Mono roller grinding mill

Abstract

A crushing mill with a single roller inside a driven cylindrical shell inner surface, both with horizontal and parallel but offset axes is disclosed. In some embodiments, the roller has protrusions such that as the roller and shell rotate rock or other material may be crushed between the shell and the roller, respectively. In some embodiments, the shell and the roller each have surface protrusions such that rock or other materials may be crushed between the shell and the roller as they rotate. In some embodiments the shell and the roller operate at differential speeds with respect to each other to induce shear forces on the material to be crushed.

Claims

1. A mono roll grinding mill (MRGM) comprising: a shell having a chamber having a cylindrical inner surface, wherein at least a portion of the inner surface of said shell comprises a first plurality of ridges extending along an axial direction of said shell; a floating roller located within the shell, said roller comprising a cylindrical outer surface, wherein at least a portion of the outer surface of the roller comprises a second plurality of ridges extending along an axial direction of said roller; wherein the shell is configured to rotate about a shell axis, said shell axis being offset from and parallel to a roller axis; wherein the MRGM is configured to receive material in the chamber, and wherein said material is comminuted by a weight of said roller without an external pressure system in a fracture zone located between the inner surface of the shed and the outer surface of the rover, and wherein said first plurality of ridges and said second plurality of ridges extend helically in said axial direction of said shell and configured to control a number of circumferential passes of said material through said fracture zone.

2. The MRGM of claim 1, further comprising exit grates extending through the shell to allow comminuted material to pass radially outward therethrough.

3. The MRGM of claim 1, wherein the roller contains a volume of solids and/or fluid to increase the weight of said roller.

4. The MRGM of claim 1, wherein the shell rotates at a first angular velocity and the roller rotates at a second angular velocity different from the first angular velocity.

5. The MRGM of claim 1, further comprising a ring-shaped shield attached to a laterally outward portion of the shell on at least one lateral end of the shell and configured to rotate therewith.

6. The MRGM of claim 1, wherein the roller has an outer diameter greater than 0.2 of the shell inner diameter.

7. The MGRM of claim 1, wherein said first plurality of ridges and said second plurality of ridges are substantially orthogonal in said fracture zone.

8. The MGRM of claim 1, wherein said first plurality of ridges is complementary in shape with said second plurality of ridges.

9. The MGRM of claim 1, wherein said first plurality of ridges and said second plurality of ridges form a worm gear configuration.

10. The MGRM of claim 1, wherein said material is received at a first end of said chamber, and wherein said material is ejected from a second end of said chamber opposite said first end of said chamber.

11. The MGRM of claim 1, wherein said plurality of protrusions is circumferentially asymmetrical.

12. The MGRM of claim 1, wherein at least one of the shell and/or the roller are frustaconic in the axial direction.

13. The MGRM of claim 1, wherein torque is transmitted from said shell to said roller to effect rotation of said roller.

14. The MGRM of claim 1, wherein the shell and/or the roller comprise a rounded edge configured to maintain an axial position of the roller within said chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a cross-sectional, end view, of one embodiment of the disclosed MRGM.

(2) FIG. 2 is a cross sectional side view of the embodiment of FIG. 1

(3) FIG. 3 is a cross sectional perspective end view of one example of the MRGM.

(4) FIG. 4 is a cross sectional end view of the example of the MRGM shown in FIG. 3.

(5) FIG. 5 is a cross sectional perspective end view of another example of the MRGM.

(6) FIG. 6 is a cross sectional end view of another example of the MRGM.

(7) FIG. 7 is a cross sectional perspective end view of another example of the MRGM.

(8) FIG. 8 is a cross sectional end view of another example of the MRGM.

(9) FIG. 9 is a cross sectional end view of an example of MRGM.

(10) FIG. 10 is a cross sectional end view of another example of the MRGM.

(11) FIG. 11 is a cross sectional end view of another example of the MRGM.

(12) FIG. 12 is a cross sectional end view of one example of the MRGM in use.

(13) FIG. 13 is a cross sectional perspective end view of one example of the MRGM in use.

(14) FIG. 14 is a cross sectional end view of a prior art mill in use.

(15) FIG. 15 is a cross sectional end view of the example of the MRGM shown in FIG. 12.

(16) FIG. 16 is a cross sectional end view of the example of the MRGM shown in FIG. 12.

(17) FIG. 17 is an end view of another example of the MRGM shown in FIG. 1.

(18) FIG. 18 is a cross-sectional view taken along line 18-18 of FIG. 17.

(19) FIG. 19 is a detail view of the region 19 of FIG. 18.

(20) FIG. 20 is an end view of another example of the MRGM shown in FIG. 1.

(21) FIG. 21 is a cross-sectional view taken along line 21-21 of FIG. 20.

(22) FIG. 22 is a detail view of the region 22 of FIG. 21.

(23) FIG. 23 is an end view of another example of the MRGM shown in FIG. 1.

(24) FIG. 24 is a cross-sectional view taken along line 18-18 of FIG. 17.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(25) In the following disclosure, various aspects of a mono roll grinding mill (MRGM) 20 will be described. Specific details will be set forth in order to provide a thorough understanding of the disclosure. In some instances, well-known features may be omitted or simplified in order not to obscure the disclosed features. Repeated usage of the phrase “in one embodiment” or “in one example” does not necessarily refer to the same embodiment or example, although it may.

(26) An axes system 10 is shown and generally comprises a vertical axis 12, an anvil radial axis 14 extending radially outward from the center of the anvil (outer) ring 22, a roller radial axis 16 extending radially outward from the center of the roller (inner) ring 28, and a lateral axis 18. The lateral axis 18 is generally aligned with the axes of rotation of the shell 22, and the axes of rotation of the roller 28. These axes and directions are included to ease in description of the disclosure and are not intended to limit the disclosure to any particular orientation.

(27) In several examples herein, a reference system is used comprising a numeric identifier and an alphabetic suffix. The numeric identifier labels a general element and an alphabetic suffix is used in some examples to show a specific embodiment of the general element. For example, the general shell is identified in FIG. 1 as 22, while one specific embodiment is shown as 22a in FIG. 3.

(28) To ensure clarity, the term “material” is used herein to indicate rock, mineral matter of variable composition, consolidated or unconsolidated, assembled in masses or considerable quantities, as by the action of heat or water and equivalent materials. The material (for example rock) may be unconsolidated, such as a sand, clay, or mud, or consolidated, such as granite, limestone, or coal. While not normally defined as rock, equivalent materials such as hardened concrete may also be used in the disclosed mill and are included in the term “material”.

(29) FIG. 1 is a cross-sectional end view of an embodiment of a Conjugate Anvil Hammer Mill (CAHM) 20 with a floating roller. The term floating indicating that the roller may not be provided with a pressure device external of the roller 28. Such external pressure systems are disclosed in U.S. Pat. No. 8,955,778 filed on Mar. 15, 2012 incorporated herein by reference. This embodiment of the CAHM comprises an outer shell 22 having a substantially cylindrical inner surface which defines a chamber 24. The shell 22 is supported in one form by bearing pads 26. Bearing pads 26 may include bearings, lubricants, and/or friction resisting materials.

(30) The outer shell 22 in one example rotates about a first longitudinal center axis 42. This outer shell 22 in in one example has a plurality of pockets or corrugations (not shown in FIG. 1, but shown in later figures), which interoperate with the roller 28 located within the outer shell 22. The inner roller 28 in one form comprising a substantially cylindrical outer surface 34 which in one form is mounted to an axial shaft 30 to rotate about a longitudinal axis which is parallel to and offset from the axis 42 of the outer shell 22, the inner roller 28 in several embodiments having a plurality of protruding elements or ridges such as the protruding elements 32 for example of FIG. 10 attached to or formed with the outer surface 34 of the roller 28, the protruding elements 32 in this form configured to increase efficiency of comminution as the inner roller 28 and shell 22 rotate.

(31) Material 38 is inserted into the chamber 24 and comminuted between the outer surface 34 of the inner roller 28 and the inner surface 51 of the outer shell 22. The material 38 may be mixed with a fluid (water) to aid in transport down the shell 22 and aid in comminution. In some embodiments, retaining shields 40 are positioned at the shell outer edges to contain material before and during comminution.

(32) As can be seen, there may be a lateral gap 36 between the inner end surface of the shell 22 or retaining shield 40 and the end of the roller 28. Thus, the feeding point 56 of the chute 58 may be inserted laterally 18 inward to form an overlap distance 48 such that material 38 inserted is less likely to be deposited in the gap 36.

(33) The density, size, shape, and weight of the roller may be specifically configured to maximize comminution based on shell configuration, and material to be comminuted.

(34) In FIGS. 1 and 2, an embodiment of the roller 28 is shown positioned inside the shell 22, wherein the rotational axes 43/42 of each ring are shown. In this embodiment, the shell 22 may be powered by a motor 44 and may rest on external bearings (pads 26).

(35) In one example, the shell 22 is supported by hydrodynamic bearing pads 26 exerting lifting/supporting force on the outer surface 66 of the outer shell 22. An embodiment is shown where the motor 44 drives the axle of the shell 22. the outer surface 28 of the roller 28 engages the inner surface 51 of the shell 22 to transmit rotational force to the roller 28.

(36) In another example, a motor may alternatively or cooperatively drive the roller 28 by way of a gearing system on the outer surface thereof, or other apparatus such as a belt, or chain drive.

(37) In some embodiments, the roller 28 may be pressed against the shell 22 by additional force, such as by filling the roller 28 with fluids (e.g. water) or other solids (e.g. sand). In one example it is desired to minimize the circumference of the roller 28 to maximize compression in a small fracture zone 78 where a larger circumference would more evenly distribute this pressure. By utilizing the weight of the roller 28 to comminute material 38 with no external pressure/drive system, power consumption directed toward forcing the roller 28 against the shell 22 can be decreased relative to prior art embodiments. This configuration operates as a constant-pressure system, rather than constant gap mill. As In this configuration, if material 38 is too hard to crush, the gap 49 between the outer surface 34 of the roller 28 and the inner surface 51 of the shell 22 will increase, rather than jamming or damaging the MRGM 20. Thus, the floating embodiment where the roller 28 is allowed to float on the material 38 above the inner surface 51 of the shell 22 increases efficiency of the apparatus in many applications.

(38) In some embodiments, the inner roller 28 has an outer diameter 52 sized between 50% and 80% of the inner diameter 50 of the outer shell 22.

(39) One example uses an inner roller 28 with an outer diameter 52 which is 0.2 (20%) of the inner diameter 50 of the outer shell 22. Another ratio between outer diameter 52 of roller 28 and inner diameter 50 of the shell 22 may be between 0.65 and 0.7. This ratio represents a trade-off between (a) a larger inner roller 28 to improve the mechanical crushing advantage and longer wear life of the shell 22 to comminute material, and (b) a smaller shell 22 can comminute lighter throughput and be able to crush larger material due to the clearance 54 at the feeding point 56 as shown in the top of FIG. 2.

(40) In one example, the roller 28 diameter is no less than 0.2 of the shell 22 inner diameter to ensure that pressure between the roller and the shell are adequate for breakage (comminution) of the material.

(41) Looking to FIG. 14, the center of mass 60 common in mills including ball mills and rod mills is seen offset from the center 42 of the shell 22 by a distance 64. This offset creating torque on the system, and greatly reducing efficiency of the overall system. Looking to FIG. 12 is shown the center of mass 68 of a MRGM where the distance 74 is significantly reduced.

(42) This torque and associated inefficiency can be further reduced where the center 43 of the roller 28 is very near the lateral position of the center 42 of the shell 22 and the speed of the shell 22 is set such that the material 38 does not build up at any location. In such an arrangement, the speed of the shell 22 in cooperation with the depth of the protruding elements 33 on the shell 22, size/mass/density of the material 38, inner diameter 50 of the shell 22 such that the material 38 is centrifugally forced toward the shell 22 and in each rotation of the shell 22 passes around the roller 28. Combined with lateral 18 movement of the material 38, this results in a helical transport 82 of the material down the shell 22 to an ejection port 96 laterally in opposition to the chute 58.

(43) Operation of one embodiment of the MRGM 20 will now be explained. Rock to be comminuted is fed into the mill in one example from a chute 58 that guides the material (rock) 38 into the chamber 24 between the outer shell 22 and inner roller 28. Rotation of the shell 22 conveys the material 38, by rotation and gravity to the comminution gap 49 between the shell 22 and the roller 28, as the roller 28 applies pressure, and impacts with other material in the MRGM 20, comminuting the material 38 within the shell 22 by way of compression fracture of the material (rock). In this embodiment, the material 38 then passes through an grate or opening or equivalent exit 96 or may be further comminuted by the rotating action of the shell 22 and roller 28 in a following rotation. In the examples shown in FIGS. 3-11 and 12, a shield 40 forms a ring attached to the shell 22. The shield 40 in one example rotates with the shell 22 and as the material 38 passes over the inner edge of the shield 40, it exits the mill 20. This inner edge may be configured to maintain the roller 28 within the shell 22. This retaining shield may be positioned on either lateral end of the shell 22.

(44) In some embodiments, the textured surfaces 62 of the shell 22 and/or textured surfaces 63 of the roller 28 as shown by way of example in FIG. 10 assist in breaking the material 38. In one previously described example the shell 22 is rotated by an external drive (motor 44) either near a central region as shown in FIG. 2 or adjacent the bearing pads 26 on the perimeter, or other methods. The material 38 generally does not conform to the surfaces 62/63; thus the material 38 will commonly bridge from one texture surface to another in a two, three, or more point contact compression resulting in shear fracture of the material 38. As each protruding element 32 contacts the material 38, the material will tend to fracture and break.

(45) In one example (G) as shown by way of example in FIG. 10, the roller 28g includes protruding elements 32. The inner surface 51 of the shell 22 may be smooth or may include protruding elements 33.

(46) Looking to the example of FIG. 3 and FIG. 4, an example (A) is shown where the protruding elements 32a on the roller 28a comprise ridges that extend laterally 18 down the roller 28a. Similarly, the inner surface 51a of the shell 22a may comprise protrusions 33a that form ridges that extend laterally 18 down the shell 22a.

(47) Looking to the example shown in FIG. 5, the shell 22b and the roller 28b have protrusions 32b and 33b comprising ridges that extend helically down the shell 22b and/or roller 28b. The ridges on the shell 22b of this example are not parallel to the ridges on the roller 28b, and are substantially orthogonal at the compression fracture zone 78. In one example, these ridges are configured to manipulate the material 38 as it passes laterally 18 down the shell 22b towards the exit 96 so as to maximize efficiency by controlling the number of circumferential passes through the compression fracture zone 78.

(48) Looking to FIG. 7 is shown an example where the shell 22c and the roller 28c have protrusions 32c and 33c comprising ridges that extend down the shell 22c and roller 28c. The ridges on the shell 22c are generally laterally aligned and the ridges on the roller 28c are substantially helical, thus they are not parallel to the ridges on the shell 22c, and in this example are substantially orthogonal at the compression fracture zone 78. In one example, these ridges are configured to manipulate the material 38 as it passes laterally 18 down the shell 22c towards the exit end so as to maximize efficiency by controlling the number of circumferential passes through the compression fracture zone 78.

(49) In the example shown in FIG. 6, the roller 28c has protrusions 32c, while the shell 22c is substantially smooth on the inner surface.

(50) In the example shown in FIG. 8, each of the roller 28e and the shell 22e have adjacent surfaces that are substantially smooth.

(51) In the example shown in FIG. 9, the shell 22f has protrusions 33f, while the roller 28f is substantially smooth on the inner surface 51f.

(52) In the example shown in FIG. 10, the shell 22g and the roller 28g have protrusions 32g and 33g.

(53) In the example shown in FIG. 11, the shell 22h and the roller 28h have protrusions 32h and 33h. These protrusions are circumferentially asymmetric, forming ramps with a leading surface of a different configuration (angle or curvature) than the trailing surface relative to the direction of material flow 98.

(54) In the example shown in FIG. 20-22 each of the shell 22j and roller 28j comprise protruding elements 33j and 32j respectively that extend laterally 18 and circumferentially down the MRGM 20. The protrusions 33j and 32j nest together as a worm gear type arrangement, facilitating lateral movement of the material 38 from the inlet 58 to the exit 96.

(55) During initial startup of the MRGM 20, an initial buildup of material 38 is anticipated at a loading end location 88. This may result in tilting of the roller 28 as shown in FIG. 21, resulting in lateral movement of the roller 28 relative to the shell 22. In at least one example, this lateral movement may be unexpectedly toward the feed end 90. Thus, a fillet 92 (rounded edge) may be formed on the inner lateral end(s) of the shell 22 as well as a cooperating fillet 94 on the lateral end(s) of the roller 28.

(56) In one example this tilting is temporary, as the material 38 begins to exit at the ejection port 96 the system is more balanced. In other examples, the MRGM 20 is configured to maintain such a tilt, so as to improve efficient movement of material 38 from the chute 58 to the ejection port 96.

(57) In at least one example, the shell 22 may not have an even inner diameter 50 down the lateral length thereof but may be a frusta-conic shape to improve material movement. Similarly, the roller 28 may not have an even outer diameter 52 down the lateral length thereof, but may be a frusta-conic shape to improve material movement.

(58) The roller 28 in one example is preferably positioned by gravity to achieve the desired gap 72 between shell 22 and roller 28. One preferable position is achieved when broken material surface area is maximized for a given shell 22.

(59) In one example, material 38 is contained in the chamber 24 by the moving shell 22 and a shield 40. In one example the feed chute 58 passes through or around the shield 40 chamber 24. The shield(s) withhold the material from escaping the mill 20 at undesired positions during comminution.

(60) In some embodiments, once the material 38 is crushed and rotates counterclockwise past a 6 o'clock position 76 (the 6 o'clock position being the position of minimum gap 49 between the two rings as shown in FIG. 3) a desired number of rotations as shown in FIG. 18 and in FIG. 21, most of the material will exit the mill 20 either through the openings 70 or through an opening in the shield 40. In these embodiments, retention of the comminuted matter will aid in crushing more of the remaining matter as is understood by looking to FIG. 12-16 where it can be seen that the material 38 tumbles, slides, and commutates the other material 38 as contact is made. In these figures it can be seen that the kidney, or shape of the comminuted material 38 is affected by the roller 28, and the roller 28 thus imparts additional pressure in the compression fracture zone 78.

(61) FIG. 14 shows a mill 20 rotating at a relatively high rate of speed without a roller, where the material 38 travels further circumferentially around the shell 22 and drops onto the kidney 53. Such examples do not control a compression fracture zone 78 and thus are less efficient than an MRGM 20.

(62) Additionally, some embodiments allow material 30 to re-enter the compression fracture zone 78 as shown in FIG. 1, 18, 21 to create a finer ground material and/or to make a most efficient MRGM 20. To this end, grates or classifiers of various designs known in the art may be utilized. For example, one example may involve grinding the material with successively finer grinding surface features between the shell 22 and roller 28 (axially from one side of the ring to the other side, parallel to the axis of rotation), whereby material 38 is fed from one lateral end of the mill 20 and discharged out the opposite lateral end. For example, an embodiment may have multiple stages of coarse to fine grinding in the same mill 20, moving material dimensional geometries from large roller, to fine pin mesh as rock axial motion is utilized by trapping comminuted material 38 as the material 38 rotates up the shell 22 inner surface 51 or by tilting the mill 20 on its rotating axis 42.

(63) In some embodiments, the shell 22 may be mechanically driven by a motor 44 or equivalent device. For example, the shell 22 may rest on a ring and pinion gear system that drives the shell by the motor 40 or engine. The roller 28 is not connected to any control or drive apparatus, and thus floats on the material 38 during comminution. This makes modification of existing mills easy as the roller 28 may simply be inserted to replace multiple rods, balls, driven rollers, etc. No control or drive mechanism need be provided to the roller 28. The control is the design of the outer surface of the roller 28 relative to the inner surface 51 of the shell, and the size, weight, density of the roller 28.

(64) In one example, the roller 28 has a first diameter at a first end, and a second diameter at other positions there along to control lateral 18 movement of material 38 along the mill 20. In one example the roller is tapered along the lateral length to accomplish this. The protrusions on the roller, and on the shell may be configured to maximize the benefits of this geometry.

(65) In one example the core of the roller 28 may be made of a different material than the outer surface. For example, the core may be made of lead, while the outer surface is steel, to maximize density, comminution efficiency, and life of the roller 28.

(66) In one example the ratio of the protrusions on the roller 28 is configured to maximize efficiency. In the example shown in FIG. 12, the relative size of the ramp-shaped protrusions 32/34 is equivalent, whereas the example shown in FIG. 15 shows arcuate protrusions 32/33 having equivalent size. In each example, the number of protrusions 32 on the roller 28 is less than the number of protrusions on the shell 22 resulting in the roller 28 rotating at a faster angular velocity than the shell 22. The example shown in FIG. 16 shows a greater number, and smaller size protrusions 32 on the roller, resulting in a more similar angular velocity between the roller 28 and the shell 22. Where the number of protrusions around the roller 28 equals the number of protrusions on the shell 22, the relative angular velocity will be the same (they will rotate at the same speed).

(67) In some embodiments, one or both of the shell 22 and roller 28 may have ridges 84 and/or grooves 86 as shown in FIG. 3, 5, 7 to increase surface contour to better grip and retain material 38 entering the compression zone 78. In this embodiment, the ridges may also impart shear stresses due to differential speeds between shell 22 and roller 28.

(68) FIG. 13 is a perspective view of a portion of an embodiment of a MRGM 20 illustrating material 38 (rock) being crushed in the mill 20. The material 38 may then reposition toward the compression zone 78 and as the anvil 22 and roller 28 rotate, the material 38 is compressed between the anvil 22 and roller 28 as the gap 72 between the anvil 22 and roller 28 decreases into the compression zone 78. As depicted in the embodiment of FIG. 2, material 38 that is smaller than the exit grates (openings) 70 passes through the outer surface 66 of the roller 28. Non-ejected material 38 may remain in the MRGM 20 and return to the compression fracture zone 78 where it will eventually be ejected. Ejection may also occur past the shield 40 as previously described.

(69) In one embodiment as shown in FIG. 1, the shield 40 may include an open region such that the rock which does not pass through the openings 70 when provided, may be ejected through the ejection port 96 along the direction of flow.

(70) Additionally, the holes 70 in the grates of the shell 22 or laterally inward of the ejection port 96 may be sized according to the degree of comminution desired. For example, if it is desired that the largest resultant crushed material 38 have a maximum diameter of 50 mm then the grates 70 of the apparatus would have an inner diameter (width/length) of 50 mm. Additionally, the grates 70 may have different dimensions in other directions, for example, a hole may have a 50 mm width and a 150 mm length, where the length may be in the direction circumferentially around the inner surface of the outer ring. The size of the hole 70 may also be selected to reduce power consumption (as there is a pronounced increase in power consumption for a relatively small percentage change in hole size).

(71) One significant disadvantage of prior art high pressure grinding roll (HPGR) and other crushing mills is that material would often jam between the shield and one or both rollers. In many prior art applications, the shield is static, and does not rotate with the shell 22, further causing material to jam between the shield and the other components. This problem has been at least partially alleviated herein a where the shield 40 of one example is attached to the shell 22 either permanently or removably and rotates therewith. Thus, the shield(s) 40 will generally hold material 38 within the chamber 24, and any material that would lie against the shield 40 in the compression zone 78, will be compressed therein.

(72) A mono roll grinding mill using a roller with no external pressure device substantially reduces capital cost, complexity and operating costs. Further, an un-driven roller in such an arrangement also substantially reduces capital cost, complexity and operating costs. Despite this no such mono roll grinding mill with floating roller exists in the prior art, despite numerous benefits outlined herein.

(73) While the present disclosure is illustrated by description of several embodiments and while the illustrative embodiments are described in detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the scope of the appended claims will readily appear to those sufficed in the art. The disclosed apparatus and method in their broader aspects are therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants' general concept.