螺旋分选机操作手册

1、螺旋分选机操作手册宏测 项 目北京华德创业环保设备有限公司南非MULTOTEC过程设备公司2009年6月目 录SECTION A MANUFACTURERS PICTURES制造商图片3SECTION B MANUFACTURERS GUARANTEE制造商保证4SECTION C Summary of WARNINGS and CAUTIONS注意事项一览6SECTION D GENERAL & TECHNICAL DESCRIPTION概述 & 技术说明8SECTION E OPERATING PRINCIPLES操作原理13SECTION F METALLURGICAL & PHYSIC

2、AL PREPARATION准备工作15SECTION G INSTALLATION AND COMMISIONING INSTRUCTIONS安装调试指导17SECTION H MAINTENANCE AND REPAIR INSTRUCTIONS维修21SECTION J FAULTFINDING ANALYSES故障分析23SECTION K ILLUSTRATED PARTS LIST部件表24SECTION A MANUFACTURERS PICTURES制造商图片SX4 型 MX7型SECTION B MANUFACTURERS GUARANTEE制造商保证MULTOTEC PRO

3、CESS EQUIPMENT offers a twelve-month guarantee on the Spiral Concentrator.B部分 制造商保修证MULTOTEC 过程设备公司为螺旋分选机提供12个月的保修期。The following conditions will apply, however:1. Scope of the Guarantee1.1 The guarantee is valid for 12 months after commissioning.1.2 All parts, except the H.D.P.E. piping, are guaran

4、teed against faulty workmanship and poor material quality.1.3 The Guarantee is subject to the correct and exact execution by the client, of all the installation, commissioning, operating and maintenance procedures as described in this manual.1.4 The Guarantee does not cover equipment failure due to

5、normal wear.本保修证适用下列条款：1 保修的范围1.1本保修证有效期为设备试运行后的12个月内。1.2除H.D.P.E.（高密度聚乙烯）管道之外，所有部件由于误操作或者不良原材料引起的损坏，不在保修之列。1.3本保修证以用户的正确操作为前提，包括安装与运行的全过程。操作与保养规程在本操作手册中将有详细描述。1.4本保修证不适用由于正常磨损而引起的设备故障。2 MULTOTECs responsibilityIn case of an equipment failure due to faulty workmanship or poor material quality, MULTO

6、TEC will repair and /or replace broken parts and reinstate the equipment to a fully operational condition.2 MULTOTEC职责在由于误操作或者不良原料引起设备故障的情况下，MULTOTEC 将修理和/或更换损坏的部件，使设备恢复到完全正常的操作条件下。3. CLIENTs responsibility3.1 The client is not allowed to use the equipment for anything else than the original applica

7、tion without the written consent of MULTOTEC. Using the equipment for any other application will render this guarantee null and void.3.2 The Client will strictly follow the instructions and procedures stated in this manual. Using different installation, operating or maintenance procedures without th

8、e written consent of MULTOTEC, will render this guarantee null and void.3. 用户职责3.1 未经MULTOTEC书面同意，用户不得将设备用于除最初约定应用之外的任何场合。未经允许将设备用于其它场合，本保修证无效。3.2 用户须严格遵照本操作手册中的操作说明和规程。未经MULTOTEC书面同意，用户采用与手册所述相异的安装、操作或者保养方式，本保修证无效。 IMPORTANT NOTE:This manual has been evaluated by the technical staff at MULTOTEC and

9、 has been found to be correct. Under no circumstances will MULTOTEC be responsible for injury or death of personnel or loss or damage of equipment due to non-conformance by the client with the instructions of procedures stated in this manual.紧要提示：本操作手册经过MULTOTEC技术人员检验，被证明正确无误。MULTOTEC对用户由于不遵守本操作手册中的

10、操作说明和规程而造成的损失、人员伤亡，以及设备损坏不承担责任。SECTION C Summary of WARNINGS and CAUTIONS注意事项一览IMPORTANT Please read this!C部分 注意事项一览重要 请阅读本部分！The warnings and cautions in this section is a summary of all the warnings and cautions that appear throughout the manual. The purpose of this section is to draw the users at

11、tention to potentially dangerous situations that may occur. These warnings and cautions are repeated in the text wherever they apply.Warnings serve to call the attention of the user to situation that could result in injury or death if not adhered to. Please do not ignore the warnings in this manual.

12、Cautions indicate situations that could result in damage or loss of the equipment if ignored. To ensure cost-effective operation of the equipment, cautions must always be adhered to.本部分之警告与告诫是对贯穿本操作手册的警告与告诫的一个概括。本部分的目的是提醒使用者注意潜在可能发生的险情。这些警告与告诫将在正文中的相关地方被重复提及。警告用来促使用户注意如果不遵照执行将可能会导致伤亡的情况。切勿忽视本操作手册中的警

13、告！注意用来指出如果被忽视可能会导致设备的损坏与损失的情况。为了确保发挥设备的最大功效，用户须遵照注意的内容提示。WARNINGS1. DO NOT WELD OR GRIND NEAR THE SPIRAL CONCENTRATORThe Spiral Concentrator is manufactured from synthetic materials such as glass reinforced fibre, resins, polyurethane, polyvinalchlorides and rubber compounds.These materials are high

14、ly inflammable and can be set alight by the sparks and flames created by grinding and welding.2. THE SLURRY FEED LINE MUST BE SUSPENDED FROM AN INDEPENDEDT STRUCTRUE.Neither the Gravity Distributor nor the Main Concentrator Frame is designed to support more than the normal operating load.警告1 不要在靠近螺旋

15、分选机处进行焊接或破碎作业螺旋分选机用复合材料，如钢化玻璃纤维、树脂、聚氨酯、聚氯乙烯以及橡胶混合物制造。这些材料极易燃，容易被破碎和焊接时产生的火星点燃。2 矿浆给料管必须独立另设支架。无论是矿浆分配器的支架，还是螺旋分选机主体的支架，在设计上就不支持超过正常工作负载的过载荷。CAUTIONS1. DO NOT USE THE SPIRAL TROUGHS AS A STAIRCASEAlthough the spirals are manufactured as sturdy as possible, they cannot support the mass of a human body

16、. Climbing up the spiral will, therefore, result in the destruction of the spiral as well as in personal injury.2. DO NOT USE POWER TOOLS TO REMOVE THE SCALE FORMED BY CALCIFICATION FROM THE SPIRAL TROUGHS.The inner surface of the spiral troughs is covered with special layers of polyurethane to ensu

17、re optimum performance of the Spiral Concentrator. The use of power tools to remove calcification scale from this inner surface will lead to serious damage of these polyurethane layers. Always remove the scale by hand, using emery cloth.3. WLEDING OR DRILLING THE HOUSING FRAME WILL DAMAGE THE GALVAN

18、ISING AND WILL CAUSE SUBSEQUENT RUST.4. DO NOT SUSPEND HEAVY EQUIPMENT FROM SPIRAL TROUGHS OR LAUNDERS.The spiral troughs and PU product launders are not designed to carry any additional load, such as product discharge launders or pipe launders. Damages caused by excessive loads on the spiral trough

19、s and PU launders will invalidate the warranty.注意1. 不要把螺旋槽当作梯子使用尽管螺旋分选机的螺旋槽被造的尽可能的坚固，他们仍然不能承受一个人的体重。因此，攀爬螺旋槽将会导致螺旋槽被损坏，同时攀爬者也容易受到伤害。2. 不要用动力工具刮除螺旋槽上由于钙化作用形成的垢层螺旋槽的内表面覆盖着特殊的聚氨酯涂层，用来保证螺旋分选机的最佳性能。如果用动力工具刮除螺旋槽内表面上的垢层，将会导致这些聚氨酯涂层的严重损坏。记得只能用砂布，手动刮除垢层。3. 对机架的焊接或钻孔将会损坏电镀层，从而会引起机架的锈蚀。4. 不要将笨重的设备悬吊在螺旋槽或洗煤槽上。螺

20、旋槽和聚氨酯洗煤槽并不是设计用来承担附加载荷的，譬如产品卸料槽或管道洗煤槽等。由于螺旋槽和聚氨酯洗煤槽承受过量载荷而引起损坏，本保修证失效。SECTION D GENERAL & TECHNICAL DESCRIPTION概述 & 技术说明D部分概述 & 技术说明1. GENERAL DESCRIPTIONA SPIRAL CONCENTRATOR is a highly specialized piece of equipment with no moving parts, which uses gravity and centrifugal force to separate small

21、particles of different densities. A typical use is to separate coal dust and fine sand when mixed with water to form slurry.The spiral concentrator comprises the following assemblies: (Refer to Fig. D1)a. Gravity Distributor (1)b. Spiral Assemblies (2)c. Housing Frame (13)d. Launders (16)1 概述螺旋分选机是高

22、度专业化的设备，无运动部件，它利用重力和离心力的作用来按照密度来分选小颗粒物料。一个典型的例子是，将煤粉或者细砂与水混合成浆液，然后用螺旋分选机来按照密度分选。螺旋分选机由以下部分组成：（参考图D1）a矿浆分配器 （1）b螺旋组件 （2）c机架 （13）d洗煤槽 （16）a) Gravity Distributor:The gravity distributor (1) is a galvanized steel cylinder fitted with centralized feed inlet (2) and a number of angled outlets (3). It is s

23、ituated on top of the spiral concentrator in a central position. The inlet is flanged for connection to the slurry feed line. Each outlet is lined with a high abrasion resistant orifice, which, in turn, is cupped with a polyurethane anti siphoning off-take (4).The purpose of the gravity distributor

24、is to receive preconditioned slurry from an upstream operation and to provide equal distribution of the slurry through each outlet to each of the respective spiral troughs. A distribution network of H.D.P.E. piping (5) links the gravity distributor to the spiral assemblies. The H.D.P.E. pipes are li

25、nked together with high abrasion resistant polyurethane elbows (6), which require no clamps.a）矿浆分配器：矿浆分配器（1）是一个镀锌的钢管，中间固定有入料口（2），四周配有若干成一定角度的出料口（3）。矿浆分配器位于螺旋分选机顶的中心位置。入料口装有法兰，用来与给料管线连接。每一个出料口都镶有高耐磨的隔板，这些隔板呈杯状，依次包裹在反虹吸装置（4）上。矿浆分配器的用途是接收上游预处理过的矿浆，将此矿浆平均分配到每个出口，使每个螺旋组件能接收到等量的矿浆。一个由H.D.P.E.管道网络（5）构成的矿浆分

26、配网将矿浆分配器与螺旋组件连接起来。H.D.P.E.管道互相连接处采用高耐磨的聚氨酯弯管（6），无需用夹具夹紧。b) Spiral Assemblies:The spiral assemblies (7) are mounted vertically in the housing frame. Each of the spiral assemblies consists of a centre column (8) about which a series of helical troughs (9) are mounted. The troughs are of uniform pitch

27、and profile. It is these troughs, which separate the materials by means of centrifugal and gravitational forces. The helical troughs are manufactured from glass-reinforced fibre, which is sprayed with multi-layers of polyurethane on the inner working surface to provide an abrasion resistant finish.

28、A single layer of Flo-Coat is applied on the underside to act as a moisture sealant.The top end of each spiral trough is fitted with a polyurethane feed box (10). Each feed box contains an in-line wear pad to disperse the slurry flow and thus reduce the wear on the trough surface. The discharge end

29、of each spiral assembly is fitted with a polyurethane product box (11) containing a hand/automatic adjustable splitter. The function of the splitter is to finally separate the materials. The collection box is divided into two or more compartments. Each compartment is fitted with discharge opening (1

30、2) leading to the launders below, via rigid H.D.P.E. piping.b) 螺旋组件：螺旋组件垂直安装在机架上。每个螺旋组件都有一个中心圆柱管，其上安装有一系列的螺旋槽。这些螺旋槽形状相同，等螺距安装。依靠螺旋槽，物料在离心力和重力的双重作用下实现了分选。螺旋槽用玻璃钢制造，其内表面喷涂多层聚亚氨酯，使内表面具有极好的耐磨性能。在螺旋槽的下侧涂有一层“Flo-Coat”涂层，起到密封、隔绝水汽的作用。每一个处于顶端的螺旋槽都固定有一个聚亚胺酯的给料箱。给料箱的内表面衬有耐磨板，可以分散矿浆流并减小对螺旋槽内表面的磨损。每一个处于出料端的螺旋槽都

31、固定有一个具有分流器的，用聚亚氨酯制成的产品收集箱。分流器可手动或自动调节，其作用是用于物料的最终分选。每一个产品收集箱分出两部分或更多的组成部分。每一部分安装有卸料口，通过刚性的H.D.P.E管道通往位于其下方的洗煤槽。c) Housing Frame:The frame (13) is an A-shaped, angular mild steel structure that is galvanized in accordance with SABS Specification No. 763. It provides a rigid housing for the various co

32、nfigurations of spiral assemblies. A cat ladder (14), mounted on the side of the frame, provides operator access to the walkway ton top of the frame.c）机架机架（13）是一个呈“A”字型的，有角的镀锌的低碳钢结构，根据南非标准化组织第763条规定制造。它为多种多样的螺旋组件提供了一个刚性的机架。在机架的侧面，安装有一个攀行梯（14），通过这个攀行梯，操作人员可以去往机架顶端的人行通道（15）。d) Launders:The launders (1

33、6) is, normally, mild steel / rubber lined and closed at one end. The launder has openings, which correspond to the discharge openings of the spiral product boxes. The launder is suspended, at an angle, on chains (17) beneath the bank of spirals. The function of the launder is to collect the separat

34、ed material and route it to the appropriate down stream operation.d） 洗煤槽：洗煤槽（16）通常内衬有低碳钢或者橡胶，一端封闭。洗煤槽有开口，与螺旋组件上产品收集箱的卸料口相连。洗煤槽呈一定角度，用链条（17）吊在螺旋组件下方。洗煤槽的作用是收集分选过的物料，并将之送往下级工序处理。2 TECHNICAL DATA for the 1000 mm Large Diameter Spiral RangeThe Spiral Concentrators are arranged in bank configurations of

35、2, 4, 6 or 8 pairs of spirals according to the requirements.2.1 Dimensional DataRefer drawing No. SC3-0204 .21000 mm大直径螺旋分选机排列技术资料按照用户的需要，螺旋分选机可以被定为2、4、6或者8组。2.1 空间尺寸数据参考图SC3-02042.2 General Operational Criteriaa) Coal SpiralsCriteria / Start 1000 mm Feed Solids Loading 3,0 t.p.h. Solids Concentrati

36、on 35% w/w Slurry volume 7,5 m3/hr Size range (-1,0mm +0,1mm)b) Heavy Mineral SpiralsCriteria / StartFeed Solids Loading 1,30 t.p.h. Solids Concentration 30% w/w Slurry volume 3,5 m3/hr Size range (-0,5mm +0,1mm)2.2 操作标准概要a） 煤用螺旋分选机标准/头 1000 mm 入料 固体处理量 3,0 t.p.h. 固体浓度 35% w/w 浆液流量 7,5 m3/hr 粒度范围 (-

37、1,0mm +0,1mm)b） 重矿物螺旋分选机标准/头入料 固体处理量 1,30 t.p.h. 固体浓度 30% w/w 浆液流量 3,5 m3/hr 粒度范围 (-0,5mm +0,1mm)NOTE:The operating criteria for each specific application are strictly subject to test work. This is due to the fact that different materials will behave differently during the process. There are quite a

38、 few factors that have a significant effect on the operating performance of the spiral concentrator. These are:Fixed： Variable:1) Gravity 1) Material characteristics (Particle size, shape, density and porosity)2) Centrifugal force 2) Solid concentration3) The trough profile 3) Slurry volume注意：为每一个具体

39、实例而制定的操作标准都严格遵照测试工作。这是基于这样一个事实的，即在处理过程中，不同的物料将会表现出不同的特性。在螺旋分选机的工作中，有相当多的因素对其有重大的影响。这些因素包括：确定因素： 可变因素：1）重力 1）物料特性（粒度，形状，密度和孔隙率等）2）离心力 2）固体浓度3）槽的纵断面形状 3）矿浆流量Due to the vast number of materials processed, there is no recipe to follow when using a spiral concentrator. Each application has its own unique

40、 problems and solutions. Therefore, a unique test has to be carried out for each application. The results of these tests determine the values of the above-mentioned variables as well as the trough profile.Of these variable parameters, the slurry volume is the most important. The concentrator can tol

41、erate some mass and solids concentration fluctuations without significant loss of performance. But, it is very important to keep the flow of slurry constant.Please contact MULTOTEC for information on test procedures for extraordinary applications.由于需处理的物料种类繁多，螺旋分选机在设计选型的时候并没有固定的成规可循。每一个应用实例都有其独特的问题和

42、解决方法。因此，对每一个应用实例都应该施行一个量身定做的测试。这些测试的结果就决定了上述可变因素的值及槽的纵断面形状。在这些可变因素中，矿浆流量是最重要的。螺旋分选机对物料和固体浓度的变化有一定的免疫力，这些变化不会对分选效果产生重大影响。但是，保持矿浆流量的恒定却是必须的，非常重要的。欲获得更多的有关应用实例测试过程的信息，请与MULTOTEC联系。2.3 Gravity DistributorMaterial: Galvanized mild steel lined with abrasion resistant polyurethane.Feed: Free discharge cent

43、ral feed inlet pipe.Operational Parameters: Particle size range: -3 mm + 0 mm Density range: 0 - 40 % solids (w/w) Volume / Outlet: 5, 0 m3 / hr 9, 0 m3 / hrPipe Network: Length: 150 mm Diameter: 50 mm or 75 O.D. Mounting: 20 degrees off horizontal.2.3 矿浆分配器材料： 镀锌低碳钢，内衬聚亚胺酯耐磨材料。给料： 自由卸料 中心给料进料管。操作参数

44、： 粒度范围： -3 mm + 0 mm 密度范围: 0 - 40 % 固体含量 (w/w) 体积 / 出口: 5, 0 m3 / hr 9, 0 m3 / hr管道网络: 长度: 150 mm 直径: 50 mm 或 75 mm 外径 安装: 水平倾斜20度。SECTION E OPERATING PRINCIPLES操作原理To separate a mixture of, say, product A (light particles) and product B (heavy particles), the spiral concentrator operates in the fol

45、lowing manner:The mixture is screened to remove all the particles larger than +1 mm. It is then mixed with water to form slurry with a constant density of 30% solids to 70% water.This slurry is then pumped into the slurry distributor (1). The distributor feeds equal volumes of slurry through each of

46、 its outlets (2), via the down pipes (3), into the various top feed boxes (4). Inside these boxes a polyurethane wear pad disperses the flow to reduce wear on the trough surface.The feed boxes feed the slurry onto the spiral troughs (5). The slurry now spirals down the troughs under the force of gra

47、vity.E部分 工作原理假定要分选含有A产品（轻颗粒）与B产品（重颗粒）的混合物，螺旋分选机按如下方式工作：混合物首先经过筛分，除去 +1 mm以上的大颗粒。然后，加适量水调成固体与水分别占30%和70%的浆液。随后，浆液用泵送入矿浆分配器（1）。矿浆分配器对它的每个出口（2）平均给料，经过下料板，可以分散矿浆流从而减小对螺旋槽内表面的磨损。给料箱将矿浆给入螺旋槽（5）。矿浆在重力作用下沿螺旋槽向下运动。The lighter particles (product A) stay suspended in the water and forced to the outer edge of t

48、he trough by the centrifugal force created by the circular movement.The heavier particles (product B) sink to the bottom of the trough where drag, created by friction, slows them down. The specially sloped trough profile forces these slow, heavy particles to move down the shorter inner route of the

49、trough.When the slurry reaches the bottom of the spiral, the materials are completely separated and can normally be seen as two separate.The adjustable splitter at the bottom of the trough is set by hand to finally split or separate the two streams of material. The materials are then fed into separa

50、te collection boxes (6/Fig. E1) with outlets leading into the launders (7/Fig. E1) below.Most often the separated materials are optionally routed from the launder to another Spiral Concentrator directly below, to be processed once more. This is called double stage process.轻颗粒（A产品）保持悬浮在水中，并在浆液环流运动产生的

51、离心力的作用下被推向螺旋槽的外缘。重颗粒（B产品）沉到螺旋槽的底部，受到摩擦阻力，运动速度变缓。具有特定坡度的螺旋槽横断面使得这些运动变慢了的重颗粒沿着螺旋槽的内缘向下运动。当矿浆到达螺旋分选机的底部，物料即被完全分离开来，一般分为两产品。螺旋槽底部安装有可手动调节的分流器，通过调节这个分流器，可以调整物料的分选密度。分选完毕后的物料，通过连接在下方洗煤槽（7/图E1）上的出料口，被分别给入各自的产品收集槽（6/图E1）。在更为普遍的情况下，可以选择性地将从洗煤槽出来的物料直接给入其下方的另一个螺旋分选机，再次分选。这叫做两段分选。SECTION F METALLURGICAL & PHYSI

52、CAL PREPARATION准备工作The successful operation of the Spiral Concentrator depends on the following very important factors:a) Pilot Plant test for specific applicationb) Layout and Configurationc) Plant installationF部分 冶金学与物理学预备螺旋分选机的良好工作依赖于以下几个极为重要的因素：a) 对特定应用实例进行的中试工厂的测试b) 布局与配置c) 工厂安装a) Pilot Plant T

53、esting MULTOTEC offers a free pilot plant facility for the testing of specific applications.The client provides MULTOTEC with a sample of the material to be beneficiated on the spiral. MULTOTEC conducts a test to determine the solids/water ratio, the flow rate, the trough profile and also whether a single or double stage process is required.Note: Closed circuit material recycling during the test has a negative effect on the test result. It is, therefore, important to remember that actual application results are normally more favorable than pilot plant result