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Article(id=1236276110565101730, tenantId=1146029695717560320, journalId=1235980550691926019, issueId=1236276104999268557, articleNumber=null, orderNo=null, doi=10.3969/j.issn.0253-6099.2025.04.019, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1739894400000, receivedDateStr=2025-02-19, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1772680793657, onlineDateStr=2026-03-05, pubDate=1753977600000, pubDateStr=2025-08-01, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1772680793657, onlineIssueDateStr=2026-03-05, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1772680793657, creator=13701087609, updateTime=1772680793657, updator=13701087609, issue=Issue{id=1236276104999268557, tenantId=1146029695717560320, journalId=1235980550691926019, year='2025', volume='45', issue='4', pageStart='1', pageEnd='200', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=1, specialIssue=null, createTime=1772680792331, creator=13701087609, updateTime=1772681498687, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1236279067746562719, tenantId=1146029695717560320, journalId=1235980550691926019, issueId=1236276104999268557, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1236279067746562720, tenantId=1146029695717560320, journalId=1235980550691926019, issueId=1236276104999268557, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=105, endPage=108, ext={EN=ArticleExt(id=1236276110930006191, articleId=1236276110565101730, tenantId=1146029695717560320, journalId=1235980550691926019, language=EN, title=Application of Heavy-Duty and Efficient Thickener with Large Processing Capacity, columnId=1236276106932842717, journalTitle=Mining and Metallurgical Engineering, columnName=MINERAL PROCESSING, runingTitle=null, highlight=null, articleAbstract=

An intermittent sedimentation test was performed for vanadium-titanium magnetite tailings to obtain settling curves of flocculated tailings, and then the solid flux in sedimentation by flocculation was calculated by Coe-Clevenger equation and material balance calculation. An innovative Φ38 m heavy-duty and efficient thickener is designed to have a unit area processing capacity of 1 000 kg/(m2·h). The industrial application of this thickener in dewatering of vanadium-titanium magnetic tailings show that with dry ore processing capacity of 1 100 t/h and the feed concentration of 20%－25%, its underflow has concentration of 45% and the overflow has solid content less than 200 mg/L. It is concluded that such thickener can solve the technical problems in the production faced by enterprises, and also bring enterprises enhanced economic and environmental benefits.

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以钒钛磁铁尾矿为研究对象，采用间歇沉降试验法获得尾矿絮凝沉降曲线；采用Coe-Clevenger方程和物料衡算法计算絮凝沉降固体通量，创新设计的Φ38 m重载高效浓密机单位面积处理量达到1 000 kg/（m2·h）。该重载高效浓密机在钒钛磁铁尾矿脱水的工业应用结果表明，给矿干量1 100 t/h、给矿浓度20%～25%时，获得了底流浓度45%、溢流固含量小于200 mg/L的技术指标，解决了企业发展所面临的生产技术难题，提高了企业的经济效益和生态效益。

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曾建红（1983—），男，湖南邵阳人，高级工程师，主要从事浓缩输送与充填技术及装备研究工作。E-mail：

, authorsList=曾建红)}, authors=[Author(id=1236348220234855102, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, orderNo=0, firstName=null, middleName=null, lastName=null, nameCn=null, orcid=null, stid=null, country=null, authorPic=null, dead=0, email=jary0123@163.com, emailSecond=null, emailThird=null, correspondingAuthor=0, authorType=1, ext={EN=AuthorExt(id=1236348220335518409, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, authorId=1236348220234855102, language=EN, stringName=Jianhong ZENG, firstName=Jianhong, middleName=null, lastName=ZENG, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=null, address=Changsha Research Institute of Mining and Metallurgy Co, Ltd, Changsha 410012, Hunan, Hunan, bio=null, bioImg=null, bioContent=null, aboutCorrespAuthor=null), CN=AuthorExt(id=1236348220415210192, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, authorId=1236348220234855102, language=CN, stringName=曾建红, firstName=null, middleName=null, lastName=null, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=null, address=长沙矿冶研究院有限责任公司，湖南　长沙　410012, bio={"content":"

曾建红（1983—），男，湖南邵阳人，高级工程师，主要从事浓缩输送与充填技术及装备研究工作。E-mail：

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曾建红（1983—），男，湖南邵阳人，高级工程师，主要从事浓缩输送与充填技术及装备研究工作。E-mail：

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Technical theory of thickener and development of the equipment[J]. Coal Preparation Technology, 2006(5): 62-66., articleTitle=Technical theory of thickener and development of the equipment, refAbstract=null), Reference(id=1236348223774848000, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, doi=null, pmid=null, pmcid=null, year=2015, volume=35, issue=2, pageStart=73, pageEnd=78, url=null, language=null, rfNumber=[2], rfOrder=2, authorNames=谢丹丹, 童雄, 谢贤, journalName=矿产保护与利用, refType=null, unstructuredReference=谢丹丹, 童雄, 谢贤, 等. 浓密机在选矿中的应用现状及研究进展[J]. 矿产保护与利用, 2015, 35(2): 73-78., articleTitle=浓密机在选矿中的应用现状及研究进展, refAbstract=null), Reference(id=1236348223883898886, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, doi=null, pmid=null, pmcid=null, year=2015, volume=35, issue=2, pageStart=73, pageEnd=78, url=null, language=null, rfNumber=[2], rfOrder=3, authorNames=XIE Dandan, TONG Xiong, XIE Xian, journalName=Conservation and Utilization of Mineral Resources, refType=null, unstructuredReference=XIE Dandan, TONG Xiong, XIE Xian, et al. The application and development of thickener in mineral processing technology[J]. Conservation and Utilization of Mineral Resources, 2015, 35(2): 73-78., articleTitle=The application and development of thickener in mineral processing technology, refAbstract=null), Reference(id=1236348223976173585, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, doi=null, pmid=null, pmcid=null, year=2024, volume=44, issue=12, pageStart=46, pageEnd=52, url=null, language=null, rfNumber=[3], rfOrder=4, authorNames=吴凡, 张凌云, 潘瑞凯, journalName=矿业研究与开发, refType=null, unstructuredReference=吴凡, 张凌云, 潘瑞凯, 等. 全尾砂浆絮凝沉降试验及深锥浓密机选型研究[J]. 矿业研究与开发, 2024, 44(12): 46-52., articleTitle=全尾砂浆絮凝沉降试验及深锥浓密机选型研究, refAbstract=null), Reference(id=1236348224072642589, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, doi=null, pmid=null, pmcid=null, year=2024, volume=44, issue=12, pageStart=46, pageEnd=52, url=null, language=null, rfNumber=[3], rfOrder=5, authorNames=WU Fan, ZHANG Lingyun, PAN Ruikai, journalName=Mining Research and Development, refType=null, unstructuredReference=WU Fan, ZHANG Lingyun, PAN Ruikai, et al. Test of flocculation settlement of whole-tailing slurry and selection of deep cone thickener[J]. Mining Research and Development, 2024, 44(12): 46-52., articleTitle=Test of flocculation settlement of whole-tailing slurry and selection of deep cone thickener, refAbstract=null), Reference(id=1236348224177500198, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, doi=null, pmid=null, pmcid=null, year=2024, volume=null, issue=10, pageStart=22, pageEnd=27, url=null, language=null, rfNumber=[4], rfOrder=6, authorNames=崔宝玉, 林志昊, 张艺邺, journalName=有色金属(选矿部分), refType=null, unstructuredReference=崔宝玉, 林志昊, 张艺邺, 等. 给料浓度对浓密机内颗粒絮凝及沉降影响研究[J]. 有色金属(选矿部分), 2024(10): 22-27., articleTitle=给料浓度对浓密机内颗粒絮凝及沉降影响研究, refAbstract=null), Reference(id=1236348224290746414, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, doi=null, pmid=null, pmcid=null, year=2024, volume=null, issue=10, pageStart=22, pageEnd=27, url=null, language=null, rfNumber=[4], rfOrder=7, authorNames=CUI Baoyu, LIN Zhihao, ZHANG Yiye, journalName=Nonferrous Metals (Mineral Processing Section), refType=null, unstructuredReference=CUI Baoyu, LIN Zhihao, ZHANG Yiye, et al. 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（a）浓度20%；（b）浓度15%；（c）浓度10%

, figureFileSmall=JkxrmczWAvIxhw39rY8vEA==, figureFileBig=kOiO+LDckLjkpgB5sL+I5w==, tableContent=null), ArticleFig(id=1236348222512362375, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=EN, label=Fig.2, caption=Settling curves of overflow, figureFileSmall=mRsLV5+923+Qgejui5p31A==, figureFileBig=4WMD4Jyc8FovZ2zeY9dOYg==, tableContent=null), ArticleFig(id=1236348222625608594, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=CN, label=图2, caption=溢流矿浆沉降曲线

（a）浓度11%；（b）浓度8%；（c）浓度5%

, figureFileSmall=mRsLV5+923+Qgejui5p31A==, figureFileBig=4WMD4Jyc8FovZ2zeY9dOYg==, tableContent=null), ArticleFig(id=1236348222738854815, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=EN, label=Table 1, caption=

Particle size of raw material

, figureFileSmall=null, figureFileBig=null, tableContent=
粒级/μm产率/%
全尾矿矿浆溢流矿浆
+850——
－850+5000.25—
－500+2502.90—
－250+1506.63—
－150+7418.08—
－74+3813.432.20
－38+2011.617.71
－2047.1090.09
合计100.00100.00
), ArticleFig(id=1236348222843712426, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=CN, label=表1, caption=

原料粒度分析结果

, figureFileSmall=null, figureFileBig=null, tableContent=
粒级/μm产率/%
全尾矿矿浆溢流矿浆
+850——
－850+5000.25—
－500+2502.90—
－250+1506.63—
－150+7418.08—
－74+3813.432.20
－38+2011.617.71
－2047.1090.09
合计100.00100.00
), ArticleFig(id=1236348222956958652, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=EN, label=Table 2, caption=

Comparison of transformation plans

, figureFileSmall=null, figureFileBig=null, tableContent=
方案优点
方案11）彻底解决斜板浓密箱处理粗粒级尾矿浆出现的堵塞、压板、跑浑等问题，提高生产作业率
2）溢流水固含量可降至300 mg/L以下
3）能保证总尾矿排放浓度稳定在45%
4）大大降低系统微细粒对选别作业的影响
5）循环水水质提升，可改善选别指标
方案21）直接投资成本比方案1低
2）絮凝剂用量较方案1略少
3）溢流水固含量可降至300 mg/L以下，能保证选矿厂的正常生产
), ArticleFig(id=1236348223066010568, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=CN, label=表2, caption=

改造方案对比

, figureFileSmall=null, figureFileBig=null, tableContent=
方案优点
方案11）彻底解决斜板浓密箱处理粗粒级尾矿浆出现的堵塞、压板、跑浑等问题，提高生产作业率
2）溢流水固含量可降至300 mg/L以下
3）能保证总尾矿排放浓度稳定在45%
4）大大降低系统微细粒对选别作业的影响
5）循环水水质提升，可改善选别指标
方案21）直接投资成本比方案1低
2）絮凝剂用量较方案1略少
3）溢流水固含量可降至300 mg/L以下，能保证选矿厂的正常生产
), ArticleFig(id=1236348223191839695, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=EN, label=Table 3, caption=

Testing of structure stability of agglomeration in tailings slurry

, figureFileSmall=null, figureFileBig=null, tableContent=
矿浆浓度/%药剂用量/（g·t－1）沉降次数1 min沉降高度/mm
1020第1次233
第2次145
第3次80
40第1次242
第2次230
第3次187
60第1次241
第2次231
第3次201
80第1次236
第2次224
第3次205
第4次135
1540第1次188
第2次78
第3次45
60第1次205
第2次165
第3次75
第4次50
), ArticleFig(id=1236348223309280219, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1236276110565101730, language=CN, label=表3, caption=

全尾矿矿浆絮团结构稳定性试验结果

, figureFileSmall=null, figureFileBig=null, tableContent=
矿浆浓度/%药剂用量/（g·t－1）沉降次数1 min沉降高度/mm
1020第1次233
第2次145
第3次80
40第1次242
第2次230
第3次187
60第1次241
第2次231
第3次201
80第1次236
第2次224
第3次205
第4次135
1540第1次188
第2次78
第3次45
60第1次205
第2次165
第3次75
第4次50
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大处理量重载高效浓密机在尾矿浓缩中的应用
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矿冶工程杂志 | 选矿 2025,45(4): 105-108
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矿冶工程杂志 | 选矿 2025, 45(4): 105-108
大处理量重载高效浓密机在尾矿浓缩中的应用
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曾建红
作者信息
  • 长沙矿冶研究院有限责任公司，湖南　长沙　410012

    • 曾建红（1983—），男，湖南邵阳人，高级工程师，主要从事浓缩输送与充填技术及装备研究工作。E-mail：

Application of Heavy-Duty and Efficient Thickener with Large Processing Capacity
Jianhong ZENG
Affiliations
  • Changsha Research Institute of Mining and Metallurgy Co, Ltd, Changsha 410012, Hunan, Hunan
出版时间: 2025-08-01 doi: 10.3969/j.issn.0253-6099.2025.04.019
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摘要
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以钒钛磁铁尾矿为研究对象，采用间歇沉降试验法获得尾矿絮凝沉降曲线；采用Coe-Clevenger方程和物料衡算法计算絮凝沉降固体通量，创新设计的Φ38 m重载高效浓密机单位面积处理量达到1 000 kg/（m2·h）。该重载高效浓密机在钒钛磁铁尾矿脱水的工业应用结果表明，给矿干量1 100 t/h、给矿浓度20%～25%时，获得了底流浓度45%、溢流固含量小于200 mg/L的技术指标，解决了企业发展所面临的生产技术难题，提高了企业的经济效益和生态效益。

浓缩  /  沉降  /  浓密机  /  尾矿  /  钒钛磁铁尾矿  /  絮凝沉降曲线

An intermittent sedimentation test was performed for vanadium-titanium magnetite tailings to obtain settling curves of flocculated tailings, and then the solid flux in sedimentation by flocculation was calculated by Coe-Clevenger equation and material balance calculation. An innovative Φ38 m heavy-duty and efficient thickener is designed to have a unit area processing capacity of 1 000 kg/(m2·h). The industrial application of this thickener in dewatering of vanadium-titanium magnetic tailings show that with dry ore processing capacity of 1 100 t/h and the feed concentration of 20%－25%, its underflow has concentration of 45% and the overflow has solid content less than 200 mg/L. It is concluded that such thickener can solve the technical problems in the production faced by enterprises, and also bring enterprises enhanced economic and environmental benefits.

thickening  /  sedimentation  /  thickener  /  tailings  /  vanadium-titanium magnetite tailings  /  flocculation sedimentation curve
曾建红. 大处理量重载高效浓密机在尾矿浓缩中的应用. 矿冶工程杂志, 2025 , 45 (4) : 105 -108 . DOI: 10.3969/j.issn.0253-6099.2025.04.019
Jianhong ZENG. Application of Heavy-Duty and Efficient Thickener with Large Processing Capacity[J]. Mining and Metallurgical Engineering, 2025 , 45 (4) : 105 -108 . DOI: 10.3969/j.issn.0253-6099.2025.04.019
正文
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浓密机的出现可以追溯到1905年Dorr浓密机的发明。普通浓密机是重力沉降浓缩设备的典型代表，它的理论基础是颗粒自由沉降，可实现颗粒的沉降分层并在池底进一步压实。随着矿石回收率提高，磨矿细度更细，尾砂颗粒的重力作用变弱，单纯依靠尾砂颗粒的重力难以自由沉降。20世纪60年代絮凝技术大力发展，絮凝剂被广泛应用到浓缩设备中。絮凝剂可以加快尾砂颗粒沉降速度、提高设备处理能力，故而适用于絮凝沉降的高效浓密机应运而生，并逐步取代了依靠重力自然沉降的普通浓密机[1-2]。
近年来，液压驱动技术及配套设备日趋成熟，液压驱动具有动力输出值高、运行稳定可靠、能耗低等显著特点。传统的大型重载浓密机均采用周边传动的结构形式，液压驱动技术在浓密机上的应用使中心传动式重载浓密机成为可能，此外液压驱动还能提供更高的驱动扭矩。另一方面，国内机械设计和制造水平大幅提升，系统有限元分析和基于计算流体力学（CFD）技术的数值模拟方法等先进手段被应用到大直径浓密机钢结构池体设计中，中心传动式重载浓密机已可灵活选择配套混凝土或钢结构池体。
长沙矿冶研究院有限责任公司在尾矿絮凝沉降试验基础上，对攀钢某选矿厂的钒钛磁铁尾矿浓缩系统进行改造，创新设计了一台Φ38 m重载高效浓密机处理该选矿厂的全尾矿。浓密机已稳定运行近6年，单位面积处理量1 000 kg/（m2·h），给矿浓度20%～25%，获得了底流浓度45%、溢流水固含量小于200 mg/L的良好技术指标，解决了原先采用大面积斜板浓密箱浓缩尾矿溢流水严重跑浑的问题，新建浓密机的溢流水进入循环水系统，提高了生产作业率，降低了成本，取得了显著的经济和生态效益。
1　原料性质
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试验原料为攀钢某选矿厂现场取样的全尾矿矿浆和斜板浓密箱的溢流矿浆，矿浆浓度（质量分数，下同）分别为24.5%和11.5%。2种矿浆原料的粒度分析结果见表1。结果表明：全尾矿矿浆中－74 μm粒级颗粒物占比72.14%、－20 μm粒级颗粒物占比47.10%；溢流矿浆中颗粒物粒径小于74 μm，－20 μm粒级颗粒物占比90.09%。
2　浓缩实验
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尾矿浓密效果受多因素影响，通常采用静态沉降法研究絮凝剂单耗和给料浓度对沉降速度和矿浆可达到的浓密浓度的变化规律，绘制尾矿沉降曲线并计算浓密机表面负荷理论值，可对设备选型提供指导[3-5]。
采用静态沉降法，以阴离子型聚丙烯酰胺（APAM）为絮凝剂，对2种矿浆进行了絮凝沉降试验，结果如图1和图2所示。结果表明：不添加絮凝剂，2种矿浆的自由沉降速度均很慢，APAM对2种矿浆的适用性较好；在矿浆原始浓度条件下直接应用絮凝剂时，絮凝沉降效果较差，随着矿浆浓度降低，饱和絮凝剂用量降低，沉降速度显著提高；全尾矿矿浆稀释浓度10%时，絮凝剂饱和用量为30 g/t；溢流矿浆粒度更细，微细颗粒易悬浮于矿浆中，难以快速沉降，需将矿浆稀释到浓度5%，饱和絮凝剂用量为60 g/t。
3　浓密机选型计算
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根据重力沉降理论及相关模型，以单个间歇沉降试验即静态浓密沉降试验确定的沉降数据为基础，推算连续沉降固体通量，代入浓密机待处理的物料量，换算得到浓密机的水平截面积，完成浓密机选型计算。
通常采用Coe-Clevenger方程（简称C-C方程）计算浓密机沉降面积。C-C方程的前提是整个沉降区悬浮物浓度相同，矿浆絮凝沉降过程中，颗粒浓度足够高时，颗粒不再作为个体沉降，而是形成颗粒群，并以絮团形式相互干涉，共同沉积，因此进入干涉沉降区后，C-C方程不再适用，需要引入修正系数[3]。本次矿浆沉降作业的目的主要是澄清，关注的是澄清液面沉降的速度，物料平衡原理适用于尾矿矿浆沉降的各个阶段，并不局限于单一沉降形式，因此可采取澄清界面的物料平衡方程计算沉降面积。
式中：A为沉降面积，m2；Ci为澄清界面处固体颗粒的质量浓度，kg/m3；ui为澄清界面处固体颗粒沉降速度，m/h；Qu为沉降底流的体积流量，m3/h；Cu为沉降底流的质量浓度，kg/m3。
针对本文研究的矿浆，分别采用物料衡算法和C-C方程计算适宜工艺条件下的沉降面积，其中C-C方程计算的沉降面积以尾矿粒度组成、颗粒表面形态、固体密度为主要影响因素进行系数修正。计算结果表明：采用物料衡算方法得到的浓密机沉降面积更大，从安全性考虑，选取较大值，全尾矿矿浆浓密机表面负荷为900 kg/（m2·h），溢流矿浆浓密机表面负荷为330 kg/（m2·h）。
4　尾矿浓缩系统改造方案
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根据试验结果并结合选矿厂现场场地面积受限的情况，提出2种改造方案。
方案1：新建1台高效浓密机，处理给入现有5台1 000 m2斜板浓密箱的全尾矿，浓密机的底流泵送至尾矿泵站再输送至尾矿库，溢流水返回选别作业循环使用，现有5台1 000 m2斜板浓密箱停用。
方案2：新建1台高效浓密机，处理现有5台1 000 m2斜板浓密箱的溢流，浓密机的底流泵送至尾矿泵站再输送至尾矿库，溢流水返回选别作业循环使用[6]，现有5台1 000 m2斜板浓密箱继续使用。
2种浓密机改造方案的比较详情见表2。
浓密机选型计算结果表明：方案1新建处理全尾矿的浓密机直径为38 m，干矿处理量1 000 t/h，给矿浓度25%，絮凝剂用量20～30 g/t，底流浓度45%，溢流水固含量300 mg/L；方案2新建处理溢流尾矿的浓密机直径为30 m，干矿处理量200 t/h，给矿浓度10%～15%，絮凝剂用量50～60 g/t，底流浓度25%，溢流水固含量300 mg/L。
方案2直接投资成本比方案1低，但存在以下缺点：
1）浓密机处理的斜板浓密箱溢流为－38 μm微细颗粒。物料粒度过细导致浓缩底流浓度偏低。
2）浓缩底流浓度25%，与斜板浓密箱底流（浓度40%～45%）汇合后，使输送至尾矿库的总尾矿浓度降低。
3）新建浓密机仅处理尾矿斜板浓密箱的溢流，斜板浓密箱继续使用，因此不能从根本上解决斜板浓密箱处理粗粒级尾矿浆堵塞、压板等问题。
综上所述，推荐方案1作为浓缩系统改造方案。该方案中新建1台Φ38 m重载高效浓密机处理全尾矿，该浓密机的处理量需达到900～1 100 t/h（考虑波动系数），浓密机的单位面积负荷高，处理－74 μm粒级占72.14%、－20 μm粒级占47.10%的细粒钒钛磁铁尾矿，需保证底流排放浓度稳定在45%左右，溢流水固含量低于300 mg/L，可实现浓密机达产达标。
5　絮团稳定性试验及浓密关键技术
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5.1　絮团稳定性试验研究
重载高效浓密机处理量大，给料流量大、流速高，高速流体沿给料井切线进入，容易对给料井内已成形的絮团产生扰动，甚至打散絮团，因此需研究尾矿絮团结构稳定性，并对给料井进行针对性流场设计。实验室内，以APAM为絮凝剂，在沉降筒内完成尾矿一次高剂量絮凝沉降试验后，多次反复倒置晃动沉降筒，对絮团施加扰动，研究絮团结构稳定性，全尾矿矿浆絮团结构稳定性试验结果如表3所示。结果表明，絮凝剂APAM用量越低，尾矿初始浓度越高，絮团越不稳定。搅动絮团后再沉降，沉降速度大幅度降低，APAM用量20 g/t时，第3次沉降的沉降速度约为第1次沉降速度的1/3。
5.2　给料井内流场的设计
为确保尾矿絮团的稳定性，给料井内矿浆需维持较低的浓度，但低浓度矿浆易出现粗细颗粒离析分离。对给料井进行了流场特殊设计，使矿浆在与絮凝剂作用前粗细颗粒混合均匀，絮凝过程中细颗粒充分包裹粗颗粒，形成较均匀的絮团，共同沉降。不能形成良好絮团的少量粗颗粒也可在中心柱附近快速沉降，仅对浓密机中心柱附近的耙架产生较大阻力，使耙架整体的扭力矩保持在较低的状态。
5.3　给矿快速稀释技术
浓密机处理的尾矿矿浆入料浓度约25%，为了获得更好的絮凝效果，必须在浓密机给料井中将给矿浓度稀释到10%～15%。给矿稀释系统采用流体自动稀释，矿浆以切线方向喷射进入给料井，经流体模型计算，在给料管上设计规格合适的文丘里管，给料井周围的澄清水通过文丘里管自动吸入给料井，将矿浆稀释至指定浓度，无需外部水源加入，浓密机的进、出水量保持不变。
5.4　重负载驱动系统
针对本项目研发了浓密机重负载驱动系统，最大扭矩（静扭矩）为15×105 N·m。驱动系统采用多齿轮驱动技术，减速机为行星齿轮减速机，传动效率高。驱动方式为液压驱动，输出扭矩大且运行平稳。液压系统中配置变量液压泵，负载敏感设计，液压系统效率高，发热量低。
5.5　自动化控制精准提耙
浓密机耙架的扭矩对其扫过的泥层高度极为敏感，当出现扭矩高负载报警时，为了保证耙架稳定工作，需将耙架提起进入上部较低浓度的泥层。耙架提升过高将会悬空，耙架扭矩大幅降低，浓密机耙架控制系统将启动降耙程序，耙架重新进入较低位置的高浓度泥层中。若提耙步长控制不合理，耙架会在泥层阻力达到提耙条件后处于反复升降动作中，并不能在泥层上界面位置精准停留，压耙风险较高。长沙矿冶研究院有限责任公司自主研发了浓密机自动提降耙控制程序对浓密机升降耙进行精准步长控制，可保证耙架稳定工作。
5.6　浓密机结构设计
采用有限元分析方法，分析浓密机各部件的负荷情况，在达到强度要求的前提下轻量化设计，降低设备运行能耗及造价。本项目设计的浓密机耙架转速较高，且可无级调速，在耙架结构强度设计中对其运转过程负荷进行动态模拟，确定强度负荷极值，保证设备稳定安全运行。
5.7　平衡的底流排放结构设计
测定浓密机底流的流变参数，选取匹配的流变模型进行分析，根据其流动性特点设计多管集矿、一管排放的平衡排放结构，使底流排料顺畅且耙架受力均匀，降低耙架阻力。
6　重载高效浓密机工业应用
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经过试验研究、方案论证及针对性的工艺、机械、结构设计和对设备加工制造质量、现场安装施工质量严格管控，Φ38 m重载高效浓密机投产即达产达标，给矿干量约1 100 t/h、给矿浓度20%～25%时，底流浓度45%、溢流固含量小于200 mg/L。
7　结语
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在传统高效浓缩理论基础上，通过技术创新开发了单位面积处理量1 000 kg/（m2·h）的重载高效浓密机。该浓密机直径38 m，处理－74 μm粒级占72.14%、－20 μm粒级占47.10%的细粒钒钛磁铁尾矿，设备运行平稳、指标优异，解决了攀钢某选矿厂场地受限、斜板浓密箱底流堵塞压板、溢流跑浑的问题，提高了生产作业率，改善了选别指标，降低了运行成本，项目取得了显著的经济和生态效益。
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doi: 10.3969/j.issn.0253-6099.2025.04.019
  • 接收时间：2025-02-19
  • 首发时间：2026-03-05
  • 出版时间：2025-08-01
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  • 收稿日期：2025-02-19
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    长沙矿冶研究院有限责任公司，湖南　长沙　410012
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2种不同金属材料的力学参数
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genus		 种数
Number of
species		 占总种数比例
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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