1 Flowsheets for copper-zinc ores of a complex composition with an increased tennantite content at the sample of Zapadno-Ozernoe and Uzelginskoe deposits
1.1 Zapadno-Ozernoe deposit
Specific features of deposit ores: complex material composition, the presence of colloform textures, massive and metacolloidal textures, dissemination of sulfide minerals, tight association of minerals between each other. Main ore minerals: pyrite, sphalerite, tennantite, chalcopyrite, covelline, chalcosine. A variety of copper minerals is also characteristic: tennantite - 55-63 % (relat.), secondary copper sulfides, chalcopyrite and the presence of colloform pyrite. The peculiarity of copper-zinc ores is a fast oxidizability.
A technology of collectively-selective flotation with a copper settlement from a water phase by sodium hydrosulfide for copper-zinc ores of an upper layer
A technology of collectively-selective flotation to get a zinc concentrate of high quality in a form of froth and flotation tails for copper-zinc ores of lower horizons
1.2 Uzelginskoe deposit
Specific features of ores of the deposit upper layer: the presence of several varieties of pyrite, emulsive dissemination of pyrite in sphalerite and chalcopyrite, thin mixtures “pyrite- sphalerite”, “pyrite- chalcopyrite”, “pyrite- fahl ore (tennantite)”. Copper content 1,01-1,02 %, zinc – 2,45-3,00 %, sulphur – 34,00-44,60 %.
A technology of collectively-selective flotation with a development of a technological and reagent modes of beneficiation
Results of studies will be applied during the industrial processing of copper- zinc ores at Uchalinskaya concentrating plant.
2 A new technological additive Х1234 for beneficiation of disseminated copper-zinc and polymetallic ores
The technological additive Х1234 is a complex mixture of polymeric compounds based on modified polymethylene naphthalene sulphonates.
In combination with main depressors of zinc minerals- sodium sulphite and zink sulfate, the technological additive intensifies depression of zinc minerals when reducing depressors in 2,5 – 4 times.
Using the combination of reagents, depressors with the additive Х1234 during the concentration of copper-zinc ores enabled to decrease losses of zinc with a copper concentrate by 8,50-10,66 % when increasing the zinc extraction to a zinc concentrate.
The feeding the additive Х1234 to a technological process when concentrating polymetallic ores enables to increase the depression of zinc minerals during decreasing losses of zinc with the copper concentrate by 1,50-2,00%, with the lead concentrate by 3,60-4,00 % and increasing extraction of zinc to the zinc concentrate by 7,00-8,00 %. The use of the technological additive during the concentration of polymetallic ores showed the possibility to get not only saleable concentrates and increase metals extraction but to reduce main reagents-depressors of zinc minerals, as well as to reduce process flotation operations.
3 Flowsheets for scarn magnetite ores of Taezhnoe and Desovskoe minefield
Specific features of deposits ores: iron content in a base ore of Taezhnoe deposit is 37,8%, and 27,8% in Desovskoe deposit.
3.1 A technology of a dry magnetic concentration
3.2 A technology of biphasic grinding and concentration
Result: a magnetite concentrate with 67,0% copper content was received.
3.3 The technology of dehydrating tailings of the wet magnetic separation
Specific features of deposits ores: iron content in a base ore 28,1 %. Base size 12-0 mm.
4 Technologies of dry and wet magnetic dressing of ferruginous quartzites of Tarynakhskoe and Gorkitskoe deposits
Specific features of deposits ores: iron content in a base ore 28,1 %. Base size 12-0 mm.
5 Technologies of dry and wet magnetic dressing of titanium magnetite ores at the “Tebinbulak” deposit (Uzbekistan)
Specific features of deposits ores: Fe content- 16,1 %, titanium dioxide - 1,9 %, vanadic pentoxide - 0,18 %.
Currently process regulations are developed for designing a mine & processing plant with an annual capacity of 22 mln. tons of base ore.
A technology of agglomeration and pellets firing was developed. Tasks to reach required key figures (strength properties, yield ratio, compression strength) were completed. Besides, there were solved issues of providing key figures specific for titanium magnetite material that are necessary for process needs of further production areas (optimal basicity index, chemical composition of charge).
The production of a high-basic agglomerate and non-flux pellets was recommended. The resulting modes allow receiving raw-material agglomerates, which meet all the requirements of a blast-furnace production area, and providing the receipt of the raw material, which is not inferior to the products quality of "Kachkanarsky” GOK. During the execution of works a problem was identified, dealing with a high content of titanium oxide in a slag of blast-furnace smelting. Two main solution approaches were proposed.
One of them was to add a high-silica middling product poor in titanium, received while concentrating ores of Tebinbulak deposit to the sintering mixture.
The second one was the additional charging to a blast-furnace charge of materials, purchased in some other places. In particular, the additional charging of sideritic ore of Bakalskoe mine group was taken into consideration. Process regulations for the blast-furnace and converter smelting of the charge as per a method “duplex process” similar to NTMK with repreparation of a vanadium slag up to conditions of the marketable product.
6 A technology of gravity gold reextraction with the use of ultra-fine grinding
There was conducted pilot testing of a centrifugal concentrator Knelson KC-CVD6 with a continuous discharge of concentrates in the technology of finely dispersed gold with the use of a process “carbon-in-pulp”. It showed high efficiency of mineral concentration with undisclosed gold in a heavy fraction, concentrate grinding in a bead mill up to the size of 2-30 mym and its further cyaniding jointly with concentration tailings.
Result: gold extraction to a final product was increased by 2-6%.
7 New technologies for processing oxidized nickel ores
8 «Dry technologies» of concentration
8.1 Application of «dry technologies» for concentration of titanium- zirconia placers
In association with IMGRE works were conducted on a process estimation of the possibility to process ore sands by using dry concentration methods for objects of a Stavropolsky placer region, which differed in content of a sum of ore minerals (ilmenite, rutile, zircon) 84,7 kg/m3(area 1) and 54,7 kg/m3(area 2).
There were carried out preliminary studies, which were aimed at the dressability of samples material as per a traditional “wet” technology.
The major concentration process is based on distinctive physical properties of ore minerals: presence of ilmenite’s magnetic properties, which rutile does not possess, while rutile having conductivity, which zircon doesn’t possess.
Operating costs of both technologies are nearly equal by average ratio of the “wet” technology to the “dry” technology- 1:1,025. The application of the “dry” concentration technology doesn’t require to construct tailings facilities, that reduces capital investments to a concentrating plant by 15-17%. Therefore, applying “dry” or “combined” concentration technology of titanium- zirconia sands enables to increase the economic efficiency of their development.
8.2 «Dry technologies» for concentration of copper bearing middling products
8.1 Technology for processing copper bearing middling products of metallurgical enterprises by using dry methods
9 Technologies for concentration of technogenic raw materials
9.1 Technologies for copper reextraction from slags of the metallurgical production with the application of a bead mill by the example of processing waste aged slags of JSC “Uralelectromed” and slag flotation tailings of the metallurgical production JSC “SUMZ”.
Results: copper extraction to the concentrate was increased by 11,20% in slags of the metallurgical production JSC “SUMZ” and by 12,59% while concentrating slags from JSC “Uralelectromed” company.
9.2 Technology for concentration of slowly cooled slag under conditions of JSC “SUMZ”.
Result: increase of copper extraction to a copper concentrate by 12-15%.
9.3 Technologies for processing oily scale of the rolling production
Studies performed on the agglomeration process by using CHMK charge showed significant performance gains of an agglomachine when using the oil-free scale. The technology is characterized by lack of wastes (secondary technogenic formations), prevents oil combustion, makes possible to utilize unlined furnaces having significantly smaller mass and requiring less operating costs. The technology payback period is around 1 year.
9.4 Technologies for processing dusts of the steel industry
Specific features of dusts — high concentration of zinc.
The technology underwent production testing at JSC “Metallurgical plant n/a A.K. Serov”. Under industrial conditions there was confirmed the technology working capacity and zinc fumes as well as metallized pellets qualified for blast-furnace smelting were received. Process regulations were developed on designing the installation for processing zinc dusts.
9.5 Technology for producing fuel briquettes.
The essence of the technology consists in briquetting of coke fines that cannot be used in shaft furnaces when producing copper by the reason of the low size.
Industrial testing of the briquetting technology underwent at the “Polymetals production” branch of JCS “Uralelectromed”. Resulting briquettes were used during copper concentrates smelting instead of coarse coke. Smelting of briquettes instead of coke showed within 3 days that consumption figures of coke remain at the same level. Improvement of a furnace run was recorded. At this, the cost of briquettes from coke fines considering the prime cost of a production area is significantly lower than the cost of the coarse coke.
9.6 Technology for concentration of red muds of the alumina industry based on the concentration of red muds of the Ural aluminum plant
Result: there was obtained iron concentrate containing total Fe -50% and yield of 35% of original red mud. After agglomeration, the iron concentrate is appropriate for smelting. The technology underwent pilot plant tests, and process regulations were developed on designing of a pilot production unit at JSC “RUSAL”.
10 Technologies for hydrometallurgical & metallurgical processing of non-ferrous metals
11 Efficient methods of preliminary ores concentration
11.1 Technology for increasing copper extraction to copper concentrate while using fine vibrating screening in the ore preparation cycle
11.2 Technology for preliminary concentration of mineral raw material based on methods of x-ray- radiometric separation
12 Unconventional ways of ore pretreatment for glass sands prior to concentration
For studying concentration processes of quartz sands of JSC “Atomstroykomplex” there was designed and manufactured an ultrasonic installation MO-156. Preliminary ore pretreatment consisted in studying impacts of attritioning & screening operations on the change of a material component due to the increase of small particles extraction. For more detailed study of the process several attritioning modes were selected.
Resulting from the study of ore pretreatment operations impact on the change of the quartz sands material composition of the II Kamenskoe deposit there was developed a process concentration scheme of the quartz sand making possible to reduce total Fe content from 0,4 to 0,04%.
The technology is applied when designing the plant for the production of bottle glass.
13 Technology for direct reduction of titanomagnetite
Metallization technology by type of Itmk3 & Hi-QIP for titanomagnetites. Studies showed that while realizing Itmk3 & Hi-QIP processes nearly all of titanium gets to a slag, vanadium goes into pig iron, providing a low rate of reduction in comparison with a blast-furnace process- less than 350kg/t of pig iron and getting slag with a high content of titanium oxide in a pelletized form, that excludes its crystallization when tapping from blast furnaces. The technology was tested in pilot conditions of the Institute.