| US20080217451A1 | 2008-09-11 | |||
| US20160136649A1 | 2016-05-19 | |||
| US20150283550A1 | 2015-10-08 | |||
| US20130025476A1 | 2013-01-31 |
| CLAIMS 1. A high pressure grinding roll comprising a high pressure grinding roll module installed in a space envelope defined by an upper walkway support structure having an ore input area and a lower structural plinth having an ore output area, the module comprising: (i) a pair of upper support beams coupled to the upper walkway support structure; (ii) a pair of lower support beams mounted on the lower structural plinth; and (iii) a pair of counter-rotating grinding rollers mounted between the upper and lower support beams, wherein the upper and lower support beams are dimensioned to provide full structural support for the pair of grinding rolls during operation so that the high pressure grinding roll module comprises a fully operational high pressure grinding roll, even prior to mounting of the module into the envelope defined by the upper walkway support structure and the lower structural plinth. 2. A high pressure grinding roll according to claim 1, wherein part of the module protrudes longitudinally beyond the upper walkway support structure. 3. A high pressure grinding roll according to any preceding claim, wherein the housing includes a plurality of coupling formations operable to be used to couple the module to the upper walkway support structure and the lower structural plinth. 4. A high pressure grinding roll according to any preceding claim, wherein the module further comprises a pair of bearing housings pivotably coupled to the housing, and each including roller bearings coupled to a respective roller. 5. A high pressure grinding roll according to claim 4, wherein the module further comprises one or more of: an HPGR controller, an oil cooling system, an electrical wiring loom connecting the HPGR controller to an interface for coupling to a roller drive mechanism, and oil lubrication pipes connecting the oil cooling system to the roller bearings. 6. A high pressure grinding roll according to claim 5, wherein the interface comprises an electrical interface for coupling to an installed roller drive mechanism, so that the existing drive mechanism can be reused without requiring it to be replaced. 7. A high pressure grinding roll according to any preceding claim, wherein the module is sufficiently strong to support installed components under dynamic load. 8. A high pressure grinding roll according to any preceding claim, wherein the module further comprises one or more of: a pair of lateral wall assemblies, each lateral wall assembly being mounted in proximity to the roller gap; and a hydraulic actuator to urge a moveable roller towards a fixed roller and thereby control the roller gap. 9. A high pressure grinding roll according to any preceding claim, wherein the module extends beyond the upper walkway support structure in an axial direction of the rollers thereby allowing wider bearing housings to be accommodated than those previously used in the installed HPGR frame. 10. A retro-fitted HPGR comprising a structural frame from a previously installed HPGR, coupled to an HPGR module according to any preceding claim located therein, wherein the HPGR module is operable to sustain dynamic loads generated by counter rotating grinding mills mounted therein. 11. A retro-fitted HPGR according to claim 10, wherein the HPGR module is operable to provide static load support to an upper walkway support structure of the structural frame, and to transfer static loads, but not dynamic loads, to a lower structural plinth of the structural frame. 12. A retro-fitted HPGR according to claim 10, further comprising an ore feeding device mounted on top of the structural frame and aligned with: (a) a new roller gap between the pair of rollers mounted within the module, and (b) a previously installed storage hopper for feeding the previously installed HPGR with ore. 13. A method of upgrading an installed HPGR, the method comprising: (i) removing components of the installed HPGR to leave an installed frame and a roller drive mechanism; (ii) inserting an HPGR module into the installed frame; and (iii) coupling the HPGR module to (a) the installed frame to provide support to an upper part of the installed frame and to transfer static load from the HPGR module to a lower part of the installed frame, and (b) the roller drive mechanism to provide drive to rollers in the HPGR module. 14. A method according to claim 13, wherein the step of removing components comprises one or more of: temporarily removing an ore storage hopper above the installed HPGR; removing a feeding device; removing the HPGR rollers; removing bearing housings; removing a hydraulic actuator; and removing a drive coupling between the roller drive mechanism and the HPGR rollers. 15. A high pressure grinding roll module comprising: (i) a housing (a) designed for dynamic load-bearing when freestanding, (b) being dimensioned to be inserted into an installed frame and for coupling thereto, and to transfer static loads through a lower part of the installed frame during operation of the module, and (c) including an end wall operable to close a roller loading entrance; and (ii) a pair of rollers mounted within the housing and removable therefrom via the roller loading entrance closed by the end wall. 16. A high pressure grinding roll module according to claim 15, wherein the end wall opens and closes the roller loading entrance by (i) pivoting about an upper or lower part of the housing, or (ii) being completely removable from other parts of the module. 17. A method of installing an HPGR, the method comprising: (i) identifying an installed frame; (ii) inserting an HPGR module into the installed frame; and (iii) coupling the HPGR module to the installed frame to provide sufficient structural support for an upper part of the installed frame. 18. A method according to claim 17, the method comprising the further steps of: identifying any components coupled to the installed frame that are equivalent to components in the HPGR module; and removing those components prior to inserting the HPGR module into the installed frame. 19. A housing for a high pressure grinding roll module which couples to an installed high pressure grinding roll frame defining a space envelope, the housing: (i) being dimensioned to be inserted into the space envelope and coupled to the installed frame, (ii) having a pair of generally c-shaped structural supports mutually coupled by transverse structural supports such that the combination of structural supports in the housing provide sufficient dynamic load support for the module during operation, and (iii) including a removable end wall operable to close the c-shaped structural supports. 20. A composite high pressure grinding roll assembly operable to grind ore delivered thereto, the assembly comprising upper and lower support structures from a previously installed high pressure grinding roll and a high pressure grinding roll module operable independently as a high pressure grinding roll coupled to the upper and lower support structures. |
FIELD OF INVENTION
The invention relates to improvements in or relating to a high pressure grinding roll (HPGR).
BACKGROUND OF THE INVENTION
HPGRs are installed at mine sites to grind material using interparticle crushing. An HPGR has two rollers that are rotatably mounted in bearing housings and driven in opposite directions. The rollers are separated from each other by a roller gap. One roller is fixed in place, the other roller is moveable ( transverse to its axis) towards or away from the fixed roller.
An HPGR is heavy (several hundreds of tons in weight, typically approximately 500 metric tons for a medium sized HPGR) and experiences significant forces during operation. This requires an HPGR to include a structural frame to maintain the rollers, bearings, and other components in position during operation.
An HPGR is also typically installed in a comminution circuit of a mine site and receives ore to be grinded from an upstream crusher or grinder, and deliver the crushed output to downstream equipment, such as a ball mill. This requires a significant amount of conveyors, feeders, structurally-reinforced concrete plinths, and the like to be provided that are custom designed to match the footprint of an HPGR.
There are several different HPGR vendors, each providing a different design of HPGR, having a different footprint and different infeed conveyors, but many of the essential components are very similar (e.g. the rollers, the motors, the variable frequency drive (VFD) controllers for the motors), and the ore input and output areas are similar, in that they are above and below the gap between the rollers, but aligned for an input area of the specific vendor’s design of HGPR.
Nevertheless, replacing an HPGR from one vendor with an HPGR from another vendor involves a significant amount of rework because of the different footprints and designs of the HPGRs. This results in weeks or months during which the mine site would not be operational. This is a significant commercial cost for the mine, and therefore is a motivator against replacing an HPGR, even when the replacement HPGR has improved operational performance. Furthermore, it involves removal, transport and disposal of a significant number of large and expensive components that are otherwise fully operational, which has a negative impact on the environment.
It is among the objects of an embodiment of the present invention to overcome or mitigate one or more of the above disadvantages or other disadvantages of the prior art, or to provide a useful alternative. SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts that are further described in the detailed description below. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter. in this application relative terms are used, such as front, rear, up, down, etc., only for ease of the description and understanding of the embodiments, not by way of limitation. Ordinal numbers (first, second, third, etc.) are assigned arbitrarily herein, and are used to differentiate between parts, and do not indicate a particular order, sequence or importance.
According to a first aspect there is provided a high pressure grinding roll comprising a high pressure grinding roll module installed in a space envelope defined by an upper walkway support structure having an ore input area and a lower structural plinth having an ore output area, the module comprising: (i) a pair of upper support beams coupled to the upper walkway support structure; (ii) a pair of lower support beams mounted on the lower structural plinth; and (iii) a pair of counter-rotating grinding rollers mounted between the upper and lower support beams, wherein the upper and lower support beams are dimensioned to provide full structural support for the pair of grinding rolls during operation so that the high pressure grinding roll module comprises a fully operational high pressure grinding roll, even prior to mounting of the module into the envelope defined by the upper walkway support structure and the lower structural plinth.
Optionally, the high pressure grinding roll module protrudes longitudinally beyond the upper walkway support structure.
Optionally, the module includes a plurality of coupling formations (such as apertures through which bolts or rivets may be inserted) operable to be used to couple the module to the upper walkway support structure and the lower structural plinth (the “pre-installed components”)(for example, using nuts screwed onto bolts protruding through the apertures), or vice versa.
Optionally, the module further comprises a pair of bearing housings coupled to the module housing, and each coupled to a respective roller. Each bearing housing may include a thrust bearing and roller bearings. The roller bearings may be submersed in oil for lubrication. The roller bearings may be cylindrical. The thrust bearing may comprise an elastomer. Each bearing housing may be pivotably coupled to the module housing via a guiding bolt (or shaft) mounted on bearings within a shoe. The shoe may be located within a yoke mounted to the housing.
Each bearing housing may include roller bearings coupled to a respective roller. Optionally, the module further comprises one or more of: an HPGR controller, an oil cooling system, an electrical wiring loom connecting the HPGR controller to an interface for coupling to a roller drive mechanism, and oil lubrication pipes connecting the oil cooling system to the bearings. The interface may be a generic electrical interface for coupling to an installed roller drive mechanism (for example, motors, Carden shafts, and gearboxes), so that the existing drive mechanism can be reused without requiring it to be replaced.
The module, even when not coupled to the pre-installed components (that is, the upper walkway support structure and the lower structural plinth) is sufficient to allow the module to be operated under dynamic loads. The module is designed to handle forces from components mounted therein, and only uses the lower structural plinth to support the static load of the module.
Optionally, the module further comprises a pair of lateral wall assemblies (also referred to as cheek plates), each lateral wall assembly being mounted in proximity to the roller gap.
Optionally, the pair of counter-rotating grinding rollers comprise a fixed roller and a moveable roller.
Optionally, the module further comprises a hydraulic actuator (for example, a cylinder and press) to urge the moveable roller towards the fixed roller and thereby control the roller gap. Each hydraulic actuator may impact an elastomeric pad coupled to a bearing housing to which the moveable roller is connected.
Optionally, the module extends beyond the pre-installed components in an axial direction of the rollers (i.e. it is wider than the pre-installed components). This may be provided to accommodate wider bearing housings than those removed from the pre-installed components.
By virtue of this aspect, part of an installed HPGR (the upper walkway support structure and the lower structural plinth) can be left in place, together with the structural steel, concrete, and other fixings, while the main operating parts of one HPGR are replaced with a complete, fully operational, HPGR. This greatly reduces the time taken to replace the main functional parts of one vendor’s HPGR with another vendor’s entire HPGR; or most of the parts of one model of HPGR from one vendor with a different model of HPGR from the same vendor.
By virtue of this aspect, a new HPGR is provided that comprises a fully operational HPGR mounted within outer components of a previously installed HPGR.
According to a second aspect there is provided a retro-fitted HPGR comprising a structural frame from a previously installed HPGR, coupled to an HPGR module, wherein the HPGR module is operable to sustain dynamic loads generated by counter-rotating grinding mills mounted therein.
The HPGR module is operable to provide static load support to an upper walkway support structure of the structural frame, and to transfer static loads to a lower structural plinth on which the HPGR module is mounted.
The retro-fitted HPGR optionally further comprises an ore feeding device mounted on top of the structural frame and aligned with: (a) a new roller gap between the pair of rollers mounted within the module, and (b) a previously installed storage hopper for feeding the previously installed HPGR with ore.
According to a third aspect there is provided a method of upgrading an installed HPGR, the method comprising: (i) removing components of the installed HPGR to leave an installed frame and a roller drive mechanism; (ii) inserting an HPGR module into the installed frame; and (iii) coupling the HPGR module to (a) the installed frame to provide support to an upper part of the installed frame and to transfer static load from the HPGR module to a lower part of the installed frame, and (b) the roller drive mechanism to provide drive to rollers in the HPGR module.
The step of removing components may comprise one or more of: temporarily removing an ore storage hopper above the installed HPGR, removing a feeding device, removing the HPGR rollers, removing a hydraulic actuator, and removing a drive coupling between the roller drive mechanism and the HPGR rollers.
The step of removing components may include providing a support frame external to the installed HPGR and coupling an upper walkway support structure thereto.
The step of removing components may include providing a temporary support between an upper walkway support structure and a lower structural plinth to prevent the upper walkway support structure from falling when components of the installed HPGR are removed (such as end pieces extending between the upper walkway support structure and the lower structural plinth, the bearing houses, the rollers, and the like).
The HPGR module may have some or all of the features of the first aspect described above.
Upgrading an existing HPGR by removing the grinding related components (rollers, hydraulic actuator, bearing housings, and any lateral wall assemblies) and replacing them with a module containing these components enables a rapid changeout of one HPGR for another with minimal or no change to the upstream or downstream connections to the installed HPGR. This makes replacement of HPGRs commercially viable.
According to a fifth aspect there is provided a high pressure grinding roll module comprising: (i) a housing (a) designed for dynamic load bearing when freestanding, (b) being dimensioned to be inserted into an installed frame and for coupling thereto, and to transfer static loads through a lower part of the installed frame during operation of the module, and (c) an end wall operable to close a roller loading entrance; and (ii) a pair of counter-rotating rollers mounted within the housing and removable therefrom via the roller loading entrance closed by the end wall.
The end wall may open and close the roller loading entrance by (i) pivoting about an upper or lower part of the module, or (ii) being completely removable from other parts of the module.
According to a sixth aspect there is provided a method of installing an HPGR, the method comprising: (i) identifying an installed frame; (ii) inserting an HPGR module into the installed frame; and (iii) coupling the HPGR module to the installed frame to provide sufficient structural support for an upper part of the installed frame.
The method may include the further steps of: identifying any components coupled to the installed frame that are equivalent to components in the HPGR module; and removing those components prior to inserting the HPGR module into the installed frame.
According to a seventh aspect there is provided a housing fora high pressure grinding roll module which couples to an installed high pressure grinding roll frame defining a space envelope, the housing (i) being dimensioned to be inserted into the space envelope and coupled to the installed frame, (ii) having a pair of generally c-shaped structural supports mutually coupled by transverse structural supports such that the combination of structural supports in the housing provide sufficient dynamic load support for the module during operation, and (iii) including a removable end wall operable to close the c-shaped structural supports .
According to an eighth aspect there is provided a composite high pressure grinding roll assembly operable to grind ore delivered thereto, the assembly comprising upper and lower support structures from a previously installed high pressure grinding roll and a high pressure grinding roll module operable independently as a high pressure grinding roll coupled to the upper and lower support structures.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Fig. 1 is a simplified front elevation view of a prior art installed HPGR for retrofitting with an HPGR module according to one embodiment of the present invention;
Fig. 2 is a simplified side elevation view of the installed HPGR of Fig. 1 ;
Fig. 3 is a simplified perspective view of an HPGR module according to an embodiment of the present invention; Fig. 4 is a simplified perspective view of part of the HPGR module (the housing) of
Fig. 3;
Fig. 5 is a simplified front elevation view of the installed HPGR of Figs. 1 and 2 after several components have been removed to leave an installed frame and another component (not shown in Fig. 5), which is a deconstructed HPGR;
Fig. 6 is a simplified side elevation view of the deconstructed HPGR of Fig. 5 illustrating the installed frame and a roller drive mechanism (the other component not shown in Fig. 5);
Fig. 7 is a simplified perspective view illustrating the installed frame of the deconstructed HPGR of Figs. 5 and 6;
Fig. 8 is a simplified perspective view illustrating a first part (a housing) of the HPGR module of Fig. 3 fully inserted into the installed frame of the deconstructed HPGR of Figs. 5 and 6;
Fig. 9 is a simplified perspective view illustrating the housing and a second part (hydraulic cylinders) of the HPGR module of Fig. 3 fully inserted into the installed frame of the deconstructed HPGR of Figs. 5 and 6;
Fig. 10 is a simplified perspective view similar to Fig. 9 but also illustrating a third part (a moveable roller assembly) of the HPGR module of Fig. 3 fully inserted into the installed frame of the deconstructed HPGR of Figs. 5 and 6;
Fig. 11 is a simplified perspective view similar to Fig. 10 but also illustrating a fourth part (a fixed roller assembly) of the HPGR module of Fig. 3 fully inserted into the installed frame of the deconstructed HPGR of Figs. 5 and 6;
Fig. 12 is a simplified perspective view similar to Fig. 11 but also illustrating a fifth part (an end wall) of the HPGR module of Fig. 3 fully inserted into the installed frame of the deconstructed HPGR of Figs. 5 and 6;
Fig. 13 is a simplified perspective view from the drive side of the HPGR module of Fig. 3 fully inserted into deconstructed HPGR of Figs. 5 and 6 to create an upgraded HPGR; and
Fig. 14 is a simplified perspective view from the non-drive side of the upgraded HPGR shown in Fig. 13.
DETAILED DESCRIPTION OF EMBODIMENTS
Reference is now made to the drawings, and particularly to Figs. 1 and 2, which are simplified views of a prior art installed HPGR 10 together with some installation features associated with that HPGR.
The HPGR 10 has a length (in a direction labelled “L” in Fig. 1) and a width (in a direction labelled “W” in Fig. 2) and is mounted on a reinforced concrete base 12 and includes a structural frame 14 (also referred to as an installed frame) in which are mounted two pairs of bearing housings 16, each pair of bearing housings 16 is axially aligned in the width direction and supports a shaft 18 on which a roller 20a, b is mounted. The bearing housings 16 provide additional structural rigidity to support the structural frame 14. The pair of rollers 20a, b rotate in opposite directions and define a gap 21 therebetween. Each bearing housing 16 is coupled to the structural frame 14 via a key extending through a keyway 22 mutually defined by the structural frame 14 and the bearing housing 16.
In this example, the structural frame 14 defines a volumetric space therein of approximately 6.85m in length by 2.73m in width by 2.7m in height (referred to as the volumetric envelope or the space envelope). In other examples, the volumetric envelope may be larger or smaller, depending on the size of the installed HPGR 10. The structural fram 14 comprises an upper walkway support structure 14a and a lower structural plinth 14b.
The HPGR 10 also includes hydraulic cylinders 24 for urging one of the rollers 20a (the moveable roller) towards the other roller 20b (the fixed roller). In this example, the hydraulic cylinders 24 are located near a closed end 26 of the structural frame 14.
The structural frame 14 includes a removable sheet metal door 28 on each side thereof. The doors 28 are located at an insertion end 30 of the structural frame 14. The doors 28 are removable to leave an opening 32 in the structural frame 14 that allows the rollers 20a, b to be slid out from the structural frame 14 via the opening 32. The doors 28 do not provide significant structural support to the structural frame 14.
A roller transport unit 34 is provided adjacent the structural frame 14 and aligned in the length and width directions with the structural frame 14 so that it provides a continuation thereof. This allows a roller 20a, b to be removed from the structural frame 14 and slid onto the roller transport unit 34 to facilitate maintenance or replacement of the rollers 20a, b. This is illustrated in Fig. 1 by an additional roller 20b’ (shown in broken or ghost lines) that represents the fixed roller 20b when it is moved outside the structural frame 14.
The HPGR 10 includes an ore feeding device 36 mounted above the roller gap 21 for choke feeding ore thereto, and an ore storage hopper 38 (also referred to as a pre-bin) for supplying ore to the ore feeding device 36. Feed conveyors 40 are provided that supply ore to the ore storage hopper 38.
In this example, the bearing housings 16 of the fixed roller 20b are designed to be load bearing and they provide support to the structural frame 14, but this means that the bearing housings 16 cannot skew.
The structural frame 14 is designed to support dynamic loads on the HPGR 10, such as when the HPGR 10 is grinding ore. Typical dynamic loads (pressing forces from the hydraulic cylinders) may be in excess of 17MN. However, rollers 20a, b are only removed when the HPGR 10 is shut down, so only static loads are present, and these generally act downwards, rather than horizontally. Static loads are generally below 6MN, and may be significantly lower (below 1MN or even 500kN) depending on the weight of the rollers 20a, b, shafts 18, bearing housings 16 and the like. When the rollers 20a, b (and bearing housings 16) are being removed or inserted, the structural frame 14 is temporarily supported by a hoist or gantry (not shown) during the changeover.
Some components of the HPGR 10 are only visible in Fig. 2 (they were removed from Fig. 1 for clarity). These components include a pair of motors 42 (one for each roller 20a, b). Each motor 42 is coupled to a Cardan shaft unit 44 that imparts rotational movement to a gearbox 46, which powers a drive coupling 48 that connects to the respective roller shafts 18 of the rollers 20a, b. The combination of the motor 42, the Cardan shaft unit 44, and the gearbox 46 may be referred to as a roller drive mechanism.
Reference will now be made to Fig. 3, which illustrates an HPGR module 100 according to one embodiment of the present invention.
The HPGR module 100 comprises a housing 102 dimensioned to be inserted into the structural frame 14 via the frame opening 32, and to handle dynamic loads from components within a the HPGR module 100 without transferring these loads to the structural frame 14. The housing 102 has a height slightly smaller than the internal height of the volumetric envelope of the structural frame 14. In this embodiment, the width of the housing 102 is slightly larger than the width of the volumetric envelope of the structural frame 14.
The HPGR module 100 further comprises two pairs of bearing housings 116 each pair of bearing housings 116 is axially aligned in the width direction and supports a shaft 118 (best seen in Fig. 13) on which a roller 120a, b is mounted. The pair of rollers 120a, b rotate in opposite directions, one roller 120a being moveable in the longitudinal direction, the other roller 120b being fixed in the longitudinal direction, and define a gap 121 therebetween through which ore will be directed, and ground between the rollers 120a, b. The HPGR module 100 also comprises a pair of hydraulic cylinders 124 for urging the bearing housings 116 of the moveable roller 120a towards the fixed roller 120b.
The bearing housings 116 include a bearing guide assembly 150 coupled to upper and lower portions thereof. As best seen from the enlarged detail of Fig. 14, each bearing guide assembly 150 includes a guiding bolt 152 mounted on bearings (not visible) enclosed by a bolt shoe 154, to allow rotation of the guiding bolt 152 about a vertical axis, as will be described in more detail below. The guiding bolt 152 also retains the bearing housings 116 in alignment as they are mounted in, and removed from, the housing 102.
Reference will now also be made to Fig. 4, which illustrates the housing 102 in more detail. The housing 102 is generally symmetrical about a longitudinally axis 160 bisecting the width of the HPGR module 100. The housing 102 comprises a plurality of interconnected beams (made of steel in this embodiment). When viewed from the front or rear (i.e. perpendicular to the longitudinal axis 160), the beams form front and rear rectangular frames 162a,b connected by upper and lower connecting beams 164a,b at the module insertion end 172 and upper and lower offset beams 165a, b at the module opening end 176.
The housing 102 comprises a pair of lower structural beams 166a, b, each extending along the longitudinally axis 160; a pair of upper beams 168a, b, each aligned with and spaced above its respective lower beam 166a,b; a pair of upright stanchions 170a,b, each extending between a respective one of the lower beams 166a,b and one of the upper structural beams 168a, b at a module insertion end 172 (also referred to as a closed end); and a pair of end walls 173a,b extending between the opposite ends of respective lower beams 166a, b and upper beams 168a, b at a module opening end 176. In this embodiment, the pair of end walls 173a, b comprise a pair of removable end pieces 174a, b and a pair of structural walls 178a,b, which are located adjacent the removable end pieces 174a,b. Each structural wall 178a,b is secured to its respective lower beam 166a,b and upper beam 168a,b to support the removable end pieces 174a,b against longitudinal forces exerted by the hydraulic cylinders 124 and to support the lower beams 166a,b and upper beams 168a,b, for example, against vertical forces.
The removable end pieces 174a,b are generally n-shaped (when viewed along the longitudinal axis 160).
In this embodiment, the upper beams 168a, b extend longitudinally beyond an upper beam of the structural frame 14 at the insertion end 30 thereof. The term “end walls” is used herein to refer to either the removable end pieces 174a, b, or the structural walls 178a, b or a combination of both the removable end pieces 174a, b, and the structural walls 178a, b.
Each of the lower beams 166a,b defines a narrowed region 180a,b at the module opening end 176, and each of the upper beams 168a,b defines a corresponding narrowed region 182a, b at the module opening end 176 (best seen in Fig. 10). Respective narrowed regions 180a, 182a; 180b, 182b are aligned so that each n-shaped removable end piece 174a,b slides over and straddles its respective narrowed region. The structural walls 178a,b are mounted on the width portions of the lower beams 166a,b and upper beams 168a,b, adjacent the narrowed regions.
The housing 102 also includes a pair of end stanchions 184a,b, each located behind a respective upright stanchion 170a,b and extending vertically between a respective lower and upper beam 166, 168.
Each of the hydraulic cylinders 124 acts against an upright and end stanchion combination 170,184. The housing 102 also includes generally L-shaped yokes 186 that are mounted on, and protrude laterally (in the width direction) from, an external side surface of the lower beams 166a,b and one (or both if desired) of the upper beams 168a,b. Each yoke 186 and its respective beam 166a,b 168 defines a channel in which the bolt shoe 154 is located (best seen in the enlarged detail in Fig. 14). This arrangement allows the bearing housings 116 to skew by rotating around a vertical axis and to move by a small amount in the longitudinal direction, while being supported by its respective yoke 186.
The installation of the HPGR module 100 will now be described with reference to Figs. 1 to 12. Initially, the HPGR 10 is identified as being suitable for being upgraded with the HPGR module 100, for example, because the housing 102 can be accommodated within the height of the volumetric envelope of the HPGR 10 as a reasonably tight fit, and the roller gap 121 aligns with the roller gap 21 of the HPGR 10 when the HPGR module 100 is inserted therein.
Next, various components of the HPGR 10 are removed. Some of these components will be reused in, or with, the upgraded HPGR, others will not be reused.
In this embodiment, the removed components include: the ore storage hopper 38 (which will be reused), the ore feeding device 36, the roller transport unit 34, the bearing housings 16, the roller shafts 18, the rollers 20a, b, the hydraulic cylinders 24, and the drive coupling 48 (none of these will be reused). This leaves the structural frame 14 mounted on the concrete base 12 and optionally the roller drive mechanism (that is, the motor 42, the Carden shaft 44, and the gearbox 46). This is illustrated in Figs. 5 and 6. Some control circuitry and cabinetry may also be present, but this is not shown for clarity.
A temporary support (not shown) is inserted between the upper walkway support structure 14a and the lower structural plinth 14b to prevent the upper walkway support structure 14a from falling when components of the installed HPGR 10 are removed.
The next stage is for the HPGR module 100 to be transported to the HPGR 10 and inserted into the structural frame 14. In this embodiment, it is performed in stages (rather than the entire HPGR module 100 being inserted as a single unit); for example, the bearing housings 116, shafts 118, rollers 120a, b, and hydraulic cylinders 124 are temporarily removed on site where the HPGR 10 is located. This is shown in different stages in Figs. 8 to 12.
A new roller transport unit (not shown) is provided to replace the removed roller transport unit 34. This new roller transport unit is designed to allow the bearing housings 116 to slide therealong for loading them into, or removing them from, the HPGR housing 102.
The module insertion end 172 of the HPGR housing 102 is aligned with the opening 32 of the structural frame 14 and a hoist is used to slide the HPGR housing 102 therein. When fully inserted, the HPGR housing 102 is secured to the structural frame 14 using bolts, clamps, or any other convenient coupling mechanism. This enables the housing 102 to support the upper walkway support structure 14a. The housing 102 only transfers static loads (e.g. the weight of the HPGR 100 and the upper walkway 14a) to the lower structural plinth 14b. Although not illustrated in the figures, the housing 102 is also secured to the structural frame 14 using bolts through apertures in the housing 102 that align with apertures in the structural frame 14. The inserted housing 102 is illustrated in Fig. 8.
The hydraulic cylinders 124 are then slid into the housing 102 until they reach the upright stanchions 170a,b and are then secured thereto (for example, using bolts). This is illustrated in Fig. 9.
The moveable roller set is then inserted into the housing 102 (that is, the bearing housings 116, shaft 118, and moveable roller 120a) and the bolt shoes 154 of the bearing housings 116 are located in their respective yokes 186. This is illustrated in Fig. 10.
The fixed roller set is then inserted into the housing 102 (that is, the bearing housings 116, shaft 118, and fixed roller 120b) and the bolt shoes 154 of the bearing housings 116 are located in their respective yokes 186. This is illustrated in Fig. 11.
The pair of removable end pieces 174a,b are then coupled to the opposite ends of respective lower beams 166a,b and upper beams 168a,b at the module opening end 176. In this embodiment, the removable end pieces 174a, b are lowered over, and straddle, the respective lower beams 166a,b and upper beams 168a,b. The removable end pieces 174a,b include an elastomer pad on a surface facing the fixed roller 120b so that the fixed roller 120b urges against this elastomer pad when the hydraulic cylinder 124 actuates the moveable roller 120a. The elastomer pad ensures that the forces are correctly transferred to its respective removable end pieces 174a,b in a balanced manner. The end pieces thereby provide resistance to horizontal forces imparted by the hydraulic cylinders 124 during operation of the HPGR module 100. The structural walls 178a, b are then connected between opposing faces of the lower beams 166a,b and the upper beams 168a,b. This is illustrated in Fig. 12.
A new drive coupling 190 (see Figs. 13 and 14) is provided to couple the remaining roller drive mechanism (that is, the motor 42, the Carden shaft 44, and the gearbox 46) to each of the newly-installed shafts 118.
A new ore feeding device 136 (only shown in section in Fig. 14) is then mounted on the structural frame 14 above the housing 102 in registration with both the roller gap 121 and the original ore storage hopper 38, which is then mounted above the new ore feeding device As illustrated in Figs. 13 and 14, this results in an upgraded HPGR 200 that includes the populated HPGR module 100 inserted within, and securely coupled to, the structural frame 14. The enables the upgraded HPGR 200 to be aligned with upstream and downstream equipment that was designed for the original HPGR 10.
An optional bridge frame 188 may be provided (as shown in Figs. 13 and 14) to support the upper walkway support structure 14a at the module opening end 176 when the components of the HPGR 10 are removed to facilitate insertion or removal of the components located within the housing 102.
It will now be appreciated that the HPGR 10 can be upgraded with a new HPGR module 100, which may include improved bearings (for example, having a thrust bearing and cylindrical roller bearings that are submersed in oil for lubrication) that allow skewing thereof. This allows in situ replacement of most of the key operational components of an HPGR without having to change any of the surrounding infrastructure, including the feeds, conveyors, concrete bases, drive mechanism, and the like. This enables in situ upgrade of an HPGR in a rapid timescale that was previously not possible.
Combining key components in the housing 102 allows easy acceptance testing of the components as a single assembly.
An upper walkway structure (not shown) having rails, ladders, and the like, that allows operators to walk above the HPGR and to inspect parts thereof, may be coupled to the upper walkway support structure 14a.
Various modifications may be made to the above embodiments within the scope of the present invention. For example, in other embodiments, the populated HPGR module 100 may be inserted into the structural frame 14 as a single unit, rather than the unpopulated housing 102 being inserted first then populated with the hydraulic actuators 124, rollers 120a, b and removable end pieces 174a,b.
In other embodiments, each end wall 173a, b may comprise a single unit rather than a combination of two units (i.e. the combination of the removable end pieces 174a,b and the structural walls 178a, b).
In other embodiments the gearbox 46 and drive coupling 48 may be replaced by a new gearbox that does not require a drive coupling.
In the foregoing description of certain embodiments, specific terminology has been used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "upper" and "lower", "above" and "below" and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms, nor to imply a required orientation of the seal assembly. The word “or” is used to indicate that one or more of the words listed may be present, unless the context requires the disjunctive use.
In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of’. A corresponding meaning is to be attributed to the corresponding words “comprise", "comprised" and "comprises" where they appear.
The preceding description is provided in relation to several embodiments which may share common characteristics and features. It is to be understood that one or more features of any one embodiment may be combined with one or more features of the other embodiments. In addition, any single feature or combination of features in any of the embodiments may constitute additional embodiments.
In addition, the foregoing describes only some embodiments of the inventions, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope of the disclosed embodiments, the embodiments being illustrative and not restrictive.
List of reference numerals:
High Pressure Grinding Roll (HPGR) 10 Roller 120a, b Concrete base 12 Roller gap 121 Structural frame 14 Hydraulic cylinders 124 Upper walkway support structure 14a Ore feeding device 136 Lower structural plinth 14b Bearing guide assembly 150 Bearing housings 16 Guiding bolt 152 Roller shaft 18 Bolt shoe 154 Roller 20a, b Longitudinal axis 160 Roller gap (or nip) 21 Front and rear rectangular frames 162a, b Keyway 22 Upper and lower connecting beams
Hydraulic cylinders 24 164a,b
Closed end (of structural frame) 26 Upper and lower offset beams 165a,b
Sheet metal door 28 Module insertion end 172
Insertion end (of frame) 30 Lower structural beams 166a,b
Opening (of frame) 32 Upper structural beams 168a, b
Roller transport unit 34 Upright stanchions 170a,b
Ore feeding device 36 Module insertion end 172
Ore storage hopper (pre-bin) 38 End walls 173a, b
Feed conveyors 40 Removable end pieces 174a, b
Motor 42 Module opening end 176
Carden shaft 44 Structural walls 178a,b
Gearbox 46 Lower beam narrowed region 180a,b
Drive coupling 48 Upper beam narrowed region 182a,b
End stanchions 184a, b
HPGR module 100 Yokes 186 HPGR module housing 102 Bridge frame 188 Bearing housings 116 Drive coupling 190 Roller shaft 118 Upgraded HPGR 200