Rudarstvo - Fabrika Za Oplemenjivanje Rude

NPO "RIVS" supplies with:
Crushingcomminuting equipment.
Flotation machines for all kinds of the ores and nonmetallic materials.
Vats for different stages of processing and for chemical processes.
Screens for dry and wet classification.
Hydrocyclones and hydrocyclone batteries.
Sandy centrifugal pumps.
Sumps and tanks for different purposes.
Means of automation of the miningconcentration equipment.
Different types of the reactant feeders.
Spares for miningconcentration equipment.
Rubbertechnical items (articles) for miningconcentration equipment.
COMPANY CARRIES OUT:
Projecting and construction of the new enterprises.
Reconstruction of the operating enterprises.
Study, working out and putting into operation of the new
technologies of concentrating of the useful minerals.
Working out of technological regulations, putting into prac
tice of the new technologies with reaching of guaranteed
technological parameters at the working enterprises.
Audit of the concentration facilities.
Working out and making of the new machines and
mechanisms.
Modernization of the miningconcentration equipment.
Working out of ACSTP of the concentration factories.
Complex automation of technological processes and
facilities of concentrating of the raw minerals.
Service of equipment and supply with spares.
NPO "RIVS" JSC, Zheleznozavodskaya str., 11, lit. A, S.Petersburg, Russia, 199155
tel. +7 (812) 326 10 02, 321 57 05, fax +7 (812) 327 99 61, email: rivs@rivs.ru, www.rivs.ru
Contents
SCIENTIFICPRODUCTION CORPORATION SCIENTIFICPRODUCTION CORPORATION
working up and putting into practice of the mod
ern technologies for concentrating of the ores of
nonferrous and precious metals, ironcontenting
and oxidized ores, nonmetallic minerals, chemical
and mancaused raw materials;
technical reequipment of the miningconcentra
tion combines and enterprises of construction in
dustry with application of the own technologies and
equipment and modern foreign equipment;
increase of output of the marketable products
owing to increase of: quality of the concentrates,
metals extraction in the concentrate, productivity of
the concentration factories;
decrease of the cost of every ton of processed ore.
Flotation machines RIF of pneumaticmechanical type in the
module and vat performance with volume of the chambers
from 0.5 to 130 m
3
; mechanical type with volume of the cham
bers from 0.2 to 12.5 m
3
; pneumatic (columnar) type with vol
ume of the chambers from 1.2 to 50 m
3
.
Every flotation machine is equipped with automated systems
of stabilization and control of the level. In the case of necessi
ty they are equipped with the systems of stabilization and con
trol of the pulp density in the chamber.
Flotation machines RIF are produced for different flotation op
erations taking into account ability of the raw minerals to be
processed. In accordance with the Customer's demand flota
tion machines may be equipped with the suction blocks.
Contact vats for mechanical mixing of the pulp in the course
of treatment with the reactants and for application of the vats
as the sumps by capacity from 1 to 100 m
3
.
Aeration vats from 6.5 to 100 m
3
capacity for conditioning of
the ore pulp.
The spheres of activity of the corporation
"RIVS" are:
Scientificproduction corporation RIVS
works out and produces:
Corporation works up and puts into practice the systems of automated control
and adjusting of parameters of equipment and systems for technological processes
of concentrating of the ores of useful minerals (ACSTP).
Scientificproduction corporation RIVS works out and produces:
Hydrocyclones with evolute input of feeding:
rubber GCR 250, 380 and combined GCK
250, 380, 500. Automated battery units for differ
ent productivity by feeding have been worked up
on the base of above mentioned hydrocyclones.
Screens of the type GRI (GIT) from the second
to eighth sizes and type GRS (GST) from third to
eighth sizes. New approach to design permits to
make the screens of the big sizes with the screen
ing area 24 m
2
and more. The screens are
equipped with the rubber sieves with rectangular
and square cells for different working conditions.
Aeration units for modernization of flotation ma
chines of the types FPM or OK with volume of the
chambers from 1.5 to 130 m
3
.
Absorbers for the screens; lining of the helical classifiers, hy
drocyclones, ball mills; aeration units for mechanical flotation
machines; elbows for nonpressure pulp pipelines; rubber cou
plings; reinforced lining for the working chambers of flotation
machines and contact vats; rubber plugs for systems of adjust
ing of level of the pulp in flotation machines; rubber plugs for
sumps, vats and distributive boxes.
Unique recipes of the rubber mixtures with provision for particu
larities of application of equipment at the enterprises ensure high
wear capability and longevity of the products.
Contents
i n t ransl at i on f rom Russi an i n t ransl at i on f rom Russi an
FOUNDING MEMBERS:
"Alrosa" jsc, "Apatit" jsc, "Mekhanobrtechnica" jsc, Moscow state mining university,
Moscow state exploration university named after Sergo Ordzhonikidze,
"Ore and Metals" Publishing house
With assistance of "Gornopromyshlenniki Rossii" noncommercial partnership
With participation of URAN IPKON RAN, FGUP "TsNIGRI",
Zapolyarny (Transpolar) affiliate of "Norilsk Nickel" mining and metallurgical company,
State Hermitage museum
L. A. Vaisberg, Chairman of the managing board
EDITORIAL STAFF:
L. A. Puchkov, EditorinChief, A. G. Vorobiev, Deputy EditorinChief, S. A. Il'yin, Mining consultant,
O. V. Fedina, Responsible secretary, L. E. Kostina, Leading editors, O. S. Myakota, Leading editors
EDITORIAL BOARD:
V. M. Avdokhin, V. A. Chanturiya (Head of "Processing and complex usage of mineral resources" section), Yu. K. Dyudin,
L. D. Gagut, S. A. Goncharov, V. V. Istomin, N. O. Kaledina (Head of "Protection of labour and environment" section),
D. R. Kaplunov (Head of "Deposit development" section), A. V. Korchak, E. A. Kotenko, E. A. Kozlovsky (Head of "Raw
material base" section), B. N. Kutuzov, V. G. Lerner, V. S. Litvinenko, A. B. Makarov, Yu. N. Malyshev, N. N. Melnikov,
O. S. Myakota, A. I. Perepelitsyn, V. L. Petrov, M. E. Pevzner (Head of "Economics and legislation" section),
G. G. Pivnyak, L. A. Puchkov, M. I. Shchadov, E. E. Sheshko (Head of "Mining equipment, power supply and automation"
section), Yu. V. Shuvalov, B. I. Smirnov, A. I. Sukhoruchenkov, K. N. Trubetskoi, , L. A. Vaisberg, I. V. Zyryanov
Analytical group of editorial board:
V. I. BorshchKomponiets, C. A. Ilin, S. L. Iofin (Head of group), V. I. Ganitskii, V. P. Gritsaev, V. N. Mosinets,
A. A. Novikov, M. G. Sedlov. R. I. Semigin, E. M. Titievsky, A. P. Velichko
Heads of representative offices in CIS and Russian regions:
S. S. Arzumanyan (Armenia), A. M. Babets (Kursk Magnetic Anomaly, Russia), N. I. Dyadechkin (Krivbass
Krivoi Rog
fields, Ukraine), A. Ibrokhim (Tadzhikistan), Yu. F. Il'insky (Moldova), V. M. Kirienko (Belorussia), K. Z. Kyrmanaliev
(Kyrgyzstan), O. N. Mal'gin (Kyzylkum region, Uzbekistan), Yu. A. Mamaev (Far Eastern region), O. A. Odekov
(Turkmenistan), M. V. Ryl'nikova (South Ural, Russia), A. F. Tsekhovoi (Kazakhstan), A. G. Tvalchrelidze (Georgia),
V. L. Yakovlev (Middle and Polar Ural, Russia), A. V. Zberovsky (DonetskDnepropetrovsk region, Ukraine)
The editor's address:
Office G550, G556, G557, Moscow State Mining University (MGGU),
6 Leninsky Prospect, Moscow, GSP1, 119049, Russia
Phone/fax: +74952369748, +74952369718
Email: gornjournal@rudmet.ru
Internet: www.rudmet.ru
Approved for printing on June 9, 2009
6 printer's sheets
Issuing editor E. V. Plotnikova
Computer design and makeup by X. L. Osina
Printed by "Street print" printing house (Russia, 115114, Moscow, Derbenevskaya ul., 20, bld.2)
E U R A S I A N MI N I N G
E U R A S I A N MI N I N G
N 2. 2009
N 2. 2009
(Gornyi Zhurnal ) (Gornyi Zhurnal )
Trade mark and title "Eurasian Mining" are exclusive property of "Ore and Metals" publishing house.
The journal is registered in the RF Ministry of Press (Certificate PI No. 7717550 dated 09.03.2004).
Gornyi Zhurnal (Russian Edition), 2009
All rights reserved. This publication or parts there of may not be reproduced in any form without permission of the publisher.
Contents
2
EURASIAN MINING GORNYI ZHURNAL 2. 2009
NTENTS
STABILITY AS A PLEDGE OF SUCCESS STABILITY AS A PLEDGE OF SUCCESS
3 Zimin A. V. Stability as a Pledge of Success (17th Anniversary of the Company Development,
Manufacture, Putting into Practice, Service RIVS)
ORE PREPARATION ORE PREPARATION
5 Kruppa P. I., Nesterov P. O. Putting into practice modernized technologies and development
of prospective directions in ore preparation
9 Ivanov A. I. Uptodate vibroscreens of RIVS scientific and production corporation
ORE CONCENTRATION TECHNOLOGY ORE CONCENTRATION TECHNOLOGY
15 Zimin A. V., Arustamyan M. A., Nazarov Yu. P., Ganbaatar Z. Development and putting into practice
the new technology of concentration of coppermolybdenum ores at Erdenet works
19 Yagudin R. A., Yagudina Yu. R., Zimin A. V., Nemchinova L. A. Technological improvement of ore flotation
at the concentrating plant of Uchalynsky mining and concentrating works
23 Shumskaya E. N., Nazarov Yu. P., Smirnov Yu. A., Arustamyan A. M., Kovalchuk Kh. U.
Quality improvement of iron ore concentrates via the method of back cationic flotation
EQUIPMENT EQUIPMENT
27 Trushin A. A. Usage of technical remedies developed by RIVS scientific and production corporation
in uptodate automated control systems for technological processes in concentrating plants
31 Sedov A. V., Skarin O. I., Serpetsky B. P. Development and putting into practice the automated
pumphydrocyclone units, manufactured by RIVS scientific and production corporation,
at the concentrating plant
EXPERIENSE OF RECONSTRUCTION OF CONCENTRATING FACILITIES EXPERIENSE OF RECONSTRUCTION OF CONCENTRATING FACILITIES
37 Arustamyan M. A., Sataev I. Sh., Kultin B. A. The main regulations of designing activity of RIVS
scientific and production corporation in mining and concentrating production
43 Abdrakhmanov I. A., Yagudin R. A., Zimin A. V., Arustamyan M. A., Kalinin E. P. Improvement
of equipment and technology at Uchalinskaya concentrating plant during 20002008
48 Akopyan M. A., Markaryan A. V., Besirganyan K. V., Arustamyan M. A., Galich V. M., Nazarov A. V.
The first results of reequipment at Kadzharan concentrating plant
EQUIPMENT AND TECHNOLOGIES FOR ENVIRONMENT PROTECTION EQUIPMENT AND TECHNOLOGIES FOR ENVIRONMENT PROTECTION
52 Zimin A. V., Gusar L. S., Yagudin R. A., Boduen A. Ya. Pilotindustrial testing of the technology
for hydrometallurgical dezincing of the copper concentrate from Uchalinsky mining and concentrating works
Contents
STABILITY AS A PLEDGE OF SUCCESS
3
The company RIVS (Development, Manufacture,
Putting into practice, Service) has been set up in 1991 for
solution of the complex tasks of processing of the ores of
nonferrous and rare metals.
The group of experienced constructors and technologists
of experimentalconstructor department of the former All
Union scientificresearch and projecting institute
Mekhanobr has become the main body of the collective.
Today NPO (ScientificProduction Corporation)
RIVS JSC includes the facilities ensuring the total com
plex of the works beginning from working up of the tech
nologies of the raw ore processing to supply of the mining
concentrating combines with equipment for achievement of
the guaranteed technological parameters.
NPO RIVS JSC disposed of the high qualified per
sonnel of researchers specialists in the field of the ore pro
cessing, constructors, mechanical engineers, specialists in the
field of automated systems of processing factories and facili
ties for output of the ferrous, nonferrous and rare metals.
There are three Academician of Departmental Acade
mies, two Doctors and twelve Candidates of the Technical
science in the staff of the employees. The most of the spe
cialists have a long length of the practice work.
The new subdivision of the company RIVSpro
ject JSC has been set up in 2005. The project works car
ried out by RIVSproject JSC were widely practiced at the
Russian and foreign enterprises of nonferrous and ferrous
metallurgy.
The branches and representations of the company have
been set up and function in Mongolia, Armenia, Ukraine,
Uzbekistan, at the Urals, at the Kola Peninsula.
NPO RIVS JSC has its own production capacities
for manufacturing of the mining and processing equipment.
The plant of the rubbertechnical articles is the member
of the corporation. The articles of the plant are dispatched
to the more than 150 customers in CIS and Mongolia.
Jointly with Uralmash Ltd. the corporation carries out
modernization, working up of the new technologies of the
ore preparing, supply with the new crushingcomminuting
equipment. Mobility of production permits to NPO
RIVS JSC to produce and to deliver to the customer of the
equipment and spares in the shortest time. Every year it is
produced 300400 cells for flotation machines with the vol
ume 0.5100 m
3
according to the orders of the enterprises.
Producing of the equipment at the level of the leading
world manufacturers by the quality and technological para
meters was the main task of setting up of industrial structure
of NPO RIVS JSC.
Usage of the modern materials, application of the best
foreign units and modern equipment permit to corporation
to produce equipment in accordance with the world stan
dards at the new qualitative level.
NPO RIVS JSC produces at its industrial facilities
the wide range of the spares for newly produced equipment
and for operating one.
The corporation carries out technical and
technological accom
pani ment
A. V. ZIMIN (NPO RIVS JSC)
A. V. ZIMIN, General Director
(17TH ANNIVERSARY OF THE COMPANY
DEVELOPMENT, MANUFACTURE, PUTTING
INTO PRACTICE, SERVICE RIVS)
(17TH ANNIVERSARY OF THE COMPANY
DEVELOPMENT, MANUFACTURE, PUTTING
INTO PRACTICE, SERVICE RIVS)
Contents
NPO RIVS DEVELOPMENT, MANUFACTURE, PUTTING INTO PRACTICE, SERVICE
4
of its mining and processing equipment within the whole
period of exploiting of the last one.
The corporation has gained the great experience of
modernization and reconstruction of equipment of process
ing plants after the long period of the machines exploiting.
The customer is guaranteed achievement of the higher tech
nological and operational parameters. For example, appli
cation in the course of modernization of mechanical and
pneumatic mechanical flotation machines and aeration sys
tems RIF have permitted to increase the quality of the con
centrates and extraction of the useful components.
Providing of exploiting screens with the rubber sieves
ESALH has allowed eliminate adherence of the ore in
period autumnwinterspring, to increase screening effi
ciency and to increase the life of the units of the screens.
The corporation uses widely its new ideas for modern
ization of the operating machineries. The high degree of
unification and suitability for repairs are the basis of the
works of NPO RIVS JSC. So, modernization of
machinery may be carried out at the site in the shortest time.
For example, after scientific researches it has been
worked up the project, made and supplied technological
equipment, carried out the setting and adjusting works and
put into operation the second section of the collective cycle
of coppermolybdenum flotation with annual output 6 mil
lion tons. Above mentioned works have been carried out for
concentration factory Erdenet (Mongolia). The factory is
one of the ten leading world producers of the copper and
molybdenum concentrates. As a result productivity of the
section has increased 1.5 times, and molybdenum extrac
tion has increased twice as much.
There are a lot of others successful examples in Russia
and in CIS, Asia and Europe. Modern technologies of pro
cessing of the minerals and competitive equipment were
worked up and made at the facilities of NPO RIVS. The
basis of RIVS is stability, reliability, high efficiency.
Reconstruction of concentration factory
at Uchalinsky GOK, Uchaly, Russia
Reconstruction of flotation section of concentration
factory Almalyksky GMK JSC, Almalyk, Uzbekistan
Section of flotation final treatment of the magnetite
concentrates at Inguletsky GOK, Krivoy Rog, Ukraine
Reconstruction of flotation section of Concentration
Factory of Zangezursky MMK, Kadjaran, Armenia
Second section of the collective cycle
of the coppermolybdenum flotation.
KOO Enterprise Erdenet, Mongolia
EM
Contents
ORE PREPARATION
5
The most significant expendi
tures at the concentration factories
are stipulated by the ore prepara
tion: capital 5060%, opera
tional to 80%.
The more efficient ore treat
ment at GOKs is possible under
following below conditions:
decrease of the maximum
coarseness of the feeding products of
the mills at the first stage of com
minuting from 2530 to 1015 mm;
application at the crushing
stages of the modern crushingclas
sifying equipment ensuring the ra
tional conjunction of the crushers
by the stages, automated control of
the crushers operation with remote
adjusting of unloading slits for ob
tain of the optimum coarseness of
the crushed products before com
minuting.
It has been carried out study
and analysis of technology of the
ore processing at the different
GOKs of CIS. The study has
shown that it is impossible to
increase efficiency of disintegra
tion at the crushing stages owing to
the following reasons:
more than 80% of the crushing
and classifying equipment are de
preciated and obsolete;
used crushers are not suitable
for rational conjunction and for op
eration in automated regime.
The specialists of NPO
RIVS JSC in cooperation with
division Mining Equipment of
Uralmashzavod JSC have
worked out the more perfect tech
nologies and equipment for realiza
tion of technologies.
The gyratory crushers are supplied
with the means of automated control
of operation of the last ones with
remote adjusting of unloading slit.
Fig. 1 shows the video frame of
control of operation of the crusher
KMD3000T2DP in automated
regime. The crusher has been put
into operation at the concentration
factory Erdenet in 2002.
The kinds of control of opera
tion of the crusher:
loading of the ore into the
crusher and maintenance of the op
timum quantity of the ore (opera
tion under the cap);
calculated unloading slit and
necessary pulling of the slit after the
established period of the operation;
electric power, consumed by
the main drive, and the current
strength;
P. I. KRUPPA, P. O. NESTEROV (NPO RIVS JSC)
PUTTING INTO PRACTICE MODERNIZED
TECHNOLOGIES AND DEVELOPMENT
OF PROSPECTIVE DIRECTIONS
IN ORE PREPARATION
PUTTING INTO PRACTICE MODERNIZED
TECHNOLOGIES AND DEVELOPMENT
OF PROSPECTIVE DIRECTIONS
IN ORE PREPARATION
P. I. KRUPPA,
Deputy General
Director
for Ore Preparation,
Candidate
of Technical science
P. O. NESTEROV,
Commercial
Director
Fig. 1. Video frame of automated control of operation
of the crusher KMD3000T2DP
Contents
6
operation of the lubricating system with indication
of the oil temperature at the entry to the crusher, in the
cam unit, in the drive units, at the discharge with con
trol of the oil level in the tank;
correlation in the work with conjugated equipment.
Fig. 24 show the improved technological crushing
schemes conformably to processing of the iron ores by
the fourstages scheme; processing of the iron and cop
permolybdenum ores by the threestages scheme with
circulating load for additional crushing of the above
screen product; processing of the ores of ferrous and
nonferrous metals, chemical raw minerals with appli
cation of the new and improved crushingclassifying
equipment.
It has to be noted that sometime the ores are char
acterized by heightened content of the moisture, ore
mud, stowing materials and clay (Korshunovsky
GOK, GMK Norilsky nickel, Uchalinsky GOK,
Sibaysky GOK and so on). It leads to sticking of the
bunkers, oreflow passages, screening surfaces and
crushing cavities of the crushers and causes the neces
sity to work with unloading slits of increased sizes. As
a result coarseness of the final product increases up to
3039 mm.
Fig. 3. Technological scheme of processing of the iron ores
at the Krivbass GOKs and at Mikhaylovsky GOK
Fig. 2. Technological scheme of processing of the iron and
coppermolybdenum ores and chemical raw minerals
at the Erdenet GOK, Stoylensky GOK,
Kostomukshsky GOK and ANOF3
Fig. 4. Technological scheme of processing of the ores of
ferrous and nonferrous metals, chemical raw minerals at
Leninogorsky GOK, GMK Pechenganickel, ANOF2,
Zyrianovsky MCK, Gaysky GOK
Contents
ORE PREPARATION
7
Modernized technologies have been put into prac
tice at CP (concentration plant) of the combine
Erdenet, at Stoylensky GOK, at the four cascades
of the middle and fine crushing of Mikhaylovsky
GOK, ANOF2. It has been offered and examined
technical and technicalcommercial offers for GOKs
Mittal Steel Krivoy Rog (Krivorozshstal) and for
Severny GOK.
Arrangement of the point of the extrafine crushing
after the common fine crushing is the prospective direc
tion of further decrease of the coarseness of the crushed
feeding product for mills. It has been constructed and
put into practice recently the number of the machines:
gyratory crusherscalibrators KMD1750TKD and
KMD2200T6KD; pressrollers RP120x80; centrifu
gal crushers of the type Titan D160 and D250. For
realization of the direction it has been worked up the
Fig. 6. Technological scheme of additional crushing
of the products of fine crushing at Zyrianovsky CP
Q, t/h
d
rated
, mm
, %
Fig. 5. Modernized technological scheme of crushing
at ANOF3
Fig. 7. Technological scheme of preparing
of the coppermolybdenum ore for processing (treatment)
at the Erdenet GOK in prospect
Initial ore Initial ore
Screening
Screening
Screening
d
0,95
= 11.3 mm
Screening (GIST72, 2 pieces)
15 million tons per year
1200 mm
Rough crushing
(KKD1500/180, 2 pieces)
Middle crushing
(KSD3000T2D, 2 pieces)
To comminuting at the mills
MShC5500x6500, 8 pieces)
To comminuting in the mills
MShC5800x6900, 9 pices
To classification
and flotation
Extrafine crushing
(crushergranulator
KMD2200TKD, 2 pieces)
Rough crushing DPU1000
(KKD1350/160, 2 pieces)
Middle crushing
(KSD2200T2D,
5 pieces)
Semiselfcrushing
(MMPS90x30, 2 pieces)
Fine crushing
(KMD3000T2DP,
6 pieces)
Extrafine crushing
(WF500, 2 pieces
or KMD2200T9D,
2 pices)
Comminuting
(MShC5500x6500,
2 pices)
Extrafine crushing
(KMD2200T8D,
2 pices)
Stock
of the roughcrushed ore
250 mm
Crushingtransport
department
Building
of the selfcrushing
Fine crushing
(KMD3000T2DP, 4 pieces)
275 mm
10 mm
8(6) mm
9(10) mm
7(8) mm
50(60) mm
9 mm
+10 mm
10(11) mm
60(70) mm
16(20) mm
Screening (GIST72, 10 pieces)
14.4 mm
= 30%
11 mm
= 60%
+8 mm
= 10%
40 mm
= 30%
+40 mm
= 40%
Contents
8
number of technological schemes (in accordance with
the technical targets of the enterprises) with obtain in
the open cycle of the crushed product with the coarse
ness 9(12) mm (fig. 57).
It has to be noted that decrease of the coarseness of
feeding of the mills and increase of productivity of the
last ones ensure perfecting of the process of comminut
ing. At the same time quality of the comminuted prod
ucts increases owing to:
application at the first stage of comminuting of the
ball mills of the type MShC instead of MSC or MShR;
transition to loading of the mills of the first stage
with the balls 60 and 80 mm diameter instead of 100
and 120 mm;
optimization of loading of the mills by the stages,
including application at the second stage of the inter
changeable mills with increased volume of the drum by
4045% (it is reached by means of use of the segment
bearings as a support for the drum).
The conception of the technical reequipment of
the orepreparing facility at the combine Erdenet
with increase of capacity is interesting.
It is recommended the mentioned below measures:
removal of the rough crushing to the openpit with
application of DPU1000 (with the crusher KKD
1350/160) in the blockmodular unit instead of rough
crushing in the crushingtransport department (DTO)
(KKD1200/150, 2 pieces) and in the section of the
selfcrushing (KSI) (SchDP15x21, 1 piece);
inclusion of the unit of fine crushing (with exclu
sion of circulating load) into DTO for additional crush
ing of the overscreen product (+10 mm) with usage of
the gyratory crushers KMD2200T6KD (2 pieces) or
pressrollers RP120x80 (2 pieces); inclusion into KSI
of the crushers WF500 (2 pieces) for additional crush
ing of the product +10 mm after the crushers MMPS
90x30 (2 pieces).
For all this it is going to decrease the nominal
coarseness of feeding product for ball mills in the
crushingflotation section to 1011 mm and in KSI
to 89 mm with increase of productivity of the ore
processing from 25 (2007) to 30 million tons.
Conclusions
1. Put into practice modernized technologies and
technique of the ore preparing have the mentioned
below advantages:
coarseness of the crushed feeding product decreas
es to 1015 mm in comparison with existing technolo
gies;
productivity of the crushing cycle and processing
sections increases by 1520%;
power inputs of the ore preparing facility decreas
es by 1520%;
life of the lining of the drum mills of the first stage
increase 1.31.4 times;
consumption of the comminuting medium de
creases by 1619% owing to transition to the balls 80
and 60 mm diameter (instead of 120 and 100 mm);
it has been optimized loading of the mills by the
stages of comminuting, improved granulometric com
position of comminuted product (for example, output
of the class +0.16 mm with poor flotability decreases by
1320%);
cost of the concentrate decreased by 1426%.
2. Capital expenses for technical reequipment of
the stages of crushing and comminuting are compen
sated within 1.52 years owing to decrease of opera
tional costs.
EM
Contents
ORE PREPARATION
9
There is the great demand for dif
ferent types of the screens in many
industrial branches. More than 300
enterprises and firms produce the
screens outside CIS including 90 big
firms: 32 in the USA, 16 in the
Great Britain, 11 in FRG, 6 in
Japan. Examination of the Russian
and foreign patents shows the
increasing interest in perfecting of
the screens, in designing of the new
models of the last ones.
The main tendencies of perfect
ing of the screens are directed to:
increase of efficiency of screening;
increase of reliability and
durability of operation;
expansion of the sphere of
application and technological pos
sibilities.
For all this the main attention is
paid to increase of efficiency of
screening.
NPO RIVS traditionally
makes efforts to perfecting of con
struction and to increase of techno
logical parameters of the screens
used in the crushing and com
minuting chains. The screens
process the big volumes of the
materials at the beginning of tech
nological process. They are
demanded high efficiency of
screening, high reliability and
durability. In the case of operation
of the crushers jointly with the low
efficient classifying equipment the
circulating load in the crushing
cycle increases. It negatively affects
the parameters of operation of the
most expensive crushers and para
meters of the cycle crushingcom
minuting as a whole. There are
two ways in increase of efficiency of
screening: extensive with
increase of the area of the sieve sur
face and intensive with increase
of the amplitude of vibration of the
screen and decrease of the angle of
the screen incline. The second way
is reached by means of application
of the selfbalanced screens with
the two selfsynchronized vibrators
instead of traditional inertia
screens with the only vibrator.
Application of the screens with
increased area of the sieving surface
is the most justified at the enterpris
es, where the project scheme per
mits to install the screens without
significant volumes of construction
works. For example, application of
the screens GST81R (fig. 1), man
ufactured by NPO RIVS
instead of the screens GST71, at
Satpaevsky CP (concentration
plant) of the corporation Kaza
khmys (Kazakhstan) has permit
ted to increase annual productivity
of the factory from 3 to 5 million
tons without replacement of the
crushing equipment. But installa
tion of equipment of the large
dimensions is impossible in the
most cases. So, it is necessary to
work up the more effective appara
tus with the same dimensions. The
screen GST72SRIF (fig. 2),
UPTODATE VIBROSCREENS OF RIVS SCIENTIFIC
AND PRODUCTION CORPORATION
UPTODATE VIBROSCREENS OF RIVS SCIENTIFIC
AND PRODUCTION CORPORATION
A. I. IVANOV (NPO RIVS JSC)
A. I. IVANOV,
Chief of Department
of the vibro
technique and ore
preparing
Fig. 1. Screen GST81R Fig. 2. Screen GST72SRIF
Contents
10
designed by NPO RIVS to
order of GMK Norilsky nickel,
is the example of the new approach
to the task. The new screen is des
tined to replace the screens GIST
72 operated at the combine earlier.
Comparative technical parame
ters of the screens GST72SRIF
and GIST72 are given in the table 1.
Replacement of the screens
GIST72 by the screens GST72S
RIF has permitted to use the single
technological chain instead of thy
two parallel ones used earlier.
It has to be noted that in the
both above mentioned cases work
ing up of the new equipment has
been accompanied by solution of
additional questions. The last ones
do not arise in creating of the
screens less than 10 m
2
and with
relatively small amplitude on vibra
tion of the box. Today it has
appeared the standard constructive
and programapparatus complexes.
They allow to calculate construc
tion of the screens at the projection
stage, to forecast technologic para
meters of operation of the screens
with the high degree of reliability
and with sufficient trustworthiness.
Constructors works for creating of
vibration screen include certainly
the following stages: calculation of
stability of the selfsynchronization
[1, 2], analysis of vibration moving
of material along the sieve, deter
mination of the frequency and the
form of vibrations, strains and
deformations of the elements of
construction of the box. Equally
with its own softwares used for
specific calculations (selfsynchro
nization, vibration moving) the
corporation uses the universal
commercial softwares for analysis
of the straineddeformed state of
the construction [3] and for deter
mination of dynamical parameters.
They realizes numerical solution of
the tasks of elasticity theory by
means of the method of the final
elements.
Dimensions, type and parame
ters of the sieving surface are
determined proceeding from tech
nologic requirements to constructed
machine. In the case of applica
tion of the sieves with the stiffness
influencing on the screening (rub
ber and polyurethane sieves) it is
necessary to analyze the strained
deformed state of the sieves.
Above mentioned task
dynamical analysis of the construc
tion of the superelastic material
is one of the most difficult in simu
lation. Calculating methods and
programs directed to analyze of the
quickpassing nonlinear processes
are used for achievement of the
aim. Fig. 3 shows the polyurethane
sieve. The form of the sieve has
been obtained by the direct integra
tion of the equations of movement
of its finalelement model. It has
been supposed that the sieve is pre
stretched, periodical movement of
the contour is described by the tar
get function of the time. The pro
gram complex LSDYNA has been
used for calculation.
The calculations allow deter
mine influence of the form of the
holes, thickness of the sieve sur
face, preliminary tension proper
ties of the material, amplitude and
frequency of vibration on the firm
ness and dynamical parameters of
the sieving surface. Definition of
the rational form of the sieve
vibration ensuring the efficient
screening is the next stage. The
vibrations may be rectilinear, cir
cular, elliptical depending on
accepted kinematic scheme of the
Comparative technical parameters of the screens
GST72SRIF and GIST72
*Maximum productivity of the screens is limited by productivity of the crusher KMD2200T
**Interrepair cycle is determined by the life of the sieve surfaces
Parameters GST72SRIF GIST72
Dimensions of the sieving surface, mm 60002500 60002500
The number of the layers of the sieves, pieces 2 2
Sizes of the holes in the sieves, mm
upper 25 30
lower 2 2
Angle of incline of the sieving surface, degree 2.5 2.5
Amplitude of vibration, mm 710 68
Maximum coarseness of initial feeding product, mm 120 120
Real productivity, t/h 650* 350
Power of electric drive, kW 222 222
Mass of the screen with the drive and frame, tons 17.3 15
Efficiency of screening of the sieves, %
upper 86 73
lower 87 54
Interrepair cycle, months 3** 2**
Fig. 3. Form of the rubber sieve
in the moment of the maximum
displacement of its contour
Contents
ORE PREPARATION
11
screen. NPO has worked up the
model of motion of the material
point relative to the surface
accomplishing harmonic oscilla
tions in accordance with the com
mon enough law (fig. 4). The
model is used for definition of
velocity of material motion.
Designing of the box and drive,
corresponding to determined earlier
kinematic parameters, has begun
after definition of required parame
ters of oscillation of the working
body. After selection of constructive
scheme it is constructed its kine
matic model. The model may be
used for achievement of distribution
of the mass and parameters of the
drive answering the purpose. The
purpose is reached by operational
changes of constructive parameters.
For example, the program ADAMS
is the suitable means. It permits to
build the kinematic scheme of the
screen on the base of 3Dconstruc
tive working drawings, to carry out
numerical integration of the equa
tions of motion of the box in auto
matic regime and to obtain the tra
jectory of motion of selected points
of its construction (fig. 5).
Analysis of the own frequencies
and forms of the screen box oscilla
tion and control of strength of its
elements are the next stages. The
calculations are carried out by
means of traditional finalelement
solution of the task about forced
harmonic vibration of elastic con
struction by the method of decom
position of the own forms and fre
quencies [4, 5]. Advantages of the
numerical simulation in compari
son with the simplified manual
calculation consist in the fact that
the number the dangerous (lowest)
forms of oscillations can not be
obtained in simplified calculations.
The constructive changes
ensuring the proper protection
against the resonance and firmness
of the construction are made in
accordance with results of analysis
of parameters of the box.
Of course, it has to be made
some assumptions and simplifica
tions in drawing up of the calcula
tion scheme of the screen [6]. First
of all it is supposed that all joints of
construction elements are perfect
ed, i. e. the contacting surfaces of
the flange junctions are deformed
equally without loss of the contact
and without slipping. The welded
seams are assumed as equally
strength and so on. Value of the
attached mass, i. e. the mass of
the screened product, that is con
sidered as hardattached to the
sieve, is assumed proceeding from
the some approximate conceptions.
So, the model can not be consid
ered as absolutely identical to the
real construction.
The proper construction of the
model for obtain of the adequate
results of calculations requires the
complete of statistical data about
the real parameters of operation of
the real constructions of the
Fig. 4. Interface of the program of vibration motion of material point
Fig. 5. Example of calculation of trajectory of motion of the points
of the sieve of the screen
Contents
12
screens, embodied in the metal.
With that end in view it is carried
out the complex of the measure
ments of parameters of the screens
in the course of the factory testing.
NPO RIVS has bought the mod
ern measuring technique (vibrome
ters, tensormeasuring stations) for
the factory testing. It is possible to
say today that constructed models
ensure the precision sufficient for
engineering calculations. After
obtaining of sufficient volume of
statistical data further works for
correction of the calculations will
permit to forecast exactly the para
meters of operation of the screens
(both for average and for different
specific working conditions).
Undoubtedly, the mathematical
simulation is carried out under sup
position of the ideal making and
quality of the units of construction
of the screen, lack of the latent
defects in the machine parts
(defects of rolling and so on). So,
the quality of the final products
depends not only on the quality of
projection but on the level of
responsibility of the workers in the
course of producing and operation
of the screens. Increase of techno
logical parameters may be reached
by increase of the loads on the
screens. But it requires to take into
account some factors that may be
insignificant in calculations of the
less powerloaded apparatus. So, it
is necessary to increase significant
ly requirements to quality of the
used materials and to keep techno
logical regimes of producing. The
screen GST52MU made by NPO
RIVS for Uchalinsky GOK may
be the example of increase of
importance of the factors that were
not taken into account earlier. The
screen is exploited for three years
with the high technological para
meters and reliability. But increase
of content of the moist clay admix
tures in initial material in the
springautumn period leads to
adhere of the moist small pieces to
the lower transport chute. It dis
places the centre of gravity of the
screen and breaks synchronization
of the vibrators. It is necessary to
exploit the screen with the lower
productivity in this period. After
detailed analysis it has been built
the mathematical model of the
screen, and the arranging scheme
(location of the vibrators) has been
changed. Fig.6 shows initial and
corrected arranging schemes of the
screen GST52.
The screen GST72SRIF
mounted at GMK Norilsky nickel
is the example of necessity to
increase the demands of quality of
the used materials. The screen pri
marily has been made with applica
tion of the modern methods of calcu
lation and projection. Its construc
tion had had the sufficient safety
margin and reserve adjusting of the
own frequencies of vibration of the
box. The results of the tensormetric
measurements were within the limits
of permissible values. But the defect
of the rolling sheet, not revealed in
the course of the entrance control,
and unsufficient perfecting of tech
nology of mounting have led to
appearance of the crack in the rolling
sheet of the box after 8 months of the
operation. Hardness of construction
of the box has been increased on the
base of analysis of the mathematical
model for elimination analogous
breakages in future. Fig. 7 shows the
forms of the own oscillations of ini
tial and corrected model of the box of
Fig. 6. Arranging schemes of the screen GST52MU:
a initial, b corrected
a
b
Fig. 7. Lowest form of the own oscillations of initial (a) and corrected (b)
models of the box of the screen GST72
a
b
Contents
ORE PREPARATION
13
the screen. The undervibrator beam
was put out of action because of un
qualitative welding technology and
subsequent thermal treatment at the
same screen. The causes of the
breakages have been eliminated, and
today the screens operate without
censures.
Thorough analysis of analogous
breakages and registration of the
last ones in the course of designing
of the new screens permits to solve
successfully the tasks of increase of
efficiency and reliability of the
screens of the types GST and GIT.
Today NPO RIVS offers to
the customers the worked up
models of the screens tested in the
course of operation. Besides,
NPO RIVS can to work out the
screens adapted to classification
of the materials with nonstan
dards coarseness and humidity,
nontraditional loading and
unloading, nonstandard width
and for especially difficult work
ing conditions.
It has to be said apart about
sieving surfaces.
Sieves are the main element of
the screen. Efficiency of screening
depends greatly on construction of
the sieves. Economic factor plays
significant part: the sieves are the
most wearing and often replaceable
elements of the screen.
Thus, life of the most popular
today steel net of the low carbona
ceous steel for screening of the ores
does not exceed few days. The main
advantage of the steel net is the big
living section. In combination
with relative cheapness it stipulates
the wide application of the steel
nets. Shortcomings of the last ones
are evident: short life and obstruc
tion of the sieves with the screened
material, especially in the case of
presence of the clayey admixtures
in the material.
So, the main direction of per
fecting of the sieving surfaces is
application of the rubber and
polyurethane sieves.
The rubber sieves have the smaller
living section than the metal ones, but
they have the following advantages:
high were resistance and con
sequently the longer (few times)
period of life;
ability for selfcleaning stipu
lated by elasticity of the rubber
threads equalizing living section
of the metal nets in the course of
operation;
lower level of the noise in the
course of operation;
lower operational costs owing
to decrease of the work inputs and
idle time of the screens because of
the more rare replacement of the
sieves.
Many firms produce the rubber
sieves today. Every firm uses its
own sort of rubber and its design
of the undersieve devices for fas
tening of the last ones.
The firm RIVS produces the
rubber sieves of the type ESALH
with the holes of the different sizes,
unreinforced, singlelayer, of the
rubber with use of the natural
caoutchouc. The sieves are charac
terized by the quickremoving, fas
tening at the special undersieves
devices without the fastening bolts,
brads and cramps. The cards with the
sizes 500x500, 500x250, 500x750 mm
may be installed at the any standard
Russian screens. After negligible
adjusting of the undersieve devices
the cards may be installed at the for
eign screens too. The sieves ESALH
and the scheme of installation of the
last ones are shown at the fig. 8. The
sieves have shown high efficiency. For
example, the sieves with the holes
25x25 mm (screen GST52MU)
mounted at Uchalinsky GOK have
been exploited for one year. They have
sieved 1 million tons of the ore, i. e.
130 thousand tons per 1 m
2
of the siev
ing surface. The rubber sieves designed
by NPO RIVS have the high wear
resistance. They are poorly subjected
to obstruction with the screening
material. They are easily changeable.
Positive results of exploiting of
the sieves have been obtained at
Norilsky concentration factory
(the screen GST72), at Alexan
drinsky miningore company (the
screen Nordberg), at Uchalinsky
GOK (GST52), at Apatite JSC
(GIST72), at Aksusky ferroalloy
plant and others.
Fig. 9 shows technological para
meters of operation of the screen
GIST72, equipped with the rubber
sieve with the holes 25x25 mm,
mounted in the building of screen
ing at ANOF3, and analogous
screen with the steel sieve with the
round holes 28 mm diameter.
Fig. 8. Sieves ESALH and scheme of mounting of the last ones
Contents
14
Brought data shows that applica
tion of the rubber sieving surfaces
ensures the higher efficiency of
screening in the working diapason
of loading. Consequently it permits
to decrease circulating load. It has
to be noted that before putting into
operation of the rubber sieves at
ANOF3 the screens GIST72
were equipped with the springy
bearings instead of the rubber
shockabsorbers. It has led to addi
tional positive effect even in the
case of application of the metal
sieves.
Of course, introducing of the rub
ber sieves in the large scale needs the
adjusted control of quality of the rub
ber mixture and regime of the sieves
vulcanization. Besides, it needs the
further perfecting of construction, first
of all of the undersieve devices.
The sieve sags often upon influence of
the high specific loads. The sag is stip
ulated by residual deformation of the
rubber. Sometime it is observed bend
ing of the bearing racks under big load.
For elimination of above mentioned
effects in operation of the sieves under
increased specific load and for screen
ing of the materials with the large
coarseness construction of the under
sieve devices has been changed. It has
been reinforced the main bearing
racks and introduced additional trans
versal sieve bearings. It has permitted
to increase significantly stability of
parameters of screening.
Besides, it is produced the sieves
for screening of the more coarse mate
rials. The holes of the sieves are round
and square. Its sizes vary from 40 to 60
mm. The sieves are thicker and in
comparison with the sieves ESALH
they are fastened by another way.
Thus, today NPO RIVS has all
necessary possibilities for increase of
technological parameters of screen
ing of the different materials in differ
ent conditions. Produced by the cor
poration the dimensional range of the
screens of the different types (includ
ing equipped with the rubber sieves
ESALH) permits to select the stan
dard solutions in the most cases. If
the standard version does not comply
with requirements of the customer,
the corporation can produce the spe
cial version of the screen on the base
of existing ones. The new screen will
have all necessary parameters.
Literature
1. . .
. ., ,
1971.
2. . ., . .

//
. 1977. 3.
3. . .,
. .
// .
2002.
4. . ., . .,
. .

//
. 1970. 1.
5. Zienkiewicz O. C., Taylor R. L. The
Finite Element Method. Fourth edition.
Vol. 1. London:McGrowHill,1989.
6. . ., . .,
. . :
, ,
. : , 1976.
EM
Fig. 9. Dependence of technological parameters of screening (%)
by the class 25 mm on the load (rubber sieve with the holes 25x25 mm):
1 efficiency of screening
2 content of the class 25 mm in the abovesieve product
Fig. 10. Dependence of efficiency of screening by the class 25 mm on the load:
1 rubber sieve, hole 25x25 mm
2 metal sieve, hole 28 mm diameter
Contents
ORE CONCENTRATION TECHNOLOGY
15
Deposit of the copperporphyrit
ic ores Erdenetyin Ovoo (the Repub
lic of Mongolia) is the ore base of the
biggest Asian enterprise of the same
name. It is one of unique natural for
mation of the world importance. Its
resources ensure operation of the
enterprise with the constant increase
of capacity for tens years.
One of the general problems of
the raw mineral base of the enter
prise is worsening of quality of the
mined ore. It means decrease of
absolute content of copper in the
ore, change of mineralogical com
position of the ore (in particular,
with deepening of the mining works
the share of primary copper miner
als in the mined ore increases, tex
turestructural properties of the ore
become complicated). As a result,
throughextraction of the metal is
decreased. Thus, extraction of
molybdenum of the ore has
decreased to 2530%.
The technological scheme used
at the concentration factory is
called cleanerscavenger (fig. 1).
The scheme is traditional for pro
cessing facilities for relatively low
grade CuMoores. The scheme
includes three flotation cycles: col
lective coppermolybdenum flota
tion of the ore comminuted to the
coarseness 6265% of the class
74 mwith obtain of the collective
concentrate containing 1315% of
the copper and up to 0.3% of the
molybdenum; final concentration
cycle including the operations of
the general, control and reclean
ing flotation and allowing to
increase content of the copper in
the foam product of recleaning up
to 25%. It permits to obtain in the
course of selection cycle the stan
dard copper concentrate in the
form of the tails of molybdenum
flotation. Technological parame
ters (%) of operation of CP (con
centration plant) Erdenet in
2005 are given below. It was the
year preceded to reconstruction of
flotation facility.
Content of Cu
in the copper concentrate 24.54
Extraction of Cu 85.09
Content of Mo
in the molybdenum concentrate 48.13
Extraction of Mo 24.48
Change of the world price business
conditions has predetermined the
necessity of approving by administra
tion of the corporation of the princi
pal decisions for perfecting of tech
nology of treatment of the CuMo
ores and for modernization of the cur
rent fleet of flotation machines. The
former technological strategies were
aimed to increase of the volumes of
the ore processing. But the newest
stage of development is connected
with increase of the depth (intensity)
of the treatment and consequently
with increase of the prices for the final
products. Thus, the general concep
tion of development of the works in
20052015 may be formulated as:
maintenance and increase of produc
tion of the copper and molybdenum in
the final concentrates in conditions of
DEVELOPMENT AND PUTTING INTO PRACTICE
THE NEW TECHNOLOGY OF CONCENTRATION
OF COPPERMOLYBDENUM ORES AT ERDENET WORKS
THE NEW TECHNOLOGY OF CONCENTRATION
OF COPPERMOLYBDENUM ORES AT ERDENET WORKS
A. V. ZIMIN, M. A. ARUSTAMYAN, Yu. P. NAZAROV (NPO RIVS JSC)
Z. GANBAATAR (KOO Erdenet Works)*
Yu. P. NAZAROV,
Leading Scientific
Worker, Candidate
Z. GANBAATAR,
Deputy General
Director, Candidate
A. V. ZIMIN,
General Director,
Candidate
M. A. ARUSTAMYAN,
Executive Director,
Candidate
Fig. 1. Current principal technological
scheme of flotation facility
* E. N. Shumskaya, S. A. Fedorov (NPO RIVS JSC), Zh. Baatarhuu,
C. Tuyaa (KOO Erdenet, Works) took part in the work.
Contents
16
decrease of content of the metals in the
ore.
NPO RIVS has cooperated with
KOO Erdenet Works earlier in
modernization and supply with spares
for flotation machines. Beginning
from 2005 the corporation takes the
active part in realization of the worked
up conception.
In accordance with repeatedly
used at the enterprises of nonferrous
metallurgy working scheme NPO
RIVS jointly with the specialists of
the combine have worked out in
20052006 the number of the mea
sures. The last ones allow to work up
the new technology of processing of
the coppermolybdenum ores directly
in the Central laboratory of KOO
Erdenet Works and to test the
technology at the operating factory.
Analysis of technological products
of CP has been carried out repeatedly.
The analysis shows that the feeding
material for flotation contains 95% of
the nonmetallic minerals. The rests
are sulphides, including 3.1% of the
most problem mineral pyrites.
Up to 90% of pyrites and to 95% of
molybdenite are in free condition.
The total volume of the tails con
tent 97% of the nonmetallic miner
als. About 90% of the last ones are in
free condition. Predominant sul
phides are the pyrites (~ 2.5%), pre
sented mainly by the opened grits
(85%). Content of the chalcopyrite
is about 0.1%, the free kind of the
chalcopyrite is about 40% of above
mentioned quantity. Almost all
molybdenite presents in the opened
form.
Thus, distribution of the minerals
in accreted and in free form permits to
establish as a preliminary that the gen
eral reserves of extraction of molybde
num lies in the reagent regime.
Largescale laboratory study as
applied to features of the ore of the
current and perspective mining with
usage of collectors of the firm Cytec
Ind and technical water of KOO
Erdenet Works has shown possi
bility of increase (to 40% absolute) of
extraction of the molybdenum in the
collective cycle without decrease of
extraction of the copper (see the
table).
The new technology of concentra
tion of CuMoores has been formed
in the course of the laboratory study.
The technology was recommended
for industrial testing of ability to con
centration at the factory of the com
bine Erdenet in collective cycle at
VI section of IFO.
It has been carried out some pre
liminary measures for preparation of
the section.
Modernization of equipment
the contact vats KCh40 have
been installed before the main industri
al productive and recleaning flotation;
it has permitted to stabilize feeding of
the both operations by the mineral and
by granulometric composition;
regular aeration blocks in flota
tion machines OK50 and OK30 in
stalled at the major and control oper
ations have been replaced by the
blocks RIF 11 and RIF 9;
it has been mounted the tech
sling constructions of NPO RIVS
instead of reduction drives.
Immediately after VI section it has
been carried out modernization of the
equipment at V section: current flota
tion machines FPM40 and FPM16
have been replaced by flotation
machines RIF 45 and RIF 16.
It has to be noted especially
mounting of the special dosage appa
ratus for recommended reagents.
Necessity of above mentioned appa
ratus was stipulated by the following
circumstances:
since the main recommended
collector is waterinsoluble, it was be
necessary to foresee loading of the
collector directly to comminuting for
better disperse;
for decrease of the time lag of
the response it has been offered to
mount the dosing devices directly at
the areas of comminuting;
for perfecting of controllability
of the reagent regime it has been of
fered to use the dosing devices com
bined with the control board.
Technological measures
it has been optimized the value
of pH of the medium in the collective
cycle;
it has been worked up the matrix
of ratio of consumption of the recom
mended (Aero MX) and the factory
made (BK901) collectors depending
on the ratio of content of the primary
and secondary copper minerals in the
feeding ore;
it has been excluded feeding of
the diesel fuel and sulphureous sodi
um in the collective cycle;
Comparative results (%) of the laboratory flotation tests
Products Output
Content Extraction
Cu Mo Fe Cu Mo Fe
Factory technology
Collective concentrate 3.15 13.83 0.167 21.51 77.22 27.54 20.13
Dump tails 96.85 0.13 0.014 2.78 22.78 72.46 79.87
Ore 100 0.56 0.019 3.37 100 100 100
Recommended technology
Collective concentrate 3.21 13.19 0.41 20.1 77.67 69.45 19.13
Dump tails 96.79 0.13 0.006 2.82 22.33 30.55 80.87
Ore 100 0.55 0.019 3.371 100 100 100
Contents
17
it has been optimized consump
tion of the foaming agent MIBK and
specified the points of loading of the
agent.
In accordance with results of
the laboratory study and industrial
testing it has been worked up the
technology (scheme + reagent) of
treatment of the coppermolybde
num ores. The technology foresees
obtain in the collective cycle of the
concentrate containing 1416% of
copper. After thickening and final
concentration in the separate cycle
the product is sent into the cycle of
selection with obtain of molybde
num final product that is sent to re
cleaning. The chamber product is
the copper concentrate. There is
the version in the offered scheme
(for the ore with the favorable com
position) that foresees exclusion of
the final concentration cycle. It is
possible if the concentrate, con
taining more than 24% of copper,
may be obtained in the collective
cycle (fig. 2).
During the testing it has been
revealed the necessity of:
feeding of additional (water
soluble) collector in the control oper
ation of the collective cycle for addi
tional extraction of copper from the
dump flotation tails;
additional comminuting of the
concentrate of the principal flotation
before recleaning operation.
Usage of the waterinsoluble col
lector Aero MX at the collective flota
tion and watersoluble Aerofloat at
the control operation is the important
element of the offered reagent regime.
It has been noted possibility to
decrease the temperature of steam
curing of the collective concentrate
from 65 to 4050
o
C in the course of
operation at the recommended regime.
It increases significantly stability of the
bearing of the units.
It has to be noted especially the
results of statistical analysis of depen
dence of parameters of the collective
flotation, carried out by means of the
factory and recommended regimes,
on the main technological properties
Parameters, %
Planned
to October 2006
Real in
October 2006
Content of Cu in the Cuconcentrate 24 23.64
Extraction of Cu 85.5 85.5
Content of Mo in the Moconcentrate 47 47.68
Extraction of Mo 30 40
Fig. 2. Recommended principal
technological scheme of flotation
facility for the ores with high content
of the primary copper materials
Fig. 3. Dependence of extraction of copper (1) and content of cop
per in the concentrate (2) in the fabric (a) and recommended (b)
regimes of flotation on the share of oxidized copper in the ore
a
b
On completion of the preparatory works in 2006 it has been carried out
industrial testing of the new technology of the collective cycle at the VI section.
The synchronous tests have been carried out at the V section with unloaded
products of the mills of selfcomminuting as a feeding material. It was necessary
for expansion of the information base.
Efficiency of technological regime, worked up at the stage of the laboratory
study and preliminary technical measures, has been confirmed in the course of
industrial tests in the AprilOctober 2006 (see lower)
Contents
18
of the ore: degree of oxidation of the
copper minerals and content of the
primary copper.
Content of the mud in the ore
increases with increase of degree of
oxidation, and flotability of the ore
decreases*. In the fabric reagent
regime (fig. 3, a) increase of degree
of oxidation leads to decrease qual
ity of the collective concentrate and
to decrease of extraction (every
additional 1% of content of Cuoxid.
involves decrease of extraction of
Cu by 0.98%). At the same time in
recommended regime extraction
decreases by 0.56% only (fig. 3, b).
With deepening of the openpit
the share of the primary copper in
processed ore and the size of dissemi
nation of the copper minerals
increase. In the fabric regime of flota
tion (fig. 4, a) every 1% of increase of
content of the primary copper leads
to decrease of extraction by 0.2% and
to decrease of content of copper in the
concentrate by 0.15%. In the recom
mended regime (fig. 4, b) increase of
content of the primary copper in
the ore almost does not affect para
meters of the process. Flotation
process is stable enough in above
mentioned conditions. First of all it
concerns the V section, purposefully
fed with the ore with increased pri
marily in the course of industrial
testing. Increase of content of chal
copyrite from 30 to 70% does not
adversely affect technological para
meters.
It has to be noted that in the work
with recommended technology it
takes the place substitution of pyrites
in the copper concentrate with the
slagforming components, contain
ing Al
2
O
3
and SiO
2
. Favorable ratio
Cu:Al
2
O
3
:SiO
2
in the final concen
trates permits to decrease or to
exclude completely at the metallurgi
cal facility necessity in additional
feeding of the silica (fig. 5).
Recommended technology has
permitted to increase extraction of
molybdenum into the final concen
trate by 15% (absolute) in comparison
with the ordinary regime. Besides, it
allows to form the scheme of treat
ment of the ores with increased pri
marily.
Obtained results have given to the
enterprise the possibility to put into
practice in the short period the rec
ommended technology at the all facil
ities of the concentration factory and
to begin modernization of the equip
ment with the regard for experience,
accumulated during initial period of
operation of the new technology.
Worked up by NPO RIVS con
ception of treatment of the copper
molybdenum ores is tested in indus
trial conditions at the different enter
prises, processing the coppermolyb
denum ores: Almalyksky GMK
(Uzbekistan), Zangezursky MMK
(Armenia).
Fig. 5. Content (%) of the some slagforming components in the copper con
centrate, obtained in the fabric (a) and recommended (b) regimes of flotation
a b
EM
Fig. 4. Dependence of extraction of copper (1) and content of cop
per in the concentrate (2) in the fabric (a) and recommended (b)
regimes of flotation on the share of the primary copper in the ore
a
b
* . . //
.: . 2005. 5.
Contents
19
Deposits of the copperzinc
pyrites formation of the Southern
Urals are presented by the three
mineral types: sphaleritechalcopy
ritepyrites; chalcopyritemag
netitepyrrotinepyrites and pyrites.
The first type is presented by the
main ore bodies of Uchalynsky and
Molodezhnoe deposits and upper
ore bodies of Sybaiskoe and Uzel
ginskoe deposits. The second type
corresponds to the lower bodies of
the manytier ore fields of Sybaiskoe
and Uzelginskoe deposits. Pyrites
ore body of Gayskoe deposit belongs
to the third type and is accompanied
by pyrophillite metasomes.
Increase of demand of quality of
the copper concentrate (without
decrease of achieved extraction) in
the course of treatment of the copper
and copperzinc ores at the concen
trating factory of Uchalynsky
GOK JSC was the foundation for
fulfillment of the special technologic
researches by the specialists of JV
(Joint Venture) IVS JSC. The goal
of the research was the more accurate
definition of technological scheme
and reactant regime of flotation in
the copper cycle. The scheme and
regime have to ensure obtain of the
copper concentrate containing not
less than 17% of copper by means of
application of the high selective reac
tants of the new generation.
Copper and copperzinc ores of
Uchalynsky and Molodezhnoe
deposits are the ore base of the
Uchalynsky concentrating plant.
Some part of the copperzinc ores of
Talganskoe deposit is sent to the
plant too.
The ores of Uzelginskoe deposit
are the main volume of the raw
material processed at the factory
today and in future. Follow men
tioned minerals are presented in the
ores:
principal pyrites, pirrotine,
melnikovite, markazite, sphalerite,
chalcopyrite and tetrahedrite;
secondary arsenopyrite,
magnetite, haematite, galena;
rare bornite, chalcocite, al
taite, hessite, silvinite telluriumbis
muth and so on;
nonmetallic minerals
quartz, schistose silicates (mainly
sericites), potassium hydromica,
peach, seldom carbonate.
In spite of the simple mineralog
ical composition (fig. 1) the samples
of the ore are characterized by sig
nificant diversity of the texture
structural features. Massive texture is
the most typical (fig. 2).
Study of comminuting of
processed at the factory ores has
shown:
massivedisseminated ores
(Molodezhnoe deposit) are com
minuted much worse than the com
pact ores (Uchalynsky and Uzelgin
skoe deposits);
pyrites is opened in the great
est degree in the ores of all kinds of
the sulfide minerals in the class
0.074 mm;
TECHNOLOGICAL IMPROVEMENT OF ORE FLOTATION
AT THE CONCENTRATING PLANT OF UCHALYNSKY
MINING AND CONCENTRATING WORKS
TECHNOLOGICAL IMPROVEMENT OF ORE FLOTATION
AT THE CONCENTRATING PLANT OF UCHALYNSKY
R. A. YAGUDIN, Yu. R. YAGUDINA (Uchalynsky GOK JSC)
L. A. NEMCHINOVA (NPO RIVS JSC, Urals branch)
A. V. ZIMIN,
General Director,
Candidate
R. A. YAGUDIN,
Chief
of Concentrating
Plant
Yu. R. YAGUDINA,
Chief of Research
Laboratory
L. A. NEMCHINOVA,
Chief of Research
Laboratory
Fig. 1. Mineralogical composition (%)
of the copperzinc ores
of Uzelginskoe deposit
Fig. 2. Chalcopyrite (Cp) accreted
with schalerite (Sf) and pyrites (Py)
(magnification 20)
Contents
20
in the compact ores of the sul
fide minerals in the class 0.044 mm
the most opened mineral is chalcopy
rite, in the disseminated ores
(Molodezhnoe deposit) sphalerite.
Fig. 3 shows dependence of degree
of opening of the general sulfides on
coarseness of comminuted copper
zinc ore of Uzelginskoe deposit.
Results of study of substantial
composition of examined ores per
mit to conclude:
expediency of separation of the
copperhead at beginning of tech
nological scheme owing to opening
of the copper minerals of the ore
comminuted to coarseness 65% of
the class 0.074 mm;
necessity of additional com
minuting of the tails of flotation of
the copperhead for opening of
the fine accretions;
expediency of the collective
flotation of the sulfides with subse
quent obtain of the final concen
trates.
Fig. 4 shows current technologi
cal scheme of flotation of the copper
and copperzinc ores at CP (con
centrating plant) Uchalynsky
GOK JSC. The scheme has been
worked up and put into practice by
the specialists of Uchalynsky GOK
JSC jointly with the specialists of JV
IVS JSC in the course of recon
struction in 20002007. The worked
up scheme involves the following
flotation cycles: separation of the
copperhead containing 1718%
of copper (at the copper ore to
20%); I and II collective copper
zinc flotation; selecting cycle
including the main and the three re
cleaning operations, allowing to
increase the copper content in the
foam product of recleaning up to
1415%.
The product of the cycle of cop
per removing from the coarse zinc
concentrate (912% of copper) is
the component of the final copper
concentrate.
It has to be noted that complica
tion of obtain of the highgrade cop
per concentrate is connected with
present in the ore of the fine easily
processed by flotation pyrites
(5070% of the total quality of
pyrites). So, it is necessary to main
tain the high residual concentration
of the lime from 300 to 500 mg/l
for depression of pyrites. It leads to
higher losses of the zinc with the
copper concentrate. Flotation under
the low concentration of the lime
(56140 mg/l) is the obliged mea
sure for prevention of the losses of
zinc. Besides, usage of the non
selective reactants complicates the
situation. The reactants are butyl
xanthagenate and foam generator
KSF (kaprolactam of the spirituous
fraction).
The laboratory studies of the
methods of increase of quality of the
copper concentrate have specified:
technological scheme of flotation;
necessary coarseness of the
comminuted ore and additionally
comminuted final products;
condition of flotation in the
copper cycle, including usage of the
highselective collectors and modi
fiers of the new generation.
The aim of the new technology is
obtain of the high quality copper
head, containing 2224% of the
copper and not less than 16% of the
copper concentrate after third re
cleaning.
It has been carried out testing of
the copper flotation in the open
cycle for choice of the most selective
reactantcollector in combination
Fig. 3. Dependence of content of the free mineral grains on coarseness
of comminuted ore (a in the class 0.074 mm, b in the class 0.044 mm)
1 chalcopyrite; 2 pyrites; 3 sphalerite
a
b
Contents
21
with the foamgenerator OrePrepX133. The following
reactants of the firm Cytec (USA) have been tested:
Aerophine 3418A; Aerophine 6931; Aero 9863; Aero
7048 (fig. 5). Butyl xanthagenate in combination with the
foamgenerator KSF were used as the standard collector.
It is obvious that the highest quality of the copper
head 23.8% of copper (extraction 33.7%) is reached
in the case of application of Aero 9863 (the summary
extraction into the total collective concentrate is 88.3%).
Usage of the more selective reactants has permitted
to optimize separation of the copper, zinc minerals and
pyrites, and to increase residual concentration of the
lime to 300500 mg/l for deeper depression of pyrites.
It has permitted to decrease the losses of zinc in the
copper concentrate.
Usage of the reactant S7261A of the firm Cytec as
the depressant of the pyrrotine and pyrites favors
increase of selectivity of flotation (losses of zinc
Fig. 4. Current scheme of flotation at Uchalynsky factory with application of the standard reactant regime
Contents
22
decrease by 3.3% in comparison
with the standard regime, extrac
tion of copper increases by 2.7%).
It has been determined that the
best opening of the useful minerals of
the studied ores takes place in the
case of comminuting to coarseness
8890% of the class 0.074 mm.
Meanwhile achieved to now coarse
ness is: for copper ore of Uselginskoe
deposit 74% of the class 0.074
mm; for copperzinc ores 8385%
of the same class. So, it is recom
mended to use the more effective col
lector (butyl xanthagenate) in the
collective cycle for additional extrac
tion of chalcopyrite and sphalerite.
Thus, recommended technological
scheme and reactant regime include:
separation of the intercycle
copperhead by means of two re
cleaning (for copper ore one re
cleaning);
directing of the final products
of recleaning to the cycle of selec
tion of the copper concentrate;
recommendation for coarseness of
the feeding material of the intercycle
flotation: 55% of the class 0.074 mm
for copper ores and 65% of the same
class for copperzinc ores;
usage of combination of the
collector Aerophine 3418A and
foamgenerator OrePrepX133 in
the cycle of selection and in flotation
of the copperhead;
use of additional depressant of
sphalerite and pyrites reactant
S7261A in flotation of the cop
perhead;
usage of the butyl xanthagenate
in the cycle of the collective flotation.
Results of the laboratory
closed tests in accordance with the
standard and offered flotation
schemes and reactant regimes
(without copper removing from
the coarse Zn concentrate) are
given in the table.
It is obvious that recommended
scheme and reactant regime of flota
tion permit to increase copper con
tent in the concentrates of the differ
ent ore by 25%. It is going to carry
out this year industrial testing of the
recommended technology for Uzel
ginskoe copper ore and for working
mixture of the copperzinc ores of
Uchalynsky, Uzelginskoe and
Molodezhnoe deposits.
Fig. 5. Technological parameters of the copper flotation with application
of the different collectors
1 Butyl xanthagenate; 2 Aerophine 3418A; 3 Aero 9863; 4 Aerophine 6931;
5 Aero 7048
EM
Technological parameters of flotation
Numerator standard flotation scheme and reactant regime, denominator recommended ones.
Type of the ore
Content in the ore, %
Cu content in
the Cuconcen
trate, %
Extraction of Cu
into Cuconcen
trate, %
Cu Zn
Copper ore of Uzelginskoe deposit 1.8/1.82 0.54/0.5 17.65/20.03 90.4/90.9
Copperzinc ore of Uzelginskoe deposit 1.15/1.19 2.91/3.29 17.44/19.09 85.8/84.4
Copperzinc ore of Uchalynsky deposit 0.97/0.93 4.03/4.22 14.86/18.57 82.9/82.2
Copperzinc ore of Molodezhnoe deposit 1.29/1.27 2.52/2.48 14.82/19.56 81.4/78.6
Working mixture of the copperzinc ores of Uzelginskoe and
Uchalynsky deposits
1.11/1.09 3.98/3.98 14.81/18.57 85/83.9
Contents
23
Technology of treatment of the fineingrained mag
netite quartzite has been currently formed in CIS. The
technology and proper apparatus base permit to obtain
magnetite concentrates containing 6468% of Fe and
510% of SiO
2
. Magnetic concentration is the basis of
the new technology. Studied earlier methods of improve
ment of quality of the concentrates (fine screening,
involving of the elements of the gravitation treatment in
the schemes) do not ensure significant increase of con
tent of Fe in the final concentrates. It is stipulated first of
all by decrease of quality of initial ore. Content of Fe in
processed ores for last 50 years has decreased more than
by 30% alongside with increase of volume of mining
more than triple [1].
Already for many years ironores processing plants in
the USA, Canada and European countries use flotation
concentration for obtain of the lowsiliceous concen
trates with high content of Fe.
Improvement of quality of the iron concentrate is
necessary first of all for decrease of spending of the met
allurgical facility. Today Russian metallurgical combines
feel the need in initial raw minerals containing not less
than 70% of Fe and not more than 3% of silica. Togeth
er with that improvement of quality of the ironcontent
concentrates does not accompanied by significant eco
nomic return for producing enterprises. Quite the con
trary, it is connected with increase of the operating and
capital costs. At the same time significant economic
effect is reached at the metallurgical and others facilities.
Surplus of silica in the iron concentrates is especially
harmful. It needs addition of great volume of the lime
stone for slagging of silica. Cost of the coke occupies the
special place in the cost of the cast iron. Share of the cost
for coke reaches 50%. So, criterion of improvement of
quality of the ironcontent raw material is the cost of the
products in consuming brunches of industry rather than
in fabricating ones.
High requirements of the metallurgists to quality are
feasible by means of development and introducing into
existing technological schemes of processing of the new
technicaltechnological solutions with provision for
characteristic of initial raw materials. Coming from
chemical composition of the ironcontenting minerals,
the highgrade concentrate may be obtained only from
the magnetite ores.
Magnetite quartzite, processed now at the Russian
and Ukraine combines, are characterized by the fine
mutual intergermination of the minerals [1, 2]. That is
why the concentrates, obtained by magnetic method and
contenting up to 68% of Fe and 510% of silica, are
characterized by coarseness at the level 8085% of the
class 0.044 mm. The dry magnetic separation of the big
pieces of material, fine screening and sedimentation are
used in some schemes apart from the wet magnetic sepa
ration (WMS).
The researches of finishing of the concentrates of
WMS by means of back cationic flotation have been car
ried out within last five years by the different organiza
tions. The study has been carried out with small differ
ence in time by the engineering center of Inguletsky
GOK, Poltavsky GOK, department of processing of
Mykhailovsky GOK jointly with the company SRT,
QUALITY IMPROVEMENT OF IRON ORE
CONCENTRATES VIA THE METHOD
OF BACK CATIONIC FLOTATION
QUALITY IMPROVEMENT OF IRON ORE
CONCENTRATES VIA THE METHOD
OF BACK CATIONIC FLOTATION
E. N. SHUMSKAYA, Yu. P. NAZAROV, Yu. A. SMIRNOV, A. M. ARUSTAMYAN (NPO RIVS JSC)
Kh. U. KOVALCHUK (Krivorozhsky GOK of Oxidized ores)
E. N. SHUMSKAYA,
Chief of Technological
Department, Candidate of
Technical science
Yu. P. NAZAROV,
Leading Scientific
Employee, Candidate of
Technical science
Yu. A. SMIRNOV,
Leading Specialist
A. M. ARUSTAMYAN,
Younger Scientific
Employee
Kh. U. KOVALCHUK,
Deputy Director for Scien
tific Work, Candidate of
Technical science
Contents
24
research center of NPO RIVS [3]. In 20042008 NPO
RIVS has worked up technological regulations for con
struction of the nodes for finishing of the concentrates of
WMS at the Centralny GOK JSC (Ukraine) and
Karelsky okatysh JSC (Russia). Productivity of every
node is 4 million tons of flotation concentrate per year.
Chemical compositions of the concentrates (table 1)
are analogous in many cases. Content of the class
44 m in the concentrate of the Centralny GOK JSCis
86%, in the concentrate of Karelsky okatysh JSC
up to 96%. Share of the free magnetite in the class
44 m exceeds 90% in both concentrates.
More than half of magnetite in the class +44 mis in
the accretions with the minerals of barren rock (fig. 1),
mainly with the quartz. It arouses the necessity to use
additional comminuting of above mentioned class.
Separating by the grains of 44 m in the modern
classifying devices (hydrocyclones, screens) may be car
ried out with efficiency 4060%. So, separation of the
accretions from the opened particles by means of
mechanical methods, subsequent comminuting and
additional treatment in magnetic separators permit to
increase significantly mass share of Fe in the concen
trate of WHS without reduction of Fe extraction into
the final product.
Centralny GOK JSC and Karelsky okatysh JSC
have set the task NPO RIVS to increase Fe content in
the concentrate up to 70.5% with extraction not less than
95%. Besides, silica content in the concentrate has to be
less than 2%.
Method of the back cationic flotation has been cho
sen as the principal technology. It is the costeffective
method. It is used successfully abroad and is tested at the
Russian and Ukrainian combines. Back cationic flotation
ensures the highest removing of the minerals of the bar
ren rocks out from initial product with minimum con
sumption of cationic collector and with small flotation
period amongst the all known methods. Modified
amines, presented by primary amines, diamines and their
compounds, are used widely now as collectors of the bar
ren rocks.
The schemes of finishing of the WMS concentrates by
the back cationic flotation are very simple. They consist
as a rule the principal and finishing operations (fig. 2).
The foamy product is sent to the finishing cycle. The last
one foresees the operations of recleaning and control
flotation in some cases. WMS is used at the some facto
ries as additional finishing operation.
The cationic collectors foreign production have
been tested in the laboratory by technological group of
NPO RIVS on the samples of the concentrates of
Centralny GOK JSC and Karelsky okatysh JSC.
Table 1. Chemical composition of the iron concentrates
of WMS
Component
Content, %
Centralny GOK JSC Karelsky okatysh JSC
Fe
total
67.60.4 68.20.4
Fe
magn
61.8 68.0
SiO
2
5.120.14 4.440.14
Al
2
O
3
0.200.02 0.180.02
MgO 0.180.04 0.120.04
CaO 0.32 0.12
TiO
2
<0.1 <0.1
MnO 0.0300.003 0.0300.003
P
2
O
5
0.016 <0.05
2
+ Na
2
O 0.210.09
S
total
0.093 0.430.07
Losses under
tempering
1.2 0.800.04
Fig.1 . Concentrate of the wet magnetic separation
(class +44 m):
a Karelsky okaysh JSC; b Centralny GOK JSC
a b
Fig. 2. Principal technological scheme of flotation finishing
of the concentrate of WMS
Contents
25
The collectors of the firm Clariant have demonstrated
the best results both by content of Fe and silica in the
concentrate and by extraction of Fe into concentrate.
It has been recommended to use the foam generator
and modifiers for improvement of parameters of flota
tion. The results of the laboratory study, carried out
by the scheme, shown at the fig. 2, are given at the
table 2.
Parameters, obtained in the laboratory conditions,
were the basis for fulfillment of the semiindustrial tests.
In the course of the last ones it has been obtained the
concentrate containing 70.5% of Fe and 1.8% of SiO
2
with Fe extraction 95.8%. The above mentioned con
centrate has been obtained from the sample of the con
centrate of Centralny GOK JSC containing 67.6% of
Fe and 6.78% of SiO2.
Besides, it has been obtained the highgrade concen
trate from the sample of the concentrate of WMS of
Karelsky okatysh JSC, containing 68% of Fe and
5.12% of SiO
2
. The final highgrade concentrate contents
70.88% of Fe and 1.17% of SiO
2
, Fe extraction
97.06%. Chemical composition of flotation concentrate
is given in the table 3. The results achieved in the course
of testing completely correspond to the technical require
ments of the customer.
Semiindustrial tests have been carried out in condi
tions of total water circulation. It has permitted to
decrease 24 times consumption of the reactants in com
parison with the laboratory tests owing to presence of the
reactants in the circulating water (table 4).
In accordance with recommended technological
scheme the tails of flotation treatment have to be joined
with the tails of WMS and send to the taildepot. It will
permit to decrease significantly remaining concentration
of collector in the liquid phase of the joined product
incoming to the taildepot, owing to sorption on the solid
phase of the tails of WMS. Ratio of volumes of the tails pulp
of magnetic and flotation treatment in this case will be: for
Centralny GOK JSC 25:1; for Karelsky okatysh
JSC 82:1. It will ensure reducing of collector concentra
tion in the liquid phase of the tails to the level lower than
LPC (Limit Permissible Concentration) (fig. 3).
Now NPO RIVS works up the project of the node
of flotation finishing of the magnetite concentrate of
Karelsky okatysh JSC. Productivity of the node will be
4 million tons per year, with possibility of increase of the
last one up to 8 million tons. It is going to begin con
struction of the first turn of the object in 2009. Pneumat
ic flotation machines RIF with great volume have been
chosen as the principal flotation equipment. The project
Table 2. Results of the laboratory tests for finishing of the Fe concentrates
Table 3. Chemical composition of the concentrates
after flotation finishing
Component
Content, %
Centralny GOK JSC Karelsky okatysh JSC
Fe
total
70.5 70.88
Fe
magn
69.2 69.85
SiO
2
1.8 1.17
Al
2
O
3
0.09 0.09
MgO 0.063 0.05
CaO 0.055 0.03
MnO 0.056 0.03
P
2
O
5
0.002 0.01
2
+ Na
2
O 0.017 0.05
S
total
0.027 0.2
Products Output, %
Content, % Extraction, %
Fe SiO
2
Fe SiO
2
Concentrate of Centralny GOK JSC
Chamber 1 (concentrate 1) 82.9 70.2 1.29 85.8 15.7
Total chamber 92.1 70.19 1.85 95.3 25.1
Foamy (tails) 7.9 39.9 64.5 4.7 74.9
Concentrate of WMS 100 67.8 6.8 100 100
Concentrate of Karelsky okatysh JSC
Total chamber 93.52 70.56 1.31 96.87 26.58
Foamy (tails) 6.48 32.9 52.24 3.13 73.42
Concentrate of WMS 100 68.12 4.61 100 100
Contents
26
foresees the partial water circulation. It will permit to
supply the section of flotation finishing with the own cir
culating water.
Flotation machines RIF have been put into practice for
the first time in the ironore industry in industrial scale in
2003 at the ROF (Concentrating Factory) 1 of Ingulet
sky GOK within the bounds of construction of flotation
section for finishing of the magnetite concentrate (fig. 4).
Productivity of the section is 4 million tons per year.
On the base of results of industrial development of the
new technology and equipment at the Inguletsky GOK
administration of the combine has decided to begin
mounting of the second turn of the node of finishing with
installation of the RIF equipment. Annual productivity
of the node is 4 million tons of the concentrate.
Working up of the method of decrease of content of
the harmful admixtures (S, K
2
O, Na
2
O and so on) is the
perspective direction of improvement of quality of the
concentrates of magnetic separation. NPO RIVS has
studied and worked up technology permitting to decrease
of sulfur content in the concentrate of WMS more than
four times.
Conclusion
Worked up technology of the back cationic flotation
ensures obtain of the concentrate containing not less than
70.5% of Fe and not more than 1.2% of silica.
Operational extraction of Fe into the concentrate of
flotation finishing is not less than 95.897%.
Organization of the partial water circulation permits
to decrease four times consumption of the collector and
to provide completely need for circulating water of the
node of flotation finishing.
Aside from silica it is decreased content of sulfur and
others harmful admixtures in the concentrate of flotation
finishing.
Literature
1. / . . . ,
. . , . . . . :
, 1998.
2. . ., . ., . .

. . : ,1988.
3. . ., . .

// . 2007. 2.
Table 4. Reactants consumption
at the different stages of study
Concentrate
of WMS
Reactant
Consumption, g/t
of the concentrate
Laboratory
study
Semiindustrial
tests
Centralny
GOK JSC
Collector 120 35
Foam
generator
20 10
Karelsky
okatysh JSC
Collector 100 25
Foam
generator
20 10
Fig. 3. Change of the collector concentration in the liquid
phase after mixing of the tails of WMS and flotation in
ratio 82:1
Fig. 4. Flotation machines RIF at the Inguletsky GOK
EM
Contents
EQUIPMENT
27
Automation of equipment and
technological processes of the con
centrating plants is one of the most
important directions of the works
carried out by the specialists of
NPO RIVS. Rapid perfecting of
the technical means of automation
permits to work out and to intro
duce into practice the more effec
tive local systems of adjusting and
developed automated systems of
control. We can note few achieved
results suitable to some technologi
cal facilities.
Crushing facility
Main attention in the course of
working out of the systems of con
trol of the crushing facility, apart
from traditional tasks of the tem
perature protection and control of
the system of the oil lubricating,
was paid to complex control of the
crushers of small and medium
crushing, since they are the com
ponents of the crushingtransport
section. It was taken into account
that the crushers of the new gener
ation, produced by Uralmash
JSC, are equipped with devices of
control of the level of filling of
receiving funnel and with automat
ed adjusting of the sizes of unload
ing slots.
The structure of automatic con
trol systems for technological
processes (ACSTP) of the crushing
capacity is rather typical for such
tasks. It involves: the central con
troller of the upper level of control
with the stations of visualization
(operator ARM), the local controllers
of the some crushers and local boxes
of control of the units of the crushers
and linetransport system.
The control strategy has been
chosen as the main goal. Criterions
of efficiency of the last one are
achievement of the maximum pro
ductivity and the least coarseness of
the crushed ore. Statistical depen
dence of productivity of the crushers
on the size of unloading slot and
dependence of power consumption
of electric drive of the crusher on
productivity by initial ore were
obtained in the course of study. The
results of study are the basis for the
program of control. It has been intro
duced conception steptreatment.
It permits to calculate necessary
adjustment of size of the slot depend
ing on quantity of processed ore.
Taking into account shortcom
ings of the control systems based on
statistical methods it has been stud
ied possibility of usage of the instru
mental methods for control of
coarseness of the crushed ore. There
are some achievements in this
sphere: it has been made the system
of automatic analysis of coarseness
of the ore in the moving oreflow by
means of mathematical working of
the signal of the scanner video cam
era. Industrial tests have confirmed
the perspective possibilities of the
offered construction of the device.
Taking into account the high
cost of the model of the granu
lometer NPO RIVS works up
the simplified model that is the
laser range finger that scanning of
the surface of the moving oreflow
(fig. 1). The study has shown that
the device produces the signals
that differ in amplitudefrequency
characteristics for different coar
seness of the crushed product. It
has been worked up the special
mathematical methods for separa
tion of the useful information from
the signals. It is impossible to
determine content of the separate
classes of the coarseness on the
base of above mentioned informa
tion, but it permits to estimate
deviation of coarseness from the
some scheduled value. Solution of
the tasks may be useful for control
of the screens efficiency, control
of coarseness of the products at the
outlets of the crushers and so on.
Besides, mathematical working of
the signals of the laser scanner
permits to obtain simultaneously
information about quantity of the
passing material. It is valuably in
itself in the case of impossibility to
USAGE OF TECHNICAL REMEDIES DEVELOPED
BY RIVS SCIENTIFIC AND PRODUCTION CORPORATION
IN UPTODATE AUTOMATED CONTROL SYSTEMS
FOR TECHNOLOGICAL PROCESSES IN CONCENTRATING
PLANTS
USAGE OF TECHNICAL REMEDIES DEVELOPED
BY RIVS SCIENTIFIC AND PRODUCTION CORPORATION
IN UPTODATE AUTOMATED CONTROL SYSTEMS
FOR TECHNOLOGICAL PROCESSES IN CONCENTRATING
PLANTS
A. A.TRUSHIN (NPO RIVS JSC)
A. A.TRUSHIN,
Chief of Department
of Automation,
Candidate
Contents
28
install the conveyor balance
(lamellar feeders, short conveyors
and so on).
Comminuting facility
Today it is worked up the num
ber of the technical solutions for
control of technological parameters
of comminuting facility, depending
on technological scheme, composi
tion of equipment and others fac
tors. Structure of ACSTP of com
minuting facility is analogous to the
structure of ACSTP of the crushing
facility. Besides, the first one
includes the controllers of the upper
level and the local controllers for
solution of the tasks of control of
technological parameters.
Since the principal position in
the range of comminuting equip
ment, produced by NPO RIVS,
is the pumphydrocyclone units,
the main efforts were directed to
automation of the equipment.*
Flotation facility
In course of working up of the
systems of automation of flotation
facility the main attention was paid
to the systems of automated adjust
ment (ASSUPRV) of the pneu
maticmechanical flotation
machines (RIF) and to devices for
dosing of flotation reactants
(UDRRIF).
The standard complete set of the
systems ASSUPRV involves the
boxes with the programmable con
trollers realizing functions of adjust
ing of level of the pulp in flotation
machines and consumption of tech
nological air fed to aeration (fig. 2).
Technical parameters of the sys
tem ASSUPRV are given below
Diapason of adjusting
of level of the pulp, mm 0500
Precision of maintain
of the level, % 2
of the air consumption, % 0100
Precision of adjusting
of the air consumption, % 2
Voltage of feeding
of the box of control, V ~220
Pressure of the feeding air, MPa 0.61
Maximum consumption
of the feeding air, l/min 50
Possibility of conjunction
with the upper level RS422
Pneumatic components ensur
ing high reliability of operation of
the systems of automation in the
heavy industrial conditions are used
widely in forming of ASSUPRV.
Depending on requests of the
customers ASSUPRV may be
equipped with the level sensing ele
ments of the different types
piezometric, ultrasonic, hydrostat
ical. Every sensing element is char
acterized by enough precision and
high reliability. Diaphragm fluid
meters are used as a standard solu
tion for measurement of the air
consumption. At the same time
NPO RIVS has successful expe
rience of application of the ther
mometrical fluidmeters produced
by the firm Sierra Instrument (the
USA). The advantage of this type of
the fluidmeters is the simplicity of
installation and high reliability.
ASSUPRV may work as the
local system or as a unit of ACSTP
of the concentrating plants. Con
nection between the systems may
be realized by means of the control
cables or by means of the lines of
interface communication. If the
system of automation works as a
part of ACSTP it may be addition
ally equipped with the different
control sensing elements for
increase of volume of information.
The sensing elements control dif
ferent technological parameters:
temperature of the pulp, value of
pH, residual concentration of
flotation reactants, density of the
Fig. 1. Principle of measure
ment of coarseness of the
crushed ore in the ore flow:
a scheme of scanning of the ore flow by the laser range finger;
b volumetric model of the ore flow
a
b
Fig. 2. Flotation machine RIF 16
equipped with the system ASSUPRV
*The more detailed information is given in the article Sedov A. V. and others Development and putting into practice the automatic pump
hydrocyclone units, manufactured by RIVS scientific and production corporation, at the concentrating plants published in the present
issue of Eurasian Mining.
Contents
EQUIPMENT
29
pulp, its consumption and so on. So, it may be inter
esting to use worked up by the corporation sensors for
measurement of the foam layer. The contactless sen
sors were worked up on the base of ultrasonic level
meters. Usage of the sensor permits to change tradi
tional approach to adjusting of level of the pulp, since
it allows carry the process directly by intensity of the
foam output. Fig. 3 shows the example of the compar
ative testing on the base of the known solution of con
trol of the foam output by means of inclination of the
sensing elements and contactless sensor worked up by
NPO RIVS. It is evident that the both sensors give
the same information and work synchronously.
Advantages of the contactless sensor in comparison
with the contact one are evident, since it is removed
some shortcomings: overgrowing of the sensing ele
ments, sticking of the foreign objects on the sensing
element and so on.
Dosing of flotation reactants is another important
direction of the work of NPO RIVS in the field of
automation. The standard structure of the unit for dos
ing of the reactants is given at the fig. 4. It involves the
dosing tables with the feeders of the reactants, the box
of the control with the programmed controller, the
working station ensuring possibility of the visual con
trol and remote control of operation of the system.
The system permits to solve the following tasks:
setting of consumption of the reactants for every
point of dosing;
calculation of consumption of the reactants for
every point of dosing;
diagnostics of the feeders refusal by the balance of
the set and real consumption of the reactants;
calculation of reserve of the reactant in the tank
and forecasting of the rest to the end of the shift.
The corporation has worked up the different ver
sions of the dosing units.
The simplest unit includes the set of the impulse
electrical, electrical pneumatic or pneumatic valves
mounted on the table of the feeders of the reactants,
controlled by the controller. In accordance with
arrangement of the dosing table the distributive col
lector is located in the upper portion of the table. It
ensures the best conditions for the reactants flow
through the feeders. Advantage of the version of the
unit is its low price and simplicity of maintenance.
The more complex and more expensive version of
the feeder (fig. 5) is the monobloc of the stainless steel.
The monobloc may be mounted without the special
table. The feeder involves the segmental rotary oven
door with the pneumatic drive. The ovendoor is joined
consecutively with the electromagnetic liquidmeter.
Construction permits to fulfill easily washing of the
feeding channel with the water in the case of need. The
feeders are the most effective in dosing of the big vol
umes of consumed reactants.
Dosing diaphragm pumps are another perspective
type of the reactants feeders (fig. 6). The working units
of the pumps are made of the corrosionresistant mate
rials. So, the pumps are rather longlived and simple in
operation. If the pumps are used in the systems of auto
mated control they are controlled by means of the cur
rent signals 420 mA. It is possible to carry out control
of the pumps by the interface network.
Besides, above mentioned feeders permit addition
ally dosing of the reactants from the vessels installed
directly near the points of feeding. It is very important
for dosing of the small portions of the reactants. The
arrangement decreases considerably the time of the
reactants transportation and favors increase of efficien
cy of control of technological process.
Fig. 3. Change of the outgoing signal of the different
sensors depending on the foam output in the time
(tenminutes intervals)
1 with the contact sensing elements;
2 with the contactless sensor
Fig. 4. Structural scheme of the plant UDRRIF
Contents
30
Technical parameters of the
units UDRRIF are given below:
Diapason of dosing
of flotation reactants
per minute from 1 ml to 50 l
Precision of the level
maintenance 1
of the reactants
consumption, % 0100
Diagnostics of the channel
of the reactants Option
Number of the points
of dosing Not limited
Voltage of the power supply
of the box of control, V ~ 220
Possibility of conjunction
with the upper level RS485
Summing up the review of the
systems of the reactants dosing it is
possible to mark their following
common advantages:
presence of the programmable
controllers with the sensor panel of
the operator, simple and obvious
process of adjusting of the systems
of adjusting and control of techno
logical process;
application of corrosionpro
tected materials for dosing ele
ments;
large range and high precision
of dosing;
possibility of operation both in
the regime of local adjusting and in
ASUTP of the concentrating factory;
lexible configuration in accor
dance with conditions of operation
and requirements of the customers.
Now the corporation works out
the complex systems of control on
the base of accumulated experience
of creating of the local and complex
systems of control of technological
processes at Almalyksky concentrat
ing factory (Uzbekistan), Kadzha
ransky concentrating factory (Arme
nia) and some Russian factories.
Information system Working
place of flotation operator is one
of the elements of the systems. The
system is realized at the monitors
placed in the working zones of
flotation operators. They are the
users points of the computer net of
ACSTP. The system is intended for
assignment by inquiry of the neces
sary information (without possibili
ty of entering of the controlling
influence) about technological
process. The information includes:
current values of the con
trolled parameters of flotation;
consumption of the reactants
by the points of dosing;
results of expressanalysis of
flotation products;
parameters of operation of the
current shift in the passed period.
Efficiency of the systems
worked up on the base of above
mentioned principles is confirmed
by successful experience of their
exploiting at Uchalinsky concen
trating factory and at the concen
trating factory of JV (Joint Ven
ture) Erdenet (Mongolia).
For increase of efficiency of the
works it has been made the analog
digital testbench. It is supple
mented with the new tasks now.
Equipment of the testbench per
mits to simulate technological
equipment and tasks as the objects
of automation, to adjust and to per
fect different versions of the soft
ware for complex systems of con
trol in the regimes approximated to
the real operation, to carry out
training of the specialists. It is pos
sible to connect the physical mod
els, imitation systems or models of
the systems of automated control to
the testbench.
Automation of the laboratory
flotation machine and the pilot
flotation plant is the example of the
practical application of possibilities
of the testbench.
The laboratory pneumatic
mechanical machine with the
chamber volume 3 liters is
equipped with the following means
of control:
sensor of the pulp level in
flotation machine on the base of
the laser levelmeter;
thermoanemometric device
for calculation of consumption of
the air, fed into flotation machine;
potentiometer sensors for pH
values and oxidationreduction po
tential;
frequencyadjusting drive of
the impeller;
reactants feeders on the base
of the peristaltic dosing pumps;
regulator of the pulp level in
flotation machine keeping up the
pulp level owing to change of the
working volume of the chamber;
box with the programmable
controller, performing the role of
the active device communication
with the object of control; the con
troller ensures collection of the in
formation from automatic sensors,
Fig. 5. Reactant feeder constructed
by NPO RIVS
Fig. 6. Table of the feeders of the
reactants with the dosing pumps
Contents
EQUIPMENT
31
forming of the controlling influence
on the executive units and connec
tion with the central computer of
the analogdigital testbench.
The listed above technical
equipment permits to solve the fol
lowing tasks:
to maintain the set conditions
of flotation tests in automatic
regime;
to analysis obtained data
without halt of the process and car
ry out opportune correction of con
ditions of the experiment depend
ing on obtained results;
to set the program of change
of the regimes in the time, i. e. to
automate the process of researches;
to obtain the worked results
of the tests in the form of the tables,
diagrams and others kinds of visual
present of the information.
The possibilities of the test
bench are realized with the highest
efficiency jointly with the pilot
plant.
Apart from automation of the
experiments, carried out at the
pilot plants directly at industrial
areas or experimental facilities, it is
possible to pass the information at
the distance by means of the chan
nels of the digital communication
to the scientifictechnical center to
analogdigital testbench. The
obtained data are worked here and
obtained results will be returned to
researchers by the same way.
Conclusion
Gained experience and modern
stores of the technical means per
mit to specialists of NPO RIVS
to solve efficiency the traditional
tasks of automation of the equip
ment and adjusting of the some
parameters of concentration and to
create the complex systems of
automation of technological facili
ties as a whole.
EM
Today application of the com
plex automated pumphydrocyclone
units (PHCU) is indispensable con
dition of projecting of comminuting
cycles at the new and at reconstruct
ed concentrating plants. Till recent
ly the main suppliers of the equip
ment were different foreign firms.
In 2000 NPO RIVS has begun
to produce its own hydrocyclones
of the different types. The distinctive
peculiarities of the last ones are the
evolvent input of feeding and usage
of easily removable insets lined with
resistance rubber. The inserts permit
to change the height of cylindrical
part of the hydrocyclone. Depend
ing on the properties of classified
material the hydrocyclones have
the completely rubber or combined
lining: the cylindrical parts of the
resistance rubber, the conic parts
of the silicon carbide.
Today NPO RIVS produces
the hydrocyclones diameters 1000,
700, 500, 380, 250 and 150 mm with
the conicity angle 20
o
and 12
o
. The
battery units were designed and
made on the base of the hydro
cyclones. Productivity of the battery
units is 2001000 m
3
/h of the pulp.
The complete set of the battery
unit involve:
hydrocyclone battery in
cluding;
THE AUTOMATED PUMPHYDROCYCLONE UNITS,
MANUFACTURED BY RIVS SCIENTIFIC
AND PRODUCTION CORPORATION,
AT THE CONCENTRATING PLANT
THE AUTOMATED PUMPHYDROCYCLONE UNITS,
MANUFACTURED BY RIVS SCIENTIFIC
AND PRODUCTION CORPORATION,
AT THE CONCENTRATING PLANT
A. V. SEDOV, O. I. SKARIN, B. P. SERPETSKY (NPO RIVS JSC)
A. V. SEDOV,
Deputy Chief
of Automation Department
O. I. SKARIN,
Leading Specialist,
Candidate of the Technical
science
B. P. SERPETSKY,
Chief of the Team
Contents
32
collapsible sand and discharge
chute;
distributive head with the cover;
pressure feeding pipeline;
hydrocyclones of the neces
sary diameter of the type GCR(K)
RIF with the sand nozzle made of
the silicon carbide;
pumps with electric drive;
lockingadjusting fittings;
control station with the two
pumping units;
system ASUGC with the soft
ware.
Choosing of the hydrocyclones,
pipelines, electric pumps for equip
ping of PHCU is carried out by
means of the modern methods of
computer calculations. The special
ists of the corporation have worked
up the program permitting to deter
mine the number and the type of the
hydrocyclones, rational dimensions
of the changeable nozzles and pres
sure in feeding of the hydro
cyclones.
Depending on intended tasks and
productivity of comminuting cycle
NPO RIVS produces the hydro
cyclone batteries of the linear and
round type.
The linear arrangement is used for
less than four hydrocyclones per
one pump, the radial arrangement
for greater number of the hydro
cyclones mounted in the battery (up
to 1618 units). The linear arrange
ment is expedient in the cycles of the
ore comminuting with usage of the
hydrocyclones more than 500 mm
diameter (GCK700, GCK100).
Lining of the hydrocyclones and
nozzles are made of silicon carbide.
Experience shows that the
hydrocyclones of the big diameter
operate effectively with the plants of
the first and second stages of com
minuting with obtain of the dis
charge product with the coarseness
85% of the class 0.074 mm.
Conventional example of calcu
lation is given in the table. It is
shown that selection of the sizes of
the changeable nozzles at the hydro
cyclones 500, 700 and 1000 mm
diameter permits to obtain the dis
charge of the nominal coarseness
110 m (it corresponds to about
85% of the class 0.074 mm). Pro
ductivity of the hydrocyclones is
148, 368 and 475 m
3
/h correspon
dingly.
It is possible the two versions of
operation of the battery of the
round type. The distributive head
is divided in two parts in the first ver
sion. Two sand baths and two dis
charging ones ensure autonomous
operation of every half of the hydro
cyclones with its pump (fig. 1). It is
recommended to use the first version
in the ore comminuting units. Feed
ing of the battery in the second ver
sion is realized through the distribu
tive head common for all installed
hydrocyclones. The head is divided
in two too. The force pipeline is
equipped with the Tjoint and with
the two pumps. It allows exploit of the
unit at the different products (fig. 2).
Apart from perfecting of con
struction of the hydrocyclones, of
increase of quality of making of the
last ones, the specialists of the corpo
ration pay great attention to working
up of the system of automated con
trol of equipment. Efficiency of
operation of the system ensures
Results of calculation of parameters of the hydrocyclones
Diameter
of the
hydro
cyclone,
cm
Size of the nozzle, cm
Productivity of the hydro
cyclone (m
3
/h) under
the pressure, MPa
Nominal coarseness of
discharge (m) under
the pressure, MPa
feeding
dischar
ging
sandy 0.1 0.15 0.1 0.15
100 22 20 25 380 465 105 96
22 25 25 475 582 117 106
22 30 25 570 698 128 116
70 17 16 16 245 300 93 84
17 20 16 306 375 104 94
17 24 16 368 450 114 103
50 12.5 10 6 119 145 99 92
12.5 12.5 6 148 182 114 100
12.5 16 6 190 232 125 113
Fig. 1. Version of arrangement
of the hydrocyclone battery
(one sump, one product, two pumps)
Fig. 2. Version of arrangement
of the hydrocyclone battery
(two sumps, two products, four pumps)
Contents
EQUIPMENT
33
directly achievement of the techni
caleconomic parameters of work of
PHCU and safety of the serving staff.
Automated system of control
PHCU is destined for continuous
measuring, control and adjusting of
technological parameters of the clas
sification process.
ASUGC ensures:
continuous centralized control
of PHCU in the regime of the real
time;
logical control of the operations
of automatic starting and stopping of
PHCU;
maintenance of adjusted tech
nological parameters within the set
bounds of the values;
remote control of the frequen
cyadjusted electric drive of the
pump and drives of the lockingad
justing accessories;
visualization of parameters of
technological process and represen
tation of the state of every unit of the
system at the given moment with ap
plication of the modern software;
control, registration and stor
age of the principal parameters of
technological process and possibility
of construction of the diagrams of
changes of the parameters in the
regime of the real time;
automatic forming and con
ducting of the history of techno
logical process with possibility of
construction of the diagrams of
change of parameters of technologi
cal process within the last hour, day,
month;
automatic forming and issue of
the reports about appearance of the
emergency situations.
Approach to realization of the
systems is illustrated by the example
of automatic control of classification
process in the hydrocyclones in the
ore comminuting cycle (fig. 3).
The tasks of the system of
automation are:
stabilization of level of the pulp
in the sump by change of speed of
rotation of the drives of the sand
pumps;
Fig. 3. Structural scheme of automated pumphydrocyclone plant
1 densitymeter; 2 ShPGC box of control of the slidegates of the pumps A and B; 3 slidegates of the pumps A and B;
4 change of pressure at the entrance of the hydrocyclones of the pumps A and B; 5 emergency level of the sandbath of the
pumps A and B; 6 adjusting slidevalve; 7 liquidmeter; 8 slidevalve of washing of the pumps A and B; 9 control of the water
pressure; 10 slidevalve of hydraulic insulation of the pumps A and B; 11 bottom gate of the pumps A and B; 12 local control
panel of the pumps A and B; 13 ShPZA box of control of the locking accessories of the sump of the pumps A and B; 14 drainage
of the pumps A and B; 15 measurement of level in the sump; 16 station of control of the pumps; 17 ShU box of control of the
hydrocyclone unit; 18 hydrocyclone battery of the pump A; 19 hydrocyclone battery of the pump B.
Contents
34
stabilization of pressure of the
pulp in feeding of the hydrocy
clones by means of change of the
number of the last ones operating in
the battery (switching of the pulp
flows);
stabilization of density of the
pulp by regulation of feeding of the
water in the sump of the sand pumps
in accordance with the readings of
the densitymeter at the discharge of
the hydrocyclones;
automatic starting and stopping
of the sand pumps with ensuring of
washing of the pumping pipes (in
starting) and discharge of the rests of
the pulp into the drainpipes (in
stopping).
It is foreseen the following tech
nical means for realization of the
enumerated functions:
1. Pneumatic boxes of control of
the battery of the hydrocyclones
ShPGC (fig. 4) for placing of the
blocks of preparation of the com
pressed air and elements of control
of the slidegates at the feeding
branch pipes of the hydrocyclones.
2. Pneumatic boxes of control of
the sump ShPZA (fig. 5) includes
the blocks of preparation of the air
too and elements of control of the
locking accessories:
slidevalves for feeding of water
for washing of the pipelines of the
pumps;
slidevalves for feeding of water
for hydraulic insulation of the pump;
bottom slidevalves of the sump
with hydraulic drive;
discharge drain valves of the
pumps.
There are the switches of selection
of the working regimes (automatic
hand), devices of control of the lock
ingadjusting accessories and indica
tors of the limit positions (open
close) at the front panel of the box.
The boxes are placed near the hydro
cyclones and sump. It allows to
observe the state of operation of
equipment at the front panel of the
box and to control locally the locking
accessories in the hand regime.
3. Station of control of the
pumps (SCP) (fig. 6) involves con
verter of frequency for frequency
adjusting of speed of rotation of the
drives of the sand pumps and power
commutating plant for switching
from the working pump to the
reserve one and backwards. It allows
to setting the pump in motion in
automatic and hand regimes by the
network or by the frequency drive.
All commutating accessories send
the information about every logical
switching and about state of equip
ment to the box of control of
ASUGC.
Since SCP is the power plant it is
placed in electric premises inaccessi
ble for technological personnel in
accordance with the standards of
safety. So, the information about the
state of operation is depicted at the
panel of the box of control.
4. Box of control ASUGC (fig. 7)
is destined for collection of the
information about technological and
technical parameters of equipment,
Fig. 4. Pneumatic box of control
ShPGC with the elements of control
and indication
Fig. 5. Pneumatic box of control
ShPZA with the elements of control
and indication
Fig. 7. Box of control ASUGC
Fig. 6. Station of control of the pumping assembly
Contents
EQUIPMENT
35
for comparison the real parameters
with the set ones and for generating
of the entering signals of adjusting
for pneumatic boxes of control and
for station of control of the pumping
assembly.
The sensor panel of the operator
is installed at the front of the box of
control. The panel is used for intro
ducing and for representation of the
all necessary parameters of automat
ed system of control PHCU. The
sensor panel of the operators
involves professional manning
machine interface with the sensor
keyboard. It is equipped with protec
tion IP65 and covered additionally
by the vision screen.
The example of representation
of the interface of the panel of the
operator is given at the fig. 8. The
devices of the light and sound sig
naling are located in the upper part
of the box. The button of emer
gency disconnection of the sand
pumps and the system of cooling
of equipment are installed inside
of the box. Besides, the box of
control communicates with the
pneumatic boxes and with the sta
tion of control of the pumping
assemblies.
5. The sensors of technological
parameters, controlling:
level of the pulp in receiving
sump;
pressure of the pulp in feeding
of the hydrocyclones;
density of the discharged prod
ucts of the hydrocyclones;
consumption of the water, fed
to the sump;
pressure of the water, fed for
washing of the pumping pipelines.
Realization of automatic control
of the mentioned above parameters
is carried out by the use of the fol
lowing technical means:
level of the pulp in receiving
sump by means of the levelmeter;
pressure of the pulp in feeding
of the hydrocyclones by means of
the sensor of pressure with ceramic
diaphragm divider and digital indi
cator of pressure (fig. 9);
density of the discharged prod
ucts of the hydrocyclones by
means of the densitymeters of the
radioisotope or piezometric type
(fig. 10);
granulometric composition
with the granulometers.
Lockingadjusting accessories
include the bottom slidevalves
with pneumatic drive, covering the
discharge holes of the sumps. It
allows to carry out automatic tran
sition to the reserve pump or to
carry out urgent replacement of
the pump. The cylinders have cor
rugated protection of the rods.
They are equipped with the system
of braking for protection from the
losses or sharp decrease of pressure
of compressed air. Besides, the
magnetic sensors of the ultimate
positions are installed at the cylin
ders (fig. 11).
Adjusting of feeding of the water
into the sump is carried out by
means of the disc lock with pneu
matic drive and electrical position
Fig. 8. Fragments of representation of the panel of the operator of the box
of control ASUGC
Fig. 9. Sensor of pressure with the
digital indication of the current value
Fig. 10. Pneumatic drive of the
bottom slidevalve with the system
of braking
Contents
36
ing having the return communica
tion by the signal.
It is foreseen the clamping valve
with pneumatic control for dis
charge of the pulp into the
drainage after stopping of the
pump (fig. 12). Operation of the
drain valve is united with operation
of the drive of the bottom valve: in
the case of closing of the drain
valve the bottom valve is opened
automatically.
Adjusting of the number of the
hydrocyclones operating in the bat
tery is carried out by means of the
slidegates of the knife type with pneu
matic drive (fig. 13). The constructive
features of the slidevalves are the elas
tic guides. They permit to squeeze out
of the slidevalve of the hard particles
falling under the knife. It increases sig
nificantly reliability of operation of the
accessories with the pulp.
Thus, application of the newest
technical means of automation of
the leading world producers, taking
into account expediency of the tech
nical solutions, permits to create the
modern high efficient systems of
control of classification in the
hydrocyclones.
Today more than ten PHCU pro
duced by NPO RIVS operate or are
prepared for putting into practice in
the facilities of the ore comminuting
or additional comminuting of the
products at the concentrating factories
of Kolskaya GMK JSC, Karelsky
okatysh JSC, Zangezursky MMK
JSC, Zhezkentsky GOK of Corpora
tion Kazakhmys, Almalyksky GMK
JSC and others.
The results of industrial exploit
ing of the hydrocyclone units in the
cycles of comminuting of the con
centrating factories show the high
technological, technical and eco
nomic efficiency of the units and
high operating reliability.
Usage of automated hydro
cyclone units allows increase
extraction into concentrate of the
set quality owing to increase of
output of the classes of the opti
mum flotation coarseness. Increase
of extraction may be 210%.
Automated regime permits to min
imize negative influence of the dis
turbances arising in the cycle of
comminuting owing to changeable
load on the mills and changeable
level of the pulp in the sump of the
pump.
Experience of application of the
hydrocyclone units shows that they
permit to:
maintain the process of classi
fication in the regime of content up
to 95% of the set class of coarseness
in the discharged products of the hy
drocyclone;
increase efficiency of classifi
cation by 510%;
increase usage of the mills fac
tor by 78%;
decrease about three times
electric power consumption;
increase the life of wearing
parts of the pumps and hydrocy
clones up to 4 thousand hours.
Fig. 12. Clamping valve for discharge
of drain of the pump
Fig. 11. Indicator of density
(PIPRIF). The box with converter
and measuring counter
Fig. 13. Slidegate with pneumatic drive installed in the entrance
into the hydrocyclone
EM
Contents
EXPERIENCE OF RECONSTRUCTION OF CONSENTRATING FACILITIES
37
It is known that success of the
any project of the mining and con
centrating production is defined by
the following principal factors:
modern reliable technology of
treatment of the raw minerals;
correct calculation and choice
of the main technological equip
ment and arrangement of the last
one;
availability of experienced and
qualified executers.
In the past there were clear pro
jecting specializations in the for
mer USSR:
scientific researches were car
ried out by NII (ScientificRe
search Institutes), the last ones
gave out the initial data for project
ing, technological regulations;
solely project works;
construction works carried
out by the organizations in accor
dance with the own plans, not co
ordinated always with one or an
other task of the project of the con
centrating production.
The most crucial and compli
cated projects were carried out by
the complex institutes involved in
three structures. The general coor
dination of the project works were
fulfilled by the Chief Directorates
of the Ministries and by the plants
customers. For all this any project
institute, with the exception of the
complex ones, has not contributed
its overall share to the work. So, the
institute was not responsible com
pletely for consequences of realiza
tion of the project on the whole.
The worked up and realized
projects of the concentrating facto
ries in Zhezkazgan, Almalyk, Tal
nakh, Kryvbass, Erdenet and so on
were the classical soviet projects in
the field of mining and concentrat
ing production in the former
USSR. The projects were worked
up by the complex institutes
Mekhanobr, Mekhanobrchermet,
Sibtsvetmet and others.
Above mentioned projects were
the basis for forming of the gener
ally adopted later standards of
technological projection, methods
of estimation of efficiency and oth
ers requests and working condi
tions.
Today the complex research
and project organizations almost
stop their activity. The organiza
tion branch structure for working
out and realization of the projects
has disappeared.
In accordance with the world
practice the functions of general
contractors of the works as a whole
are given to the engineering orga
nizations. They carry out the com
plete set of the works beginning
from conception of the project,
supply with equipment, construc
tion up to the total completion of
the project.
NPO RIVS combines the tra
ditional and the modern experi
ence of its own research, design
subdivisions and machinebuilding
facility. It ensures the key partici
pation in realization of the pro
THE MAIN REGULATIONS OF DESIGNING ACTIVITY
OF RIVS SCIENTIFIC AND PRODUCTION
CORPORATION IN MINING AND CONCENTRATING
PRODUCTION
THE MAIN REGULATIONS OF DESIGNING ACTIVITY
OF RIVS SCIENTIFIC AND PRODUCTION
CORPORATION IN MINING AND CONCENTRATING
PRODUCTION
M. A. ARUSTAMYAN (NPO RIVS JSC)
I. Sh. SATAEV, B. A. KUTLIN (RIVSproject JSC)
M. A. ARUSTAMYAN,
Executive Director,
Candidate
I. Sh. SATAEV,
Executive Director,
Candidate
B. A. KUTLIN,
General Director,
Doctor
Contents
38
jects. And what is more, concord of knowledge and
possibilities of the company permits to build the pro
duced machine into technological schemes and to ful
fill additional optimization of the new technologies by
means of creating of the most effective constructions
of the new machines, combination of the last ones and
the regimes of the work.
Today the corporation is able to ensure the whole
complex of the works for creating of the new and for
renovation of existing facilities: beginning from selec
tion of the most effective technology to the final trans
fer of the object to the customer with attainment of
guaranteed technological parameters.
Till recently the projection stage has been absent in
the chain of NPO RIVS. The project works have been
carried out by contractor organizations in accordance
with the technical tasks worked up by NPO RIVS. In
this case the contractor has been inevitably given in own
ership the technology, knowhow and specific para
meters of equipment and the means of automation. But
responsibility to the customer remained on initiator of
the project.
In 2005 it has been set up the own branch subdivi
sion RIVSproject JSC.
From the very beginning it has been established pri
orities of fulfillment of the works of the corporation:
1. Carrying out of the own scientificresearch
works with the real ore samples and giving out of
technological regulations for projection. At this
stage it has been established the technological para
meters: optimum output of the products of concen
tration and content of the one or another compo
nents in the products; specific load on the equip
ment, conditions of comminuting for effective
opening of the minerals and others; choice of the
machines for all operations.
Sequence and depth of studying of some stages of
the project ensuring maintenance of achieved level of
production or its increase; the terms of fulfillment of
the every stage are coordinated with the terms of deliv
ery and mounting of the equipment.
2. In the most cases it is carried out detailed tech
nological audit of the current state of the concentrating
factories. As a rule, for this it is recommended to renew
the ore preparing facility for decrease of coarseness of
the crushed ore by means of replacement of the crush
ers, screens, classifying equipment, development of
automated control systems for technological processes
(ACSTP). That the offered measures are accompanied
by decrease of the capital investments, operating costs
(first of all electric power and comminuting bolls) and
are compensated in 1215 months.
In the course of reconstruction of the crushing
facilities it is selected, as a rule, modernized conical
crushers produced by Uralmashzavod. The crushers
allow to carry out the optimum conjunction of the
crushers at the three stages of crushing and to install as
far as possible the new high effective screens manufac
tured by RIF or others Russian producers. As a rule,
analysis of the versions shows some pricing advantages
of equipment produced by the Russian firms. They
ensure decrease of coarseness of the crushed ore from
2225 to 1415 mm in the open and to 12 mm in
the closed crushing cycles.
3. At the same time according to order of the cus
tomer and in accordance with the technical parame
ters, suitable for conditions of the project, it is offered
equipment, means of automation, power supply corre
spondingly to the technical solutions of the corpora
tion. The last one works in cooperation with the
known firms: Outokumpu, Metso Minerals, Cetco,
Diemme and others.
In processing of the ores with high content of the
mud and moisture (GOKs of the Republic Bashkor
tostan and Kazakhstan) the semiselfcomminuting
crushers of the ore are the priority equipment. Besides,
it is recommended the technologies of the classical ore
preparing with separation of the fine fractions by
screening or washing of the ore and separating of flota
tion treatment of the fine fractions (mud) in the inde
pendent cycle (fig. 1).
Two projects with technology of semiselfcom
minuting are realized partially today. It is completed
projecting and expansion of Kajaransky concentrating
factory with increase of its yearly productivity from 8.5
to 12.5 million tons of the ore. It is foreseen installa
tion of the mill 10.34 meters diameter of the firm
Fuller (the USA). The peculiarity of the project is
the version of directing of the critical class of
coarseness directly to the ball mill of the second stage
of comminuting with exclusion of the operation of
additional crushing.
It is carried out the working projecting and it has
been begun construction of Khaibullinsky concentrat
ing factory with annual productivity 3 million tons of
the ore at the deposit Yubileynoye in Bashkiria.
Projecting of flotation facilities uses in maximum
degree the factors marked by technological regula
tions, contrast range of properties of the valuable min
erals revealed in the course of oxidation and thermal
Contents
39
treatment of the pulp. Thus, separation of the copper
head, oxidizing steaming and heat conditioning of
the pulp in the lime medium are used in the cycle of
the zinc flotation in the course of concentrating of the
copperzincpyrites ores (fig. 2).
The rubbing complex for mechanized renovation of
the surface of the finecomminuted minerals before
flotation operations is the latest work of the corpora
tion. It is very important in technology of the pulp
conditioning. The prototype of the complex was used
at Uchalinsky GOK. It permitted to increase content
of zinc in the zinc concentrate from 46 to 50% with the
same level of extraction.
Today it is projected the comminuting complex. It
will permit to involve in treatment every year 4 million
tons of the outbalance dumping ores at Almalyksky
GMK with hydraulic transportation of the ore pulp to
the distance 6.5 kilometers to the copper concentrat
ing factory.
It is carried out now the project of treatment of the
out of balance raw minerals of Kalmakyrsky mine.
The project may be the prototype of the module solu
tion for many mining and concentrating works accu
mulated sizeable volumes of the out of balance and
poor ores. On addition of flotation facility the project
is utterly completed with the standard Russian equip
ment and may be realized in the shortest time.
It has been worked up the project and begun recon
struction of the fluorspar concentrating factory
Borundur in Mongolia.
Successful development of the project of the sec
ond turn of concentrating factory Erdenet in Mon
golia is the pride of NPO RIVS. The new flotation
technology has been worked up and put into practice
in 20062007. The technology has ensured double
increase of extraction of molybdenum. It has been
worked up the projectestimate documentation, orga
nized making and delivery of the metallic construc
tions and equipment (flotation machines RIF 25 and
RIF 16, contact vats RIF 100 and others). Some share
of the body articles of flotation machines RIF 16 and
contact vans, nonstandard equipment were made at
Fig. 1. Example of technological scheme of concentration of the copperzinc ore with separating of the mud flotation
in the independent cycle
Contents
40
the local repairmechanical plant. Construction
assembling works, technological adjusting of the
process and putting into operation were carried out in
the shortest time. The project annual capacity of the
new facility has been increased from 4 to 6 million tons.
It has been built and put into operation the third
flotation section of Sybaisky concentrating factory
(Bashkiria) (fig. 3). The section was constructed in
2008 in accordance with projection solutions of NPO
RIVS. Its productivity is 1.5 million tons of the ore.
The technologists of the corporation use actively in
all works flotation reactants of the firms Saitec (the
USA) and Clariant (Germany). The reactants are
the basis for preparing of technological regulations for
Fig. 2. Technological scheme of the zinc flotation cycle of CuZn ore with operations of conditioning of the pulp
in the contact vats RIF
Contents
41
projecting of additional flotation of the ferrocontain
ing concentrates in Kryvbass. Besides, it is projected
flotation facility with productivity 4 million tons of the
concentrate for Karelsky okatysh JSC.
The longterm experience of NPO RIVS demon
strates convincingly efficiency of usage in the projects
of the flotation machines RIF. One of the advantages
is the possibility to choose the type, dimension and
working regime taking into account technological fea
tures of the raw ore and the purpose of the operations.
It is marked that equipping of flotation facilities with
flotation machines of the type RIF or modernization
of the operating machines by means of placing of the
aerators RIF into flotation chambers have improved
significantly technological parameters at the concen
trating factories of the combines Pechenganickel
(OK40), Erdenet (FPM12.5), Uchalinsky GOK
(FPR40) and others. Power inputs have been
decreased significantly. So, the flotation machines and
units of the last ones may be used independently in the
further projects.
Experience of work of NPO RIVS shows that
application of automated pneumaticmechanical
flotation machines for recleaning has the number of
advantages in comparison with intensively propagated
lately pneumatic (columnar) machines.
More and more attention is paid by the corporation
in its projects to application of the new equipment in
the cycles of additional comminuting and processing
of the products of flotation. They are the ball mills
Vertimill, automated hydrocyclone units with the
complete automation. The equipment is involved in
the working out projects of Khaibullinsky, Kajaransky
and others concentrating factories.
It is preferred installation of the press filters in
accordance with the project of the filtering facilities
of copper, zinc and molybdenum concentrates.
Experience of operation of Uchalinsky GOK and
GOK Erdenet demonstrates convincingly possi
bility of the total exclusion of drying of the concen
trates or significant decrease of expenditures for this
operation.
Fig. 3. Flotation section 3 of Sybaisky concentrating factory
Fig. 4. Dosing table for flotation reactants UDFR
1 terminal box; 2 frame of the table; 3 dosing pump;
4 collector
Contents
42
Technical solutions for ASAK and ACSTP of the
concentrating facilities, used in the projects of RIVS
project, are directed to application of the immersible
systems of the operational analytical control Amdel
(Austria), PERT (the USA). Dosing of flotation reac
tants is carried out on the base of the worked up and
produced by corporation units UDFR (fig. 4).
Every principal technological apparatus (ore mills,
flotation machines, hydrocyclone units, press filters),
used in the projects of the corporation, are equipped
with the devices of control of regulated parameters.
The last ones form the initial base for automated con
trol and adjusting from the control panel of the opera
tor. Besides, they are the basis for building of the
expert systems (fig. 5).
Thus, synchronous combination of technological
tests, working out of the equipment and selection of
the optimum parameters of the used equipment of the
firm are the guarantee of high level of the projects of
NPO RIVS.
RIVSproject JSC, as a part of NPO RIVS, is
the organization that is able to working up the projects
for the whole complex of the works at the mining and
concentrating facilities. The basis factors are:
availability of the own base for fulfillment of the
regulating works, facilities for making of the equipment,
possibilities of its mounting and putting into practice,
guarantees of achieving of the project parameters;
close creative cooperation with the organiza
tions, projecting operation of the mining complex.
EM
Fig. 5. Structure of the complex of the technical means of ACSTP of Khaibullinsky CP
Contents
43
Taking into account constant
decrease of reserves of the high
grade ores, mining and concentrat
ing works are obliged to increase the
volumes of output. It is impossible
without introducing of the new
technique and technology. The
most perspective direction in the
mining branch is introducing of the
new equipment and technologies at
the facility of processing of the raw
minerals.
Side by side with Gaysky GOK
Uchalinsky GOK is one of the biggest
copper processing works at the Urals.
In total they produce more than 70%
of the copper concentrates and about
90% of the zinc concentrates.
Bystage reconstruction of the
facilities of the concentrating plant of
Uchalinsky GOK JSC has been
completed in 2007. Reconstruction
has been started in 2000 with usage of
the modern equipment and new
technology.
Analysis of the volumes of
processed ore at CP (concentrating
plant) of Uchalinsky GOK in
19842007 has shown that output of
the plant in period of reconstruction
has not decreased. Quite the contrary
productivity of the plant has increased
by 24% up to 5 million tons of the ore
every year (fig. 1).
The raw mineral base of Uchalin
skaya concentrating plant includes:
copperzincpyrites ore of
Uchalinskoe deposit;
copper ore of Uzelginskoe de
posit;
two types of the copperzinc ores
of Uzelginskoe deposit: pyritescon
taining and pyrrhotinecontaining;
copperzinc ore of Molodezh
noe deposit.
Brought ores of Aleksandrovskoe,
Nikolaevskoe, Safyanovskoe deposits
indifferent periods formed the biggest
share of processed ores.
The principal ore minerals of the
ores processed at Uchalinskaya plant
are pyrites, sphalerite and chalcopy
I. A. ABDRAKHMANOV,
General Director, Candi
date of Technical science
R. A. YAGUDIN,
Chief of Concentrating
Plant
A. V. ZIMIN,
General Director,
Candidate of Technical
science
M. A. ARUSTAMYAN,
Executive Director,
Candidate of Technical
science
E. P. KALININ,
Director
IMPROVEMENT OF EQUIPMENT AND TECHNOLOGY
AT UCHALINSKAYA CONCENTRATING PLANT DURING
20002008
IMPROVEMENT OF EQUIPMENT AND TECHNOLOGY
AT UCHALINSKAYA CONCENTRATING PLANT DURING
20002008
I. A. ABDRAKHMANOV, R. A. YAGUDIN (Uchalinsky GOK JSC)
A. V. ZIMIN, M. A. ARUSTAMYAN (NPO RIVS JSC)
E. P. KALININ (NPO RIVS JSC, Urals Representation)
Fig. 1. Change of volume of processed ore at Uchalinskaya concentrating plant
by the years:
1, 2 before the reconstruction (19841991 and 19921999 correspondingly);
3 after reconstruction (20002007)
Contents
44
rite (fig. 2). Mineral composition of
the ore is rather simple, but it is char
acterized by complicated texture
structural features.
Analysis of work of the plant in
19842007 demonstrates steady
decrease of copper and zinc content
in the concentrated ores (fig. 3).
Unfavorable factors, defining
concentrationability of the ores, are:
nonuniformity of distribution
of the useful minerals in the ore,
wide range of sizes of the mineral
formations, that demands addition
al crushing;
complex fine mutual accretion
of sulfides, spreading of collomorphic
varieties of the last ones disposed to
overcrushing;
presence of the varied forms of
pyrites, fine inclusions of pyrites in
chalcopyrite and sphalerite (fig. 4).
Simultaneously with beginning of
reconstruction of the first section of the
plant it was carried out the research
works for perfecting of the scheme and
regime of flotation. The results of the
researches were used in the projected
scheme of processing of the ore.
On the base of study of processed
at the plant ores, carried out by the
specialists of JV (Joint Venture)
IVS JSC, it has been worked up the
technological scheme of concentra
tion, including the new technological
solutions (fig. 5):
separating of the intercycle
copperhead and recleaning of the
last one;
obtain and separating of the
highgrade (by copper content) col
lective concentrate with its subse
quent additional crushing to coarse
ness 9092% of the class 44 m;
introducing of the station of
preparing of the pulp before separating
of the first zinchead, including con
ditioning with the copperas and lime;
additional flotation of sphalerite
from the tails of the collective flota
tion;
additional crushing and classifi
cation of the tails of the first reclean
ing of the zinchead and the con
centrate of additional flotation before
send of the last ones to the thickener;
heat and aeration conditioning of
the pulp in the first zinc recleaning;
removal of copper and ferrum
out of the zinc concentrate with ob
tain of zinc with the chamber product
and finishing of the copperpyrites
product in the separate cycle.
Worked up technological scheme
was the basis for project of reconstruc
tion of Uchalinskaya concentrating
plant. Bystage introducing and per
fecting of the scheme was carried out
in the course of reconstruction.
Technical reequipment of the
plant has been begun from flotation
and filteringdrying facilities since
Fig. 3. Change of content of copper (a) and zinc (b) in processed ore
by the years:
13 the same positions as at the fig. 1
a
b
Fig. 2. Mineral composition (%)
of the copperzinc ore
of Uchalinskoe deposit
Fig.4. Spreading of chalcopyrite (Cp)
and sphalerite (Sf) in the intergrain
space of pyrites grains (Py).
Uchalinskaya copperzinc ore
Contents
45
they are priority and give the biggest
efficiency.
Before reconstruction the main
building of the plant has been equipped
with flotation machines of the two
types: FPM16 (on the base of flota
tion machine OK16) and FM6.3
including 412 chambers. Above men
tioned equipment has worked about 20
years before beginning of the recon
struction. It was obsolete and depreci
ated. Great costs of repair of the equip
ment have increased the cost of the
concentrate. It was not possible to
improve parameters of concentrating.
The first stage of reconstruction (for
annual volume of the ore processing
1.5 million tons) has been realized in
the short time (nine months and
twenty days) without decrease of the
rate of output of the products owing to
well coordinated and competent work
of the specialists of the combine and
JV IVS JSC. The first section of the
operations of copper, collective and
zinc flotation has been put into oper
ation in February 2001.
On the base of results of testing of
filtering of the copper and zinc con
centrates the administration of
UGOK JSC. has decided to buy
the four pressfilters of Italian firm
Diemme as the most correspond
ing to conditions of Uchalinskaya
concentrating plant. Four modern
pressfilters were installed in the fil
teringdrying section after disman
tling of technological lines 3 and 4.
Comparison of results of the work
of the concentrating plant shows
increase of extraction of copper by 7%
and zinc by 2.9% in period of
reconstruction (fig. 6, a).
At the second stage it has been
reconstructed the second and third
sections in the cycles of the copper,
collective flotation and additional
flotation of zinc with increase of vol
umes of annual processing of the ore
up to 3 million tons.
In the course of reconstruction in
2002 the screens GIT51 in the crush
ing facility of the concentrating plant
has been replaced by the more efficient
selfbalancing screens GST52UM
produced by JV IVS JSC. Besides, it
has been carried out stabilization of the
assemblies of additional crushing at the
first and second sections of the crush
ing facility of the main building of the
concentrating plant.
The main attention in the course
of the second stage of reconstruction
has been paid to increase of extrac
tion of zinc. It has been put into
practice temperature treatment of
the pulp in the lime medium before
the operations of the main and first
recleaning zinc flotation. Introduc
ing of steaming has permitted to
depress pyrites, to make more active
and to stabilize flotation of spha
lerite, to decrease the circulating
loads. The biggest amount of the
accretions of sphalerite with pyrites
presented in the tails of the first zinc
recleaning, in spite of additional
comminuting of the products before
the principal zinc flotation. So, it
has been organized additional com
minuting of the above mentioned
tails and broadening three times of
Fig. 5. Principal technological scheme of flotation
at Uchalinskaya concentrating plant
Contents
46
the front of flotation of the second
zinchead with introducing of the
heat conditioning. It has permitted
to extract into the final product up to
70% of zinc (as against 50% earlier)
and to increase the through extrac
tion of zinc to 50%. Besides, the
losses of copper and zinc in the tails
and in the concentrates of the
opposed names have decreases.
Fig. 6, b shows the change of
extraction of zinc into the zinc con
centrate in the course of reconstruc
tion.
Comparison of results of the work
of the concentrating plant on comple
tion of the second stage of reconstruc
tion shows increase of extraction of
copper by 9.3%, of zinc by 4.9%
without decrease of quality of the zinc
concentrate.
There is one serious problem at the
Urals miningmetallurgical complex.
The fact is that the ores are mined at
the Southern Urals, but the main
capacities for melting and refining are
located at the Central Urals. Besides,
efficiency of the miningmetallurgical
complex is decreased because of com
paratively low quality of the concen
trates produced by the Urals factories.
Thus, average copper content in the
copper concentrate, produced by
Uchalinskaya concentrating plant,
was 1516%. It is lower than the aver
age world index (2225%).
Owing to abovestated the third
stage of reconstruction of the concen
trating plant was directed to increase
of quality of the copper and zinc con
centrates.
Besides, modernization of equip
ment at the crushing facility of the
concentrating plant has been contin
ued at the third stage of reconstruc
tion. It has been mounted the second
screen GST52UM and has been
begun renewal of the crushers the
crusher KMD2200 has been
replaced by the more perfect KMD
2200T1DM produced by Ural
mashzavod.
It has been stated in the course of
study that increase of quality of the
concentrates demands opening of the
finest accretions of the sulfide miner
als. In this connection in the August
2006 the industrial tests have stated
expediency of usage of the cylindrical
pebbles 25 mm diameter instead of
the balls 40 mm diameter as the com
minuting medium in the operations
Fig. 6. Change of extraction of copper (a) and zinc (b) into the concentrates
of the same name by the years:
13 the same as at the fig. 1
a
Fig. 7. Change of copper content in the copper concentrate (1)

and extraction of copper (2) (IXII months of 2007)
Contents
47
of additional comminuting. Analo
gous measure has been carried out in
September 2007 in the mills of the
third stage of comminuting: the steel
balls 60 mm in diameter have been
replaced by the cylindrical pebbles
32 mm diameter.
After putting into the practice of
the new section of finishing of the
rough zinc concentrate copper
content in the common copper
concentrate has increased up to
17.4% without decrease of extrac
tion (fig. 7). The new section is des
tined for additional comminuting
of the zinc concentrate with pre
liminary washing of the last one,
for one principal cleaning and three
recleaning of the copperpyrites
product. Content of zinc was 48%,
extraction 81.2%.
For further intensification of the
process in the zinc cycle of the sec
ond section of the concentrating
plant it has been carried out industri
al testing of the rubbing complex
OFK15 RIF. The tests have been
carried at the end of 2007 at the
beginning of 2008. They have per
mitted to increase content of zinc in
the concentrate up to 50.2% without
decrease of extraction.
The researches directed to
increase of quality of the copper
concentrate were carried out in the
laboratory of JV IVS JSC in 2007.
The principal element of the offered
technology was application of the
high selective reactants of the new
generation. Recommended tech
nology will permit to increase con
tent of copper in the concentrate in
the course of flotation of the copper
ore of Uzelginskoe deposit up to
20%, of the copperzinc ores up
to 18.5%.
Modern flotation facility of the
concentrating plant is equipped with
flotation machines RIF45 2
chambers, RIF25 111 chambers,
RIF16 26 chambers, RIF8.5
109 chambers. They are equipped
with the systems of automatic stabi
lization of level of the pulp, consump
tion of the air ASSUPRB (designer
JV IVS JSC).
Replacement of the obsolete
flotation machines with the mod
ern and less powerconsuming ones
RIF (fig. 8), equipped with the
modernized impeller and original
stator, has permitted to decrease
the number of the chambers from
412 to 248 and to improve parame
ters of concentrating.
In the course of bystage recon
struction with simultaneous introduc
ing of the new technology at the con
centrating plant it has been reached
following technological results (see
the table).
volume of processed ore has in
creased from 3.5 to 5 million tons per
year;
total extraction of copper and
zinc has increased to 168.65% and
consequently it has increased output
of the final products: copper
twice, zinc by 32%;
it has been ensured possibility of
combined processing of the ores of dif
ferent deposits with the single techno
logical high efficient scheme, worked
up by the common efforts of the spe
cialists of the combine and JV IVS
JSC, with usage of the flotation ma
chines RIF.
The program of the works for 2008
foresees fulfillment in October
November of industrial testing of the
new technique and technologies for
further increase of quality of the cop
per concentrate obtained from pyrites
copperzinc ores.
Change of the principal technological parameters of the work
of Uchalinskaya concentrating plant in the course of its reconstruction
Stages
of reconstruction
Volume of processing
of the ore,
thousand tons
Extraction
Cu Zn
Before reconstruction 3500 75.9 72.6
First stage 4499.8 82.9 77
Second stage 4847.9 85.1 78.9
Third stage 4384.5 87.7 81.2
Fig. 8. Section of finishing of the rough zinc concentrate
at Uchalinskaya concentrating plant
EM
Contents
48
Kadzharan concentrating plant is
the part of Zangezur MMK JSC. It
processes the coppermolybdenum
ores. Kadzharan coppermolybdenum
deposit is the raw mineral base of the
combine. The deposit is located near
the town Kadzharan at the height
more than 2000 meters above sea
level. The ore is mined at the openpit.
The ore minerals, presented in the
mined ore, are chalcopyrite, molyb
denite, chalcosine, malachite, covel
lite, azurite. The isomorphous admix
tures are rare and rare earth elements:
rhenium, bismuth, selenium, telluri
um, gold and silver. The elements are
extracted partly into molybdenum and
copper concentrates. Plenty of the
clayey components and ferric hydrox
ides, uneven dissemination of the ore
minerals are the features of the ores of
the deposit.
Initial project of the concentrating
plant has been worked up by the insti
tutes Gyprotsvetmet (general design
er) and Mekhanobr. The technologies
have been worked up in the different
periods by the institutes Mekhanobr,
Miningmetallurgical institute JSC
(Armenia) and others.
The plant has been put into opera
tion in 1952. It has been reconstructed
and expanded in subsequent years
with simultaneous perfecting of the
technology.
Initial project productivity of the
plant was 1.7 million tons per year
(5 thousand tons per day). Accord
ing to the second and third projects
productivity has been increased to
5.1 million tons per year (15 thousand
tons every day). It has been reached to
1966. In accordance with the project
of 1972 productivity of the plant has
been increased up to 7.1 million tons
per year (21 thousand tons every day).
It has been reached to 1977. The new
technical project has been worked up
in 1978. According to the project
productivity has been increased up to
8.5 million tons per year (25 thousand
tons per day) (fig. 1).
Before beginning of reconstruction
in 2004 the plant processed 8.2 million
tons of the ore containing 0.0519% of
molybdenum and 0.186% of copper.
In the same period it has been reached
following technological parameters:
content of molybdenum and copper in
the concentrates of the same name
49.98 and 27.64% correspondingly;
extraction of molybdenum and copper
into the concentrates of the same
name 82 and 70.73% correspond
ingly; content of molybdenum and
copper in the tails 0.00889 and
0.054% correspondingly.
THE FIRST RESULTS OF REEQUIPMENT
AT KADZHARAN CONCENTRATING PLANT
THE FIRST RESULTS OF REEQUIPMENT
AT KADZHARAN CONCENTRATING PLANT
M. A. AKOPYAN, A. V. MARKARYAN, K. V. BESIRGANYAN (ZMMK JSC)
M. A. ARUSTAMYAN, V. M. GALICH, A. V. NAZAROV (NPO RIVS JSC)
M. A. AKOPYAN,
General Director
A. V. MARKARYAN,
Technical Director,
Candidate
K. V. BESIRGANYAN,
Chief
of Concentrating
Plant
M. A. ARUSTAMYAN,
Executive Director,
Candidate
V. M. GALICH,
Leading Specialist,
Candidate
A. V. NAZAROV,
Main Engineer
of the Project
Fig. 1. Change of the volume of processing at the Kadzharansky concentrating
plant by years (* planned parameters)
Contents
49
It has been risen the tasks for col
lective of Zangezur MMK JSC to
increase output of the final products,
to improve qualitative and quantitative
parameters, to decrease production
costs including repairs of equipment
and power inputs, to increase prof
itability of the works.
Administration of ZMMK has
chosen NPO RIVS as the partner.
NPO RIVS has committed itself to
combine functions of the general
designer and general contractor in
working up of the project, making of
equipment and delivery of the last one,
construction and transfer of the object
to the customer.
The project of expansion of the
concentrating plant, carried our by
NPO RIVS, foresees increase of
annual productivity of the works by
the ore processing up to 12.5 million
tons at existing areas with construction
of industrial building of the semiself
comminuting.
Construction and modernization
of the plant demanded combination of
the stages of the working projecting,
construction, making and delivery of
equipment, technological adjustment
and byturn putting of the sections into
operation without decrease of the vol
umes of current output of the plant.
With that end in view the special
ists of NPO RIVS have carried out
the audit of the concentrating plant
with issue of recommendations con
cerning to sequence of the stages of
projection and modernization of
equipment. It has been worked up
strategy of reconstruction till 2000:
to begin putting into operation of
flotation facility in the first place with
the complete replacement of the obso
lete and depreciated equipment by the
flotation machines RIF of the new
generation with the greater solitary ca
pacity;
to perfect the technology of the
ore preparing with usage of semiself
comminuting mills of the great vol
ume (405 m
3
) at the first stage, ball
mills (260 m
3
) at the second stage with
bystage removal from the operation
of the obsolete crushingcomminuting
equipment;
to replace the drum vacuum fil
ters by the pressfilters in the section of
filtering of the copper concentrate;
to put into practice the new tech
nologies with application of high effi
cient flotation reactants;
to work up and to make ACSTP
of the plant;
NPO RIVS has carried out the
following works in the course of
preparing of technological regulations
for projecting:
study of substantial composition
of the ores and technological products
of processing;
study of technological proper
ties (ability of the products to com
minuting, concentrating, thickening)
of the ores of perspective mining;
working up of the regime of the
ore preparing with application of
semiselfcomminuting;
perfecting of the reactant regime
and scheme of the ore concentrating;
forming of the schemes and
regimes of comminuting and flotation
of the ore of prospecting mining;
definition of specific loads on
the equipment;
calculation and selection of the
principal technological equipment.
The collectiveselective scheme of
processing of the coppermolybde
num ore has been approved in techno
logical regulations of the project.
Flotation scheme foresees obtain of
the coppermolybdenum concentrate
in the operations of the main and con
trol flotation, finishing of the rough
collective concentrate including three
stages of recleaning, cycles of selec
tion of the molybdenum concentrate
and operations of the sand and mud
flotation with obtain of the final 50%
molybdenum and 27.5% copper con
centrates.
NPO RIVS uses the most
advanced world achievements in the
field of processing in working out of
technological regulations and in selec
tion of the principal equipment: per
spective reactants of the firm Caytec,
the mills of semiselfcomminuting
and ball comminuting of the great vol
umes produced by the firm Fuller,
automatic machinery of the firm Out
okumpu and American firms, press
filters Larox, vertical mills Vertimill
and others. Some designs are worked
up jointly with the foreign partners.
Side by side with this it is installed
technological equipment produced by
NPO RIVS (flotation machines,
systems for dosing of flotation reac
tants, vibroscreens). It demonstrates
convincingly in practice advantages of
the equipment.
Modernization of flotation facility
of the main building
Feature of modernization of flota
tion equipment of the main building is
increase of volumes of the ore process
ing and output of the final products
without stopping of production.
Putting into practice of facilities of
flotation section has been delayed sig
nificantly because of lack of the free
areas and small dimensions of existing
building of flotation section of the
plant (project of 1952).
Installation of the initial eight
chambers of pneumatic flotation
machines RIF 25 for collective cop
permolybdenum flotation has per
mitted to release 80 chambers of
flotation machines FPM3.2. The
first section of the collective flotation
(24 chambers RIF 25) has been
mounted at released areas.
Pneumatic mechanical flotation
machines RIF 25 and RIF 45 have
been installed at the same industrial
Contents
50
areas in the collective flotation cycle
at the six sections after bystage dis
mantling of the flotation machines
FPM3.2 and FPM16 (about 200
chambers). The operations of finish
ing of the rough collective concen
trate have been equipped with flota
tion machines RIF 8.5. The machines
RIF 3.5 and RIF 0.5 have been
installed in molybdenum flotation
cycle, the machines RIF 3.5 in the
cycle of the sandcopper flotation;
RIF 8.5 in the mud flotation. There
are two lines molybdenum and copper
flotation at the plant: working line and
reserve one. Some flotation machines
RIF 8.5, RIF 3.5, RIF 0.5 are
equipped with the suction mechanical
blocks for exclusion of the great num
ber of the pumps for pumping of the
products of flotation. Special contact
vats KCh 40 and KCh 25 RIF are
used for conditioning and steaming of
the pulp before flotation.
Now it has been installed flotation
machines of the collective cycle (five
sections), the cycles for selection of
molybdenum concentrates and for
copper flotation (working lines). It
has been installed 315 chambers of
the flotation machines RIF of the dif
ferent types at the plant as a whole
(fig. 2). All flotation machines are
equipped with the systems ASSUP
RV for automatic adjusting and
maintenance of level of the pulp and
air consumption in the chambers of
flotation machines.
Two mills MShC3200x3100
(one for every line of recleaning)
were installed in the main building
of the plant for additional com
minuting of the rough copper
molybdenum concentrate. The mills
are equipped with automated bat
tery pumphydrocyclone units.
The last ones are equipped with the
hydrocyclones constructed by
NPO RIVS (fig. 3).
The mill VTM60 (Vertimill) is
installed in the operation of additional
comminuting of the concentrate of the
first molybdenum recleaning.
Four forcepump CNV8001.6
(three working and one reserve
pumps) were mounted and put into
operation for supply of the pneumatic
mechanical flotation machines of the
type RIF with the air of low pressure in
amount 1700 m
3
/min. The force
pumps are located in the separate
building not far from the main build
ing of the concentrating plant. Air
feeding from the forcepumps to the
main building is carried out through
the two airflows 1200 mm diameter.
All parameters of operation of the
forcepumps, control sensors, starting
and stopping of the equipment are
controlled automatically from the
operator post.
Watercooling tower has been
installed for economy of the drinking
water used for cooling of the force
pumps. Its productivity is 150 m
3
/h.
Owing to bystage construction
and putting into practice of the new
capacities of the plant it has been
reached increased extraction of the
metals: copper up to 72.8%, molyb
denum up to 82.6%. The summary
extraction of the metals has increased
by 3% and more.
Quality of the copper and molyb
denum concentrate for all this has not
decreased in spite of constant (by the
years) decrease of content of molybde
num in initial ore. Technological para
meters of operation of the concentrat
ing plant before and after reconstruc
tion are given at the fig. 4 and 5.
The project of increase of pro
ductivity of Kadzharan plant by the
ore to more than 12.5 million tons
per year and reconstruction of the
plant foresees the complete transfer
of the plant to the lowstage
scheme of comminuting of the
coarse crushed ore (350 mm). It
has been installed for the first time
in nonferrous metallurgy of CIS
Fig. 2. Flotation section with flotation machines RIF
Fig. 3. Automated pumphydro
cyclone unit involving
twelve hydrocyclones NPO RIVS
Contents
51
10.34 meters diameter and mills
MShC6100x9500. On completion
of the project productivity of the
plant by processing of initial ore will
be increased more than 1.5 times.
Today it is fulfilled mounting of
and ball mills of the firm Fuller,
pumphydrocyclone units, the
pumps for pumping of the high abra
sive materials. Equipment for facility
of semiselfcomminuting was made
during two years. Productivity of the
facility of semiselfcomminuting on
initial ore will be 7 million tons yearly
at the first stage. After mounting of the
second ball mill output of the facility
will increase to 10 million tons per
year. It will permit to realize gradual
putting out of operation of existing
mills MShR3200x3800 and MShC
3200x3100.
It is foreseen construction of the
stockyard of the floor type (without
the bunkers) for coarsecrushed ore
feeding to the mills of semiselfcom
minuting. The ore will be sent to the
stockyard through the transport
gallery by the belt conveyor.
The project foresees installation of
the three pressfilters with filtering
area 61.2 m
2
(one pressfilter in the
reserve) instead of seven drum vacu
umfilters. Installed pressfilters, pro
duced by the firm Larox, work in auto
matic regime and produce the product
with the moisture not more than 8%
and with content of solid components
in the feeding material 6065%.
It is envisages to install two belt
vacuumfilters LON4.5 (one is the
reserve) for filtering of molybdenum
concentrate.
Automation of reconstructed con
centrating plant will be realized within
the bonds of creating of the single
automated system of control of tech
nological process (ASCTP).
It is offered to carry out continuous
control of content of the metals in the
products of concentrating on the base
of the complex of analyzers Courier
6SL for 27 points.
Two compressors of high pressure
of the firm Atlas Copco have been put
into operation for ensuring of work of
executive mechanisms and devices of
controlmeasuring devices and appa
ratus.
The project foresees creating of
the modern ASCTP for concentrat
ing plant, ensuring centralized con
trol of state of the equipment and
technological process.
Investments for concentrating
plant as a whole will increase 100
million USD.
Completion of construction
and modernization of the plant will
lead to decrease of cost of the
product by 0.77 $/t. Expected cost
will be 4.39 $/t, without deprecia
tion charges 2.88 $/t.
Period of covering of invest
ments for the project will be 3 years
and 8 months.
The reached real technicaleco
nomic parameters of initial stages of
reconstruction of Kadzharan have
confirmed the correctness of the tech
nical solutions of the project.
Fig.4. Technological parameters of operation
of Kadzharan concentrating plant by molybdenum:
1 molybdenum content in the ore; 2 molybdenum extraction
Fig. 5. Technological parameters of operation
of Kadzharan concentrating plant by copper:
1 copper content in the ore; 2 copper extraction
EM
Contents
52
Today the copper, zinc and, par
tially, pyrites concentrates are pro
duced in the course of processing of
the copperzinc ores at the Urals
concentrating plants. But complex
substantial composition of the ores
creates the problems in obtaining of
the high quality concentrates from
the ores with subsequent metal
extraction with usage of the modern
concentrating technique and tech
nology. Coefficient of complexness
of use of the copperzinc raw miner
als is about 20% lower than the last
one in processing of the copper or
leadzinc ores.
The biggest losses of the zinc
(1215%) at Uchalinsky concen
trating plant take the place in the
copper concentrates. It means that
the losses of the metal at Uchalinsky
plant only are about 15 thousand
tons every year. Besides, the zinc
compounds influence negatively on
the metallurgical process of copper
producing.
The autoclave leaching (AL) is
one of the effective methods of
direct opening of the minerals. It
ensures high extraction in the case of
processing even of the lowgrade
copperzinc raw minerals.
The methods of AL have been
studied for many years in the leading
scientific institutes: Urals Polytech
nical institute, Gyntsvetmet,
Gypronickel, IMET named by
Baikov A. A., VNIItsvetmet and
others. It has been studied the fol
lowing processes of AL of the cop
perzinc products: sodium, ammo
niac, sulfurous, neutral [14] (i. c.
1788050).
The neutral method has been
chosen as the most efficient among
the listed above methods of AL. The
neutral method allows separation of
copper and zinc in the course of pro
cessing of the sulfide copperzinc
polymetallic concentrates in the sin
gle apparatus, in the single techno
logical process. The technology is
characterized by low materials and
energy consumption.
Technology of hydrometallurgi
cal treatment of the copperzinc
products is worked up conformably
to specific object, since it depends
considerably on ratio of copper and
zinc content in the object.
It is known that 9596% of zinc
and 1015% of copper are passed
into solutions in the course of leach
ing of the copperzinc concentrate
under the temperature 185200
o
C
and pressure 0.30.5 MPa (by oxy
gen). Indicated regime is suitable for
the concentrate contenting about
20% of zinc and 9% copper. At the
same time selectivity of zinc leaching
decreases when the ratio of content of
Zn and Cu in the concentrate
decreases lower than 2. In the sample
of the concentrate of Uchalinsky
GOK the ratio is about 0.2. So, con
ditions of leaching of the copper con
centrate were determined proceeding
from above mentioned circumstance.
It has been determined in the
laboratories (NPO RIVS JSC,
IMET named by Baikov A. A.) the
L. S. GUSAR (RIVSproject JSC)
R. A. YAGUDIN (Uchalinsky GOK)
A. Ya. BODUEN (SPGGI (TU)*
R. A. YAGUDIN,
Chief
of the Concentrating
Plant
A. Ya. BODUEN,
EngineerTechnologist,
Candidate
A. V. ZIMIN,
General Director,
Candidate
L. S. GUSAR,
Main Specialist,
Candidate
PILOTINDUSTRIAL TESTING OF THE TECHNOLOGY
FOR HYDROMETALLURGICAL DEZINCING
OF THE COPPER CONCENTRATE FROM UCHALINSKY
PILOTINDUSTRIAL TESTING OF THE TECHNOLOGY
FOR HYDROMETALLURGICAL DEZINCING
OF THE COPPER CONCENTRATE FROM UCHALINSKY
* Sataev I. Sh. (RIVSproject JSC), Yagudina Yu. R., Boichenko D. N., Nazarova R. U., Chernov N. A. (Uchalinsky GOK JSC) and Zait
sev A. M. (IMET named by Baikov A. A.) took part in the work.
Contents
EQUIPMENT AND TECHNOLOGIES FOR ENVIRONMENT PROTECTION
53
principal parameters of leaching (the
claim 2006101197/02 of the iventors
certificate).
Adopted technological scheme
involves following principal opera
tions:
preparing of the pulp of the
copper concentrate with the certain
density and loading of the pulp into
autoclave;
autoclave leaching of zinc from
the copper concentrate with supply
of oxygen (air) under the tempera
ture higher than 180
o
C and hy
drothermal sedimentation of copper
from obtained zinc solution;
separating of the liquid and solid
phases with obtain of the copper con
centrate and polluted zinc solution;
educing of the indium concen
trate from the zinc solution;
cleaning of the zinc solution
from Fe with obtain of the easily fil
tered sediments;
cleaning of obtained solutions
from cadmium with obtain of the
zinccadmium cake;
sedimentation of zinc in the
form of carbonate hydroxides;
tempering of carbonate hydrox
ides with obtain of pure zinc oxide.
It has been created at Uchalinsky
GOK experimentalindustrial unit
for testing of technological scheme
of removal of zinc from the copper
concentrate (fig. 1).
Taking into account the fact that
all technological operations are car
ried out on the equipment of the
same type it has been chosen for
experimentalindustrial tests the
scheme of the apparatuses shown at
the fig. 2.
The general look of experimental
industrial unit for zinc removal from
the copper concentrate is shown at
the fig. 3, the general look of the lab
oratory autoclave at the fig. 4.
Chemical composition (%) of
the studied sample of the copper
concentrate of Uchalinsky plant is
given below:
Copper 19.11
Zinc 3.82
Sulfur 88.7
Ferrum 43.14
Lead 1.58
Antimony 0.072
Cadmium 0.011
Gold (g/t) 4.8
Silver (g/t) 83.8
According to results of Xray
phase and petrographic analysis
the sample is presented in com
mon by chalcopyrite, sphalerite,
pyrites and some nonmetallic
micaceous minerals type vermi
culite (fig. 5).
Distribution of the classes of
coarseness in the studied sample is
following: +74 m 0.7%; 74
+44 m 1.9%; 44 m 97.4%.
Fig. 1. Technological scheme of removal of zinc from the copper concentrate
Contents
54
Autoclave zinc removal
from the copper concentrate
with hydrothermal sedimentation
of copper
Method of the work. For every
test of AL it has been prepared the
sample including 15 liters of water
and 6 kg of the copper concen
trate. Prepared pulp was mixed
carefully and was loaded into
autoclave with the operating mix
ers. Temperature of the pulp in the
autoclave was increased up to
170175
o
C by means of the
heater. After that it has been fed
oxygen, and pressure in the auto
clave has been increased up to
1.51.55 MPa. Temperature has
been kept automatically within the
diapason 185192
o
C. After two
hours feeding of oxygen has been
stopped. Hydrothermal sedimen
tation of copper passed into solu
tion took the place during 11.5
hours after stopping of oxygen
feeding.
When the temperature of the
autoclave decreases to 100
o
C the
pulp is unloaded and sent to the
press filter. Liquid and solid phases
were analyzed for content of the
principal components.
It has been carried out more than
20 tests of AL. Average results of the
tests are given below:
Output of the copper
concentrate (%) 80.65 (73.85)
Content in the copper
concentrate (%):
Cu 23.68 (26.16)
Zn 0.59 (0.45)
Fe 32.28 ()
Content in the zinc solution
after autoclave leaching, g/l:
Cu 0.21 (1.77)
Zn 12.59 (19.2)
Fe 44.53 (56)
Cd (mg/l) 41.68 (57)
Note: It is given in the brackets the results
after addition in the process of 8 liters of
recirculating solution
Copper extraction into concentrate
reached to 99.9% in the course of AL.
Educing of indium
from the zinccontaining solution
Educing of indium, gallium
and germanium from the zinc
Fig. 2. Scheme of the chain of the apparatus
1 autoclave; 2 reactor; 3 filter; 4 tank
Fig. 3. Experimentalindustrial unit
for zinc removal from the copper
concentrate
1 autoclave, 2 reactor, 3 filter,
4 tank
Fig. 4. Laboratory autoclave
25 liters capacity
1 casing of the water cooling of elec
tric drive of the mixture; 2 distributor
of the water cooling, 3 frame of the
autoclave, 4 tubular heat exchanger
of cooling of the autoclave
Fig. 5. Initial copper concentrate.
Reflected light (magn.200)
Contents
EQUIPMENT AND TECHNOLOGIES FOR ENVIRONMENT PROTECTION
55
containing solutions by means of
hydrolysis is fulfilled under
pH = 2.53. Degree of sedimen
tation of indium is more than
95%. Solid hydrate sediment,
containing indium, is easily fil
trated and may be sent to the zinc
plant as a highgrade product.
In 2007 indium content in the
dispatched by Uchalinsky GOK
copper concentrate was about
2025 g/t. It means that every year
it is passed to the copper plants
about 67 tons of indium, and they
are lost irrevocably, though indium
has the high price at the interna
tional market.
Removal of the twovalent
and trivalent ferrum, arsenic
and antimony from solutions
As a result of the oxidizing AL
of the copper concentrate and
hydrothermal sedimentation of
copper, and after educing of indi
um from solutions by hydrolysis
almost all passed into solution fer
rum is in the twovalent form. It is
known, that for purifying of the
zinccontaining solutions from the
ferrum, it is necessary to convert
the last one to the trivalent com
pound. After that Fe is educed from
solution in the form of different
sulfate hydroxides. But the pulps,
obtained in the process, are filtered
badly and are thickened very badly.
At the zinc plants content of Fe
in the solutions is 11.5 g/l Fe(III)
and 0.20.5 g/l Fe(II). The last one
is oxidized be feeding of the man
ganese ore or manganesecontent
ing mud. Obtained solutions con
tent 130150 g/l of zinc and are
characterized by the rather small
concentration of Fe (1.52 g/l).
The last one is easily removed by
hydrolytic purification of the solu
tions with pH = 4.55.4 and does
not hamper process of sedimenta
tion and filtering of the pulp.
At the same time in this course
of autoclave oxidizing leaching of
the copper concentrate consider
able amount of Fe is passed into
solutions (probably owing to
decomposition of chalcopyrite). Its
concentration reaches 4060 g/l.
After hydrothermal sedimentation
of copper almost all amount of Fe
is in twovalent state.
Oxidizing of the great volumes
of the Feions by the manganese
ore will lead to considerable con
sumption of the last one, to accu
mulation of the Mnions in solu
tion, to increase of density of solu
tions and to total discomposure of
the processes of sedimentation and
filtering.
So, it has been used the method
(i. c. 468522) of oxidizing of the
Feions in solution by air or by
oxygen with obtain of the easily fil
tering crystalline sediments of the
complex sulfate hydroxides of Fe.
Arsenic and antimony are removed
completely from the solution with
above mentioned sediments.
Method of the work. Technolog
ical experiments were carried out
by the following means: 20 liters of
solution (after sedimentation of
indium) were poured into the reac
tor with the mixer and heated to
5060
o
C. Air was fed through the
dispersant. The unit is supplied
with pHmeter. Value of pH of the
pulp in the course of oxidizing was
kept in diapason 4.24.5 by means
of feeding of the lime milk. The
samples were selected every 0.5 hour
for monitoring of the process by
content of the ions Fe(II).
Depending on content of Fe (II)
in initial product (2560 g/l) the
residual concentration of the Fe
ions (equal to 0.10.3 g/l) was
reached in 2.53.5 hours (fig. 6).
After that it was carried out re
crystallization of the sediment with
obtain of the crystalline easily fil
tered compounds.
As a result of the oxidizing oper
ation and sedimentation of Fe it is
obtained the cake that is the mix
ture of gypsum and yarosite. It is
formed about 8.5 kg of the cake of
the 20 liters of initial product con
taining 52 g/l of Fe. Mass share of
the principal components in the
cake are (%): Zn 0.88; Fe 16.9;
S 14.2.
Thus, removal of Fe permits to
solve the following tasks:
Fig. 6. Kinetics of oxidizing of the twovalent Fe
Contents
56
obtain of the zinccontaining solution;
arrangement of circulation of solution for increase
of the zinc concentration in the last one;
removal of arsenic and antimony from solution.
Obtained ferrocontaining cake may be used as a
component of the stowing compounds (pat. of RF
830824 and 2001118530).
Removal of cadmium from solution
Cleaning from Fe, arsenic and antimony zinccon
taining solution is neutralized up to pH = 5.25.4 and
subjected to cementation with the zinc dust for sedi
mentation of cadmium and the rests of copper accord
ing to known, used at the all zinc plants technology.
After coppercadmium cleaning the solutions do not
content of the copper ions. Concentration of cadmium
decreases to 0.5 mg/l.
Separating of commercial zinc compounds
Cleaned from admixtures of Fe, arsenic, antimony,
cadmium, copper and others metals the zinccontain
ing solution (solution of zinc vitriol) may be used for
needs of the concentrating plant.
For separation of zinc from solution in the form of
carbonate hydroxide and oxide it is carried out the
operations of sedimentation and tempering.
Method of the work. Solution of ZnSO
4
(10 g/l)
and sedimentation substance solution of K
2
CO
3
(100g/l) in correlation 1:1.1 were loaded by the
small portions into thermostatic cell under the tem
perature about 50
o
C and with the constant mixing.
Owing to increase of pH value of the solution up to
88.5 after addition of the sedimentation substance, it
has been added 3% solution of the sulfuric acid for
decrease of pH up to ~5.
Period of sedimentation is about one hour (begin
ning from feeding of the latest portion of K
2
CO
3
). The
fallen sediment has been filtered at the vacuum filter
and washed with the small amount of water. The sed
iment is white finecrystalline powder. Degree of its
sedimentation from solution reaches 97.5%. In accor
dance with results of Xray phase analysis of the pow
der dried under the temperature 100
o
C it consists of
the mixture of zinc hydrocarbonate, mainly of
Zn
5
(OH)
6
, (CO
3
)
2
, containing about 36% of zinc.
After tempering during one hour under the temper
ature 500
o
C the sediment has decomposed completely
with forming of pure zinc oxide.
Conclusions
It has been carried out in the semiindustrial scale
testing of technology of removal of zinc from the copper
concentrate of Uchalinsky concentrating plant with sep
arating of zinc as commercial products zinc vitriol and
zinc oxide (extraction 8590%).
In the course of testing it has been obtained follow
ing results:
copper content in the copper concentrate increases
from 19.1 to 25% (extraction 99%) with simultaneous de
crease of content of zinc from 3.8 to 0.5%;
concentration of copper in the zinccontaining so
lution does not exceed 0.10.5 g/l;
arsenic and antimony are removed completely from
initial raw materials into the ferrocontaining cake.
Application of the autoclave leaching in the metallur
gical producing of copper will allow;
decrease of amount of the slag;
prevent of forming of speiss;
decrease of viscosity of the slag and correspondingly
the losses of copper, gold, silver;
decrease of throw out into surrounding of the com
pounds of arsenic and antimony.
4. Preliminary calculations confirm high technical
economic efficiency of the worked up technology and
rapid recoupment of the capital investments.
Literature
1. . .
. . : ,
1989.
2. /
. . , . . , . . , . . .
, 2002.
3. . ., . .

// .
2003. 7.
4.
/ . . , . . , . .
. // . 2000. 3.
EM
Contents
SCIENTIFICPRODUCTION CORPORATION SCIENTIFICPRODUCTION CORPORATION
working up and putting into practice of the mod
ern technologies for concentrating of the ores of
nonferrous and precious metals, ironcontenting
and oxidized ores, nonmetallic minerals, chemical
and mancaused raw materials;
technical reequipment of the miningconcentra
tion combines and enterprises of construction in
dustry with application of the own technologies and
equipment and modern foreign equipment;
increase of output of the marketable products
owing to increase of: quality of the concentrates,
metals extraction in the concentrate, productivity of
the concentration factories;
decrease of the cost of every ton of processed ore.
Flotation machines RIF of pneumaticmechanical type in the
module and vat performance with volume of the chambers
from 0.5 to 130 m
3
; mechanical type with volume of the cham
bers from 0.2 to 12.5 m
3
; pneumatic (columnar) type with vol
ume of the chambers from 1.2 to 50 m
3
.
Every flotation machine is equipped with automated systems
of stabilization and control of the level. In the case of necessi
ty they are equipped with the systems of stabilization and con
trol of the pulp density in the chamber.
Flotation machines RIF are produced for different flotation op
erations taking into account ability of the raw minerals to be
processed. In accordance with the Customer's demand flota
tion machines may be equipped with the suction blocks.
Contact vats for mechanical mixing of the pulp in the course
of treatment with the reactants and for application of the vats
as the sumps by capacity from 1 to 100 m
3
.
Aeration vats from 6.5 to 100 m
3
capacity for conditioning of
the ore pulp.
The spheres of activity of the corporation
"RIVS" are:
Scientificproduction corporation RIVS
works out and produces:
Corporation works up and puts into practice the systems of automated control
and adjusting of parameters of equipment and systems for technological processes
of concentrating of the ores of useful minerals (ACSTP).
Scientificproduction corporation RIVS works out and produces:
Hydrocyclones with evolute input of feeding:
rubber GCR 250, 380 and combined GCK
250, 380, 500. Automated battery units for differ
ent productivity by feeding have been worked up
on the base of above mentioned hydrocyclones.
Screens of the type GRI (GIT) from the second
to eighth sizes and type GRS (GST) from third to
eighth sizes. New approach to design permits to
make the screens of the big sizes with the screen
ing area 24 m
2
and more. The screens are
equipped with the rubber sieves with rectangular
and square cells for different working conditions.
Aeration units for modernization of flotation ma
chines of the types FPM or OK with volume of the
chambers from 1.5 to 130 m
3
.
Absorbers for the screens; lining of the helical classifiers, hy
drocyclones, ball mills; aeration units for mechanical flotation
machines; elbows for nonpressure pulp pipelines; rubber cou
plings; reinforced lining for the working chambers of flotation
machines and contact vats; rubber plugs for systems of adjust
ing of level of the pulp in flotation machines; rubber plugs for
sumps, vats and distributive boxes.
Unique recipes of the rubber mixtures with provision for particu
larities of application of equipment at the enterprises ensure high
wear capability and longevity of the products.
Contents
NPO "RIVS" supplies with:
Crushingcomminuting equipment.
Flotation machines for all kinds of the ores and nonmetallic materials.
Vats for different stages of processing and for chemical processes.
Screens for dry and wet classification.
Hydrocyclones and hydrocyclone batteries.
Sandy centrifugal pumps.
Sumps and tanks for different purposes.
Means of automation of the miningconcentration equipment.
Different types of the reactant feeders.
Spares for miningconcentration equipment.
Rubbertechnical items (articles) for miningconcentration equipment.
COMPANY CARRIES OUT:
Projecting and construction of the new enterprises.
Reconstruction of the operating enterprises.
Study, working out and putting into operation of the new
technologies of concentrating of the useful minerals.
Working out of technological regulations, putting into prac
tice of the new technologies with reaching of guaranteed
technological parameters at the working enterprises.
Audit of the concentration facilities.
Working out and making of the new machines and
mechanisms.
Modernization of the miningconcentration equipment.
Working out of ACSTP of the concentration factories.
Complex automation of technological processes and
facilities of concentrating of the raw minerals.
Service of equipment and supply with spares.
NPO "RIVS" JSC, Zheleznozavodskaya str., 11, lit. A, S.Petersburg, Russia, 199155
tel. +7 (812) 326 10 02, 321 57 05, fax +7 (812) 327 99 61, email: rivs@rivs.ru, www.rivs.ru
Contents

Rudarstvo - Fabrika Za Oplemenjivanje Rude

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Rudarstvo - Fabrika Za Oplemenjivanje Rude

Enviado por

Direitos autorais:

Formatos disponíveis

NPO "RIVS" supplies with:

Fig. 7. Change of copper content in the copper concentrate (1)

Você também pode gostar