于辊面结构先进，耐磨材料的抗磨损性能优良，故能极大的延长设备的有效工作时间。

2.6 Its operating rate is high, up to over 95%. HPGR adopts the advanced auto-control and auto-inspection system to monitor and control the main indexes such as temperature, roll gap, pressure, feed volume, and power which could guarantee the normal working of main frame. Meanwhile, good anti-abrasiveness of roll material and advanced roll surface can prolong the effective working time greatly.

2.7 机器易损件工作寿命长。该机主要易损件是挤压辊辊套，由于工作时辊子表面能生成自生式料垫，它能保护辊面不直接与矿石磨损和冲击，使磨损主要发生在抗磨性很强的硬质合金柱釘上，因而使辊面工作寿命大幅度提高；而碳化钨柱钉局部折断后可更换修补，故可使辊面寿命长达10000－20000小时；料柱下端挡料侧板经采用新的复合材料后，寿命可以保证使用一年以上，该侧板体积较小，只有几公斤重，更换起来也很容易。

2.7 Wearing parts can work longer. The wearing parts of machine are tyres over rolls. The auto-genous wear layer can protect roll surface to not contact or impact with ores. Abrasion is mainly occurred on the tungsten carbide studs so that service life of roll surface can be prolonged greatly. Moreover, if tungsten carbide studs are broken partly, broken parts can be repaired and replaced. In that case, service life of roll surface can be up to 10000-20000 hours. The lateral plate at the bottom of stock column adopts new composite material, and its service life can be ensured to use more than one year. The plate has small volume, only a few kilograms, which is also easy to replace.

3 高压辊磨机的应用 The Application of HPGR

自从由德国引进生产制造技术以来，高压辊磨机在我国应用已有二十几年的历史。其中在建材工业中应用的最成功最普遍，设备的国产化率也最高。可以说目前国内的各大中型水泥企业，基本都装备使用国产的高压辊磨机设备，并取得了很好的经济效益和社会效益。进入二十世纪初，高压辊磨机开始用于冶金工业。首先由武钢公司程潮球团厂引进德KHD 洪堡威达克公司一台高压辊磨机，用于磨碎铁矿石球团给料生产中，取得了非常好的效果。紧接着柳钢公司球团厂、昆钢公司球团厂、邯郸钢铁公司烧结厂、沙钢烧结厂等，也都先后从德国引进不同型号的价格昂贵的高压辊磨机，用于磨碎铁矿石球团给料。2003

年杭州钢铁公司铁前部要求与中信重机公司合作，共同研制开发磨碎铁矿石球给料用的高压辊磨机设备，为国家节省外汇。经过一年多的试验研究和调研，终于在2005年生产出国内第一台冶金工业用的高压辊磨机，经过几年的生产实践证明，其技术性能等各项指标基本达到了国外引进产品水平。目前国产的高压辊磨机产品正陆续装备于国内各个球团厂，如冷水江烧结厂、天津荣程钢铁厂球团厂、长钢烧结厂等。在矿山选矿工业生产中，高压辊磨机的使用始于2004年，在这个领域中，第一个吃螃蟹的是马鞍山南山矿业公司凹山选矿厂，首先由德国魁珀恩公司引进一台高压辊磨机用於细碎铁矿石，自从2006年投产以来，由于设备的各项性能优越，产品质量、产量及成本等均取得了很好的效果。紧接着陕西金堆城钼业公司百花岭选矿厂、司家营矿业公司铁矿选矿厂、山东黄金集团三山岛金矿选矿厂、以及马钢和尚桥铁矿选矿厂和霍邱张庄铁矿选矿厂等，也都先后由德国引进不同型号的高压辊磨机，致使国家的大量外汇流入到外国人的腰包，同时也更加促动了国内有关设备生产制造企业的极亟性，在吸收消化国外先进技术的基础上，研制开发国产的矿山选矿生产用的高压辊磨机，相信在不久的将来，国产的高压辊磨机即会源源不断的装备于我国的矿山选矿事业。

High pressure grinding roll has been widely used in our country for more than twenty years since its manufacturing technology was introduced from Germany. Its application in building material industry is the most successful and common, and also localization rate is the most higher. So to speak, domestic large-medium cement companies are all equipped with homemade high pressure grinding roll machines and achieved very well economic benefits and social benefits. At the beginning of 20 century, HPGR has been used in metallurgical industry. Wuhan Iron and Steel Corp. Chengchao pellet plant introduced a unit of high pressure grinding roll from KHD Humboldt Wedag International AG to use in the feed of grinding iron ore pellets which also achieved very well results. Liuzhou Iron and Steel Company pellet plant, Kunming Iron and Steel Holding Corporation pellet plant, Handan Iron and Steel group Corporation sintering plant and Shagang Group Corporation sintering plant were introduced HPGR successively with different models and expensive price to use in grinding iron ore feed. In 2003, Hangzhou Iron and Steel Group Company asked to cooperate with Citic Heavy Industries Corporation to research and develop high pressure grinding roll machines used in grinding iron ore feed to save foreign exchange for the country. After more than one year of tests and studies, the first domestic HPGR used in metallurgical industry were finally produced successfully in 2005. After many years of production practice, its technical properties had reached the level of imported equipments. Now, homemade HPGR is successively used in domestic sintering plants such as Lengshuijiang Sintering Plant, Tianjin Rongcheng Iron and Steel pellet plant, and Shougang Changzhi Iron and

Steel Corporation Sintering Plant. HPGR ’s application in mineral processing industry was beginning at 2004. In this field, the first mover was Magang Group Nanshan Mine Company Aoshan Mineral processing plant introduced the first HPGR to use in find grinding iron ore from Germany Köppern Company. Since it was put into production in 2006, product quality, capacity and cost were all achieved well results due to its good functions and properties. Then, Many mineral processing plants such as Shanxi Jinduicheng Molybdenum Group Baihualing Mineral Processing Plant, Sijiaying Mine Company Iron Processing Plant, Shandong Gold Group Sanshan Island Gold Ore Processing Plant, Magang Heshangqiao Iron Processing Plant and Huoqiu Zhangzhuang Ore Processing Plant and so on, were introduced different models of high pressure grinding roll one after another from Germany which also caused national much foreign exchange to flow into foreigners. Meanwhile, it also aroused the enthusiasm of national manufacturers to research and exploit domestic HPGR used in mineral processing. We believe that domestic high pressure grinding roll would be applied in mineral processing industry more and more in the near future.

4、铁矿石的辊磨试验 Grinding Test of Iron Ore

我公司于2008年开始对高压辊磨机用于破碎矿石的试验研究，并设计制造了一台GM52－14型试验用的高压辊磨机。先后为通钢选矿厂、印度尼西亚某选矿厂、河南东大矿业公司选矿厂等进行了多次试验，为设备选型、生产工艺流程编制和产品设计提供了可靠的技术术据。

Our company begun to research and develop HPGR applied in breaking ore in 2008 and produced a unit of GM52-14 HPGR for tests. We had done many tests for mineral processing plants such as Shougang Tonggang Group Concentrator, an Indonesia Concentrator and Henan Dongda Concentrator, providing reliable technical base for model selection, drawing up production technological process and design products.

下面谨以印度尼西亚铁矿石破碎试验为例，介绍辊磨试验情况：

In the following, we just take Indonesia Iron ore breaking as an example to introduce the test of grinding test:

4.1 任务来源Task ：

受印度尼西亚某矿山公司委托，要求对来自该矿山的铁矿石进行高压辊磨机辊磨处理试验。

Authorized by a Indonesia mine company, we did test to process iron ore from their mine by high pressure grinding roll.

4.2

铁矿石原始状况：Original condition of iron ore:

（1） 矿石粒度 ：

印尼某矿山邮来的铁矿石粒度从20mm-150mm 大小不等，矿石含铁品位及成分组成不详，航空快运至我公司（见照片一）。

(1) Ore size

Iron ore provided by the Indonesia mine was different from 20mm to 150mm. Iron grade and composition inside of ore were not clear. Ores were expressed to our company by air (see

picture 1).

照一 印尼铁矿石 Picture 1 Indonesia Iron ore

（2） 铁矿石含水率：

矿石由印尼发运时的含水率约为11％。由于国际邮件、报关、检验等繁琐手续，耗时月余；加之我国的大陆性气候，天气比较炎热，致使矿石运抵我公司后的含水率经测试降低至3.8％。

(2) Moisture content of iron ore:

Before delivery, moisture content was about 11%. Due to international express, customs clearance and inspection and other tedious procedures, it took about one month to send ores from Indonesia to us. Besides, due to the continental climate, moisture content of ores was only 3.8% by test after arriving at our company.

（3） 铁矿石硬度：

此次发来的铁矿石硬度软硬不均，软的普氏硬度4－6度，用手锤很容易击碎，硬的普氏13－17度，破碎比较困难。

(3) Hardness of iron ore:

The delivered Ore hardness was different. For these soft ones, protodyakonov coefficient of rock strength was only 4 to 6, which was easily crushed by hand hammer. For hard ones, it was

13 to 17 grades which were different to be crushed.

4.3试验要求 ：Test requirements:

（1） 矿石含水率：

(1) Moisture content of ore

为了恢复印尼原矿石的含水率，我们将用于试验的含水3.8％的矿石浸在水中10整天（见照片二），然后取出测试其含水率为11％，基本与印尼发运时原矿石含水量相吻合，以确保在试验时不会失真；

To recovery the moisture content of Indonesia ore, we put ores with moisture content 3.8% into water for ten days (see picture 2). Then its moisture content was 11% by test which was

almost the same with original ores before delivery. That would ensure test was reliable.

照二 浸水矿石 Picture 2 ores in water

（2） 矿石粒度 ：

拫据印尼矿山工艺流程的编制，要求高压辊磨机的入料粒度为30-40mm ，故将邮来的矿石均破碎至上述要求，其中参杂有少量的碎料（见照片三）；

(2) Ore sizes:

According to the technological process of Indonesia, feeding size should be 30-40mm for HPGR. So, ores were crushed based on the above requirements with little crushed aggregates.(see

picture 3)

照三 试验用矿石 picture 3 ores for test

（3） 本次试验的矿石含水率有两种，即低限3.8％和高限11％。本次试验共用矿石60公斤，其中含水率3.8％的矿石20公斤，其余40公斤为含水率11％的矿石；

(3) in the test, moisture content of ores had two kinds, the lowest 3.8% and highest 11%. It took 60kg ores for this test. And 20kg was ores with 3.8% moisture content and 40kg was with moisture content 11%.

（4） 经高压辊磨机辊磨处理后的产品，要求对其进行粒度分级，以了解辊磨后的粉碎效果。

（4）particles processed by HPGR are classified according to their size to see the result of grinding.

4.4 试验目的：Test purpose

（1） 了解印尼铁矿石采用辊磨机一次性加工处理后的破碎效果和设备的适用情况；

(1) Research the breaking results of Indonesia iron ore processed by HPGR one time and the application of equipment;

（2） 用辊磨机处理物料的最高含水率国内外均限制在10％以下，对于印尼高于10％含水率的矿石能否采用辊磨机进行加工处理？欲通过此次试验进行探讨；

( 2 ) the max. moisture content of materials processed by HPGR should be lower than 10% at home and abroad. Regarding to the Indonesia iron ore, its moisture content was higher than 10%. Whether was it suitable to be processed by HPGR? That was also the discussing topic in the test;

（3） 试验加工处理印尼铁矿石的辊磨机工艺参数及设备的各项技术指标

(3) All processing parameters and technical indexes of HPGR used to process Indonesia iron ore.

（4） 检验辊磨机处理后的矿石产品粒度的显微状态

(4) Check the microscopic state of final products from HPGR.

4.5试验设备：Test equipment

（1） GM52-14高压辊磨机试验机；

(1) GM52-14 High pressure grinding roll trail machine;

（2） φ200mm 系列标准筛；

(2) φ200mm series of standard screen;

（3） JA5102电子天秤

(3) JA5102 electron balance;

（4） 101－1型烘干箱；

(4) 101－1Ttype dryer;

（5） 500公斤地中衡；

(5) 500kg platform scale;

（6） 试验用小型锤式破碎机；

(6) Small-scale hammer crusher for trail;

（7） 电子显微镜。

(7) Electron microscope.

4.6 试验参数 ：test parameter:

（1） 压辊直径 roll diameter ： φ520mm

（2） 压辊宽度 roll width ： 140mm

（3） 压辊转速 roll rotary speed ： 9－15rpm

（4） 试验压力 test pressure ： 10Mpa

（5） 原始辊缝宽度original gap between rolls ： 3mm

4.7 辊磨试验结果 ：Test result:

（1） 含水率3.8％和11％两种矿石，经分别进行辊磨处理后，其产品均呈大小不等的物料破碎压实后的片状料饼（见照片四），基本没有粉状物料出现；

(1) Two kinds of ores: moisture content 3.8% and 11%. Two kinds of ores were processed separately by HPGR. The final products were flake material cake from the both kinds of material with different size.(see picture 4). There was no power material;

（2） 料饼产品的大小和形状无论是含水率低的和高的物料均相差不大，料饼宽度约小于50mm ，厚度小于12mm 小；但在密实度及硬度上稍有区别，含水率低的料饼要比含水高的料饼密实度和坚硬度大些，但两种料饼都很硬，用手很难揑碎；

(2) Regarding to these flake final products, there were no big differences between high moisture ore and less moisture ore, no matter size or shape. Flake width was about 50mm, and thickness was less than 12mm. while there were differences between compactness and hardness. Flake with lower moisture was harder and more compact, compared with the high moisture material. Both flakes were hard and difficult to be crushed by finger.

（3） 将料饼用小型锤式试验机打散后，其组成料饼的矿石料度很细（见照片五）；用系列筛分級后，其粒度组成为；

☆ 颗粒≤1mm 的矿石占 84％

☆ 颗粒≤2mm 的矿石占 7％

☆ 其余9％的颗粒为＞3mm ＜５mm 的矿石产品。

(3) Ore size was very fine after flake particles were crushed by small-scale trail hammer crusher (see picture 5). Its size was as following after screening:

☆particle size ≤1mm about 84%

☆particle size ≤2mm about 7%

☆particle size ＞3mm ＜5mm about 9%

（4） 经辊压机处理后的矿石产品，除了粒度的宏观明显变化外，在高倍显微镜下检验，颗粒内部存在尚未延伸的微裂纹（见照片六）。

(4) micro-cracking was found inside of ore products processed by high pressure grinding roll

under the high-power microscope except the obvious macroscopic changes. (See picture 6)

照四 料饼 picture 4 flake product 照五打散后细粒矿石

picture 5 fine ore after crushing

照六 颗粒内微裂纹 picture 6 interior micro-cracking

4.8试验结果分析 ：Test result analysis

（1） 颗粒大小不等的矿石经辊磨处理后通常呈压实物料的片状料饼排出, 一般情况下料饼极易散开。但此次印尼的矿石料饼却非常坚硬，对于出现这种情况，由于没有对矿石成

分进行化验，我们初步分析可能是由于矿石内嵌布有粘性物料所致。

(1) Ores with different size were discharged in the form of flake after processed by HPGR. Usually flake cakes were easily broken up. However, this Indonesia iron ore was very harder. We preliminarily analyzed there was viscous objects inside of ores since we did not test the composition of ores.

（2） 此次通过对印尼含水率高于10％以上的矿石采用辊磨机试验，其结果无论从辊磨粒度、辊磨产量以及辊磨机设备的适应能力上都非常理想。因此，对于辊磨机给料的含水率问题，我们认为不应一概而论，应拫据不同的物料有所区别，最好通过试验后确定。因为对于含水率高又不需进行昂贵的干燥工艺就进入下道工序的流程，可以成倍的提高产量和节省大量的生产资金。

(2) The test that Indonesia ores with over 10% moisture were processed by high pressure grinding roll machine was satisfied no matter size, capacity or the adaptability of HPRG equipment. Therefore, regarding to the problem of moisture content of HPGR feed, we could not lump under one head. We’d be better make conclusion after test based on the different materials. So, materials with the high moisture content could be processed without expensive dry process which could improve capacity greatly and save huge production capital.

（3） 铁矿石经辊磨细碎后脉石被解离并大部成粉状存在，而含铁品位较高的则呈微细颗粒，并且颗粒内部经检验证实存在有许多尚未造成颗粒破碎的微裂纹。

(3) Matrix of iron ore was dissociated even powder after processed by high pressure grinding roll. Ores with high grade of iron became fine particles. Some particles were proofed with a lot of interior micro-cracking after test.

4.9 试验结论 ；Test Conclusion;

（a ） 试验证明对印度尼西亚这种具有特殊性能的铁矿石，选用高压辊磨机作为二级碎矿设备，是正确合理的，其结果必将使企业获得巨大的经济效益和社会效益；

(a) The test proved that was right to select HPRG as the secondary crushing equipment for the special Indonesia iron ore. The user must gain huge economic and social benefits;

（b ） 高压辊磨机可以处理含水率高于10％以上的物料，但最好通过对具体物料进行试验后确定。

(b) High pressure grinding roll can process materials with moisture content over 10%. But it would be better to make decision after test for different materials.

（c ） 本次试验由于使用物料较少，因此对于辊磨机加工处理铁矿石的最佳工艺参数无法通过多次试验进行优选；但通过试验证实，高压辊磨机的各项技术性能完全适用于破碎铁矿石的要求。

(c) The best processing date of iron ore can’t be confirmed due to less material in the test. However, it was proved that high pressure grinding roll was completely suitable to process iron ore.

（d ） 辊磨机处理后的铁矿石，由于颗粒内部存在微裂纹，故可极大的提高后续作业的生产率和降低能耗。

(d) Iron ore processed by HPGR had micro-cracking inside which could improve productivity of the following work and cut down energy-consumption effectively.