Ore Raw Materials Research Articles

СИСТЕМНІСТЬ РІШЕНЬ РОЗШИРЕННЯ ВИРОБНИЦТВА ВИСОКОЯКІСНОЇ ПРОДУКЦІЇ ЕКСПОРТООРІЄНТОВАНИМ МЕТАЛУРГІЙНИМ ПІДПРИЄМСТВОМ

The study outlines the approaches toward the rationalization of the technological process of pellet production by combining iron ore extraction in the quarry, its milling, concentrate enrichment, pellet firing. The practice of system implementation of modern technology of flotation processing of iron content into the concentrate as a strategic task of improving the quality of pellets is described. The peculiarities of involving a significant percentage of "low-grade" ores in production in case of necessity are revealed. It was concluded that the implementation and successful functioning of the quality management system are affected by engineering mistakes, poor cooperation with suppliers, the return of low-quality products to the enterprise, additional transportation expenses. The sequence of development of the fundamental documents of the quality management system regarding the implementation of the policy in the field of expansion of export supplies of pellets and improvement of the organizational structure of the company's management is covered. The iron content in pellets was predicted using the auto regression model. An improved structure of management of foreign economic activity in case of the implementation of the project on additional production of high-quality pellets is proposed. The costs for increasing the volume of production of iron ore raw materials for the project for the successful functioning of the automated management system for the entire technological process of charge preparation, pelletizing and firing of pellets are systematically defined. A risk assessment was carried out in conditions of implementation of the model for calculating the capital assets of the complex of equipment for the production of high-quality pellets of a well-known global company. Decisions regarding the positioning of the plant's pellets on the world market with determination of the pricing strategy are justified.

STUDY OF THE MODES OF RECOVERY AND DESTRUCTIBILITY OF CHROME BRIQUETTES UNDER CURRENT AND THERMAL LOADS

For an objective assessment of the recoverability of the resulting oxidized materials and deciphering the physico-chemical characteristics of their reduction processes occurring during the smelting of carbonaceous ferrochrome, special studies are needed. In this regard, the kinetics of the briquette reduction process has been studied in this article, which is extremely important for understanding the mechanism of carbothermic reduction in order to improve metallurgical technologies using coated materials. During the study, 6 different variants of briquettes with chromium ore and various types of carbon reducing agents were studied, such as China coke, Shubarkolsky special coke, Borlinsky coal and Shubarkolsky coal. The degree of chromium reduction was studied in the Tamman furnace by thermogravimetric method at temperatures of 1200; 1300; 1400; 1500; 1600 ° C for 1 hour. This article also provides calculations to determine the degree of reduction of chromium and iron using the Yander and Gistling-Brownstein equations. Of the six briquette variants, the best results in studying the kinetics of reduction of chromium ore raw materials were obtained using briquettes № 1, 3, 5. The study emphasizes the critical importance of understanding the reduction and destructibility modes of chromium briquettes to optimize the melting processes of carbon ferrochrome. The conclusions from this study are key to the development of both scientific understanding and practical applications in the metallurgical industry. This article summarizes the main results and meanings of the authors’ research, emphasizing its contribution to improving the efficiency and quality of carbon ferrochrome production through the systematic study of reduction behavior in chrome ore briquettes. Keywords: ferrochrome, chrome briquettes, coal, coke, degree of reduction, Yander equation, Gistling-Brownstein equation.

THE INFLUENCE OF WASTE ACCUMULATION SITES FROM MINING AND PROCESSING PLANTS ON THE HYDROSPHERE OF ADJACENT TERRITORIES

The nature and directions of changes in the state of water bodies of the territory, for a long time (50 60 years) adjacent to the storage areas of mining waste (dumps) and enrichment (tailings) of iron ore raw materials, have been studied. It has been established that dumps and tailings are sources of the adjacent territories’ intense hydrosphere chemical pollution with highly mineralized filtrates. The most intense pollution and increase in groundwater levels at all horizons occurs in the first 10-15 years.In the future, in proportion to the service life of man-made structures, the area and level of chemical pollution of surface and underground water bodies increases, hydrogeological processes are increasing: flooding of lands, landslides, sinkholes.

Study of metallisation of titanomagnetite burnt pellets

To efficiently process titanomagnetite deposits in the Urals, new technological solutions must be developed. One such solution is the production of metallized titanomagnetite pellets, followed by electric smelting. Modern electric smelting technologies have strict requirements for the materials used, including a metallization degree above 90%, high metallic iron content (>85%), low FeO content (<1%), and high compression strength. This article explores the potential for producing metallized pellets suitable for further processing into electric arc furnace smelting or for HBI production from enriched concentrates of Gusevogorsky and Pervouralsky deposits under laboratory conditions. The scheme for enriching the poor concentrate of Pervouralskydeposithas been developed. The study analyzed the chemical, phase, and mineralogical compositions of the obtained concentrates. The results showed that the total iron content after beneficiation was more than 65% for both deposits. The study concluded that titanomagnetite iron ore raw materials are suitable for the metallization process. The degree of metallization of burnt pellets, after reduction by gas of CO+N2 composition (90/10%) at exposure (240 min), reached 92% and higher.

Enrichment of valuable metals from silver tailings using the alkali roasting-leaching method

To solve the tailings accumulation and mineral resource scarcity issues, this study uses silver tailings as a raw material and sodium carbonate roasting followed by water and acid two-step leaching process to investigate the enrichment of copper, cobalt, and lead. Based on the identification of occurrence forms of copper, cobalt, and lead in the silver tailings, the process parameters of the Na2CO3 roasting and acid leaching were optimized. The silver tailings were mixed with sodium carbonate at a mass ratio of 1:1.3 and roasted at 750 °C for 30 min, and the roasted clinker was leached using water at 80 °C for 15 min. The water leaching residue was then leached using H2SO4 acid at a concentration of 3 mol/L, a liquid–solid ratio of 10 mL/g, and at room temperature for 3 min. We finally obtained leaching efficiencies of 97.02 % and 86.45 % for copper and cobalt, respectively; 79.17 % of lead went into the acid leaching residue. The copper and cobalt were significantly enriched in the polymetallic enriched ore powder at 10.76 and 7.12 times the content in the tailings, respectively, reaching industrial grade that could be used as a new type of ore raw material for the extraction of copper and cobalt. Lead was enriched in the acid leaching residue at a content of 7.61 times that of the tailings and was mixed with the tailings to be further roasted and leached to enrich the lead. These results provide a theoretical foundation for the full resource utilization of metallic tailings.

Changes in the physical and mechanical properties and structure of rocks depending on the depth of mining operations in iron ore quarries

The trend of the activity of open-quarry mining enterprises of iron ore raw materials is an increase in depth quarries. It is investigated in the work, changes in physical and mechanical properties and rock structure depending on the depth of mining operations in quarries. Natural geophysical and laboratory methods of research were applied. It was established that the angle of internal friction, Poisson’s ratio and rock density practically do not depend on depth of mining operations. But with an increase in the depth of iron ore quarries, there is an increase in the compressive and tensile strength of rocks. Indicator of specific adhesion has significant dynamics of fluctuations depending on the mineral composition of rocks and can either increase or decrease in deep horizons, which must be taken into account in each specific calculation. For example, by determining marginal angles of slopes of sides and ledges. According to the data of geophysical studies, it is established a characteristic increase in the intensity of creep shear processes and surface deformations rocks when the quarry depth increases. The results of research are recommended to be taken into account when organizing the mining and technological process in deep iron ore quarries.

Гибридная интеллектуальная система машинного обучения для моделирования процессов обработки фосфатного рудного сырья

The results of a study are presented, the purpose of which was to create an intelligent machine learning system for modeling the processes of charge agglomeration during processing of phosphate ore raw materials. The relevance of the study is justified by the need to improve the information support of technological systems management processes in the context of the digital transformation of the production environment, carried out within the framework of the Fourth Industrial Revolution and characterized by the massive introduction of the industrial Internet of things, which leads to an avalanche-like increase in the volume of technological data. Their processing using modern analysis methods, including artificial intelligence methods, can improve the quality of decisions made and provide competitive advantages. The scientific novelty of the research results is the structure of the proposed hybrid intelligent machine learning system for modeling phosphate ore processing processes, which is based on the joint use of a dynamic model of the sintering process in the Simulink environment and a deep neural network. The architecture of the neural network was developed taking into account the specifics of the mathematical description of the agglomeration process and includes input fully connected layers that receive measurement results of process variables, as well as a recurrent layer that processes the combined sequence from the outputs of fully connected layers. The integration of a Simulink model and a deep neural network makes it possible to quickly adapt an intelligent system to a specific sintering machine through the use of a two-stage machine learning procedure – first on a Simulink simulation model, and then on a real object. Taking into account the significant inertia of the processes accompanying agglomeration, this approach ensures prompt changes in the settings of the hybrid intelligent machine learning system for the new composition of raw materials and technological parameters. A program has been developed that provides a convenient graphical interface for preparing and using an intelligent system, and simulation experiments have shown that the process of additional training for new technological parameters is much faster than initial training while maintaining high accuracy of the obtained modeling results.

Уран и редкоземельные элементы в диктионемовых сланцах Прибалтийского бассейна (Кайболово-Гостилицкая площадь)

The article presents the results of the study of dictyonema shales of the Baltic basin (Leningrad Oblast, Kaibolovo-Gostilitsy prospecting area) for uranium (updated data on uranium mineralization of dictyonema shales) and rare earth elements (for the first time – as a new promising raw material source). At the same time, updated author’s data on the total metalliferous content of dictyonema shales was made In relation to uranium, its average content in dictyonema shales has been clarified, the distribution of uranium in the section of sedimentary strata according to new well profiles has been given, and the features of its distribution have been clarified, in comparison with earlier authors’ publications on this object of research. For rare earth elements in dictyonema shales, the results on their concentrations on a much larger analytical material are presented (670 samples, instead of 88, data on which were published earlier). For the first time, the features of the distribution of rare earth elements over the prospecting area and in the section of sedimentary strata along the profiles of wells are illustrated. New data on the petrographic composition of dictyonema shales are presented. An additional study of mineral impurities of dictyonema shales was carried out using a new method of areal scanning of preparations with an electron probe microanalyzer using the “Feature” software module. The correlations between the concentrations of uranium and rare earths with other micro- and macroelements, the forms of uranium and rare earth elements in dictyonema shales, geochemical indicators, conditions and genesis of the formation of uranium and rare earth mineralization developed in them was clarified. Based on an earlier assessment of the resource potential of uranium and rare earths, a modern assessment of their prognostic mineral resources and possible recoverable industrial reserves and the cost of potential ore raw materials of the studied acute-deficient metals for energy and a number of important industries has been made. The authors express the opinion that the mineral resource base of uranium and rare earth elements in Russia can be significantly increased due to the presence of these critical metals in the dictyonema shales of the Baltic sedimentary basin, since only within the studied Kaibolovo-Gostilitsy prospecting area the largest uranium resources and large resources of rare earths have been discovered, which may increase even more with further geological research in the conditions of a developed infrastructure of the middle zone of the Russian Federation.

Technique for Selecting Control Decisions in Optimizing Technological Modes of Processing Iron Ore Raw Materials Using Electromagnetic Influences

Purpose of reseach. The paper considers the process of selective pre-destruction of interphase boundaries in iron ores by using magnetic-pulse treatment. When analyzing the stress-strain state and viscous fracture, the relative similarity of the fracture criteria in the main minerals of iron ores due to magnetically-striction deformation of magnetite grains. Methods.It has been established that the strength and toughness of the destruction of magnetite exceeds the analogous properties of calcite in the composition of skarn iron ores, the strength and toughness of quartz fracture exceeds the analogous properties of magnetite. A difference in the character of the destruction of skarn ores and ferruginous quartzites. The criterion for estimating the degree of softening of interphase boundaries in iron ores due to the magnetic-impulse action based on the probabilistic approach is formulated. Results.A theoretical estimate is made of the degree of selective softening of iron ores under magnetic-pulse treatment, taking into account the strength and magnetostriction properties of magnetite. The results of experiments on nanoindentation of interphase boundaries before and after magnetic-pulse processing are presented. Conclusion. By analyzing the lengths of developing microcracks under the influence of a nanoindenter, the possibility of reducing the fracture toughness after a magnetic pulse treatment of iron ore.

Нейросетевое прогнозирование дефектов производства металлургической продукции

The paper is devoted to the current problem of reducing the percentage of defective products produced at serial steelmaking plants. To study the patterns of defect formation, a neural network was created that predicts the formation of defects such as “crack” in castings produced by the open-hearth method. To train the neural network, statistical data on the chemical composition of ore raw materials and the corresponding values of the percentage of defects were used. The data was taken under the conditions of an ongoing serial production process, which led to a high degree of noise in the information both on the chemical composition of the ore raw material and on the mechanical properties based on the results of its heat treatment. Outliers of statistical information were detected and removed using the original author’s neural network technique. A neural network model for controlling thermophysical and chemical-energy-technological processes of thermal processing of ore raw materials was created on the basis of a perceptron-type neural network with sigmoid activation functions. By conducting virtual computer experiments on a neural network model, some important dependences of the probability of formation of the defects under study on the content of manganese, phosphorus, silicon, chromium and sulfur were identified. Based on the identified dependencies, practical recommendations have been developed to reduce the percentage of defects by adjusting the chemical composition of ore raw materials. Despite the relatively low accuracy of the developed neural network model, the application of the practical recommendations obtained made it possible to reduce the percentage of defective products manufactured in a large-scale production process by 2.51 times.

К оценке опасности выщелачивания некондиционного сырья в кучах

The issues of identification of environmental hazards when implementing the concept of the involvement of poor metal-containing raw materials and tailings from ore processing through the application of a new leaching technology with a detailed version of heap leaching on the earth have been considered. The methodology of identification of the environmental consequences of the implementation of the technology of deep processing of non-conventional mineral raw materials considering the impact of mineral waste on the environment of the field development region has been formulated. An environmental component of the complex ecological and economic effect comprised of the consistently implemented stages of the existence of the enterprise has been considered. The main factors of negative environmental impact received a quantitative assessment; the territories adjacent to the enterprise have been ranked by the degree of the anthropogenic impact. The options to determine the extent of damage caused by the contamination of ecosystems with heavy metals have been proposed. Models to determine the environmental damage caused by industrial effluents as the main transporting medium and the efficiency of utilization of substandard raw materials based on the profit criterion have been formulated. The mechanism of removal of reagents and solutions to the environment by airflows has been specified. An approximate calculation of parameters of the environmental contamination for ore leaching of ore raw materials in the Sadonskoye deposit has been provided. It has been demonstrated that the chemical contamination of soils is prioritized when determining the environmental hazard and the hazard for the enterprise employees. It has been proved that the combined ecological and economic model of assessment of the efficiency of utilization of substandard raw materials joins ecological and economic aspects within a single natural and anthropogenic system, whereas the ecological and economic efficiency of production is a function of integrating methods of field development, including the application of a safety criterion for ecosystems of the environment. The study results can be used for the adjustment to the legislation on mining in the Russian Federation.

Пути интенсификации развития необжитых регионов Российской Федерации

The uninhabited regions development in the Russian Federation, located in remote and hard-to-reach areas of Siberia and the Far East, where up to 90 % of the estimated resources of especially valuable (strategic) raw materials have been explored, is an important scientific and practical problem. Energy supply of territories in extreme climate conditions, including the Arctic shelf, will ensure the new logistics solutions implementation in the field of exporting ore raw materials to the world market by cheap water transport. The object of the study is the uninhabited regions of the Russian Federation. The purpose of the study is to present a thesis expert assessment of the draft general strategy for the intensification of the development of the Eastern regions of Russia, taking into account the current level of technology and its development. Research objectives are as follows: making an expert assessment of the draft general strategy for the intensification of the development of the Eastern regions of Russia, based on information from speeches by outstanding scientists, professors, members of the Russian Academy of Sciences V. B. Ivanov, P. P. Poluektov, A. A. Vertman, V. Zh. Arens; identifying promising areas for the implementation of the development strategy of uninhabited regions of the Russian Federation on the basis of various types of nuclear power plants. The methodology and methods of the study consist in applying a comparative approach to the implementation of domestic and foreign solutions in the uninhabited regions’ development. The article outlines the technical and economic considerations, made by V. B. Ivanov, P. P. Poluektov, A. A. Vertman, V. Zh. Arens. The general system strategy for the uninhabited regions’ development of the Russian Federation on the basis of nuclear power plants of various types is briefly considered: floating nuclear power plants located on offshore non-self-propelled extreme barges; underground nuclear power plants based on mastered reactors of submarines of the Navy, which can be built in typical horizontal tunnels; mini-river-based nuclear power plants. The underground location of the mini-NPP allows for the safe operation of nuclear power sources. Expert assessments have shown that the project to intensify the Eastern regions development in Russia can now be successfully implemented.

ОСОБЕННОСТИ РАБОТЫ ДОМЕННОЙ ПЕЧИ НА АГЛОМЕРАТЕ РАЗНОЙ ОСНОВНОСТИ

The paper shows the peculiarities of blast furnace performance when different types of iron ore material are used. It is noted that the main types of iron ore raw materials are sinter and pellets, their advantages and disadvantages are given. The influence of increased pellet consumption on blast furnace smelting is indicated. The influence of sinter basicity on its strength and recoverability is noted. The results of calculating the indicators and the operation mode of the blast furnace at increased sinter basicity and an increased ratio between its consumption and pellets are presented.

Modern methods of industrial wastewater treatment and softening

The growing demand for clean water has significantly increased the need for coagulants in wastewater treatment, particularly for agricultural production organizations. In response to this pressing issue, the provision of iron-rich raw materials to enterprises producing coagulants has become a critical priority. To address this challenge, the paper focuses on exploring the potential of producing coagulants from local iron ore raw materials available in the Karakalpakstan and Navoi regions. Ongoing scientific research efforts are dedicated to studying the composition of the iron ore resources in these mines and determining their potential applications. By leveraging the local iron ore deposits, this approach aims to develop a sustainable and cost-effective solution for the production of coagulants, ultimately supporting the growing demand for clean water in the agricultural sector.

Актуальний стан проблеми переходу з видобутку корисних копалин відкритим способом на технології комбінованого відкрито-підземного та підземного видобутку залізорудної сировини

Актуальний стан проблеми переходу з видобутку корисних копалин відкритим способом на технології комбінованого відкрито-підземного та підземного видобутку залізорудної сировини

Improvement of the transitional technology from open pit to underground mining of magnetite quartzite

The paper analyzes the disadvantages of the technology of iron ore open pit mining and current environmental problems of open pit mining. The paper also addresses problems of possible displacement and strains of rocks in the classical open pit mining method with extraction of minerals exclusively by open pit mining, studies current transitional technologies from open pit to integrated open pit-underground and subsequent underground mining, and presents an improved methodology for studying the stress-strain state of the massif during transition from open pit mining to integrated open pit-underground and subsequent underground mining. There are studied, developed and proposed options of environmentally friendly technologies of integrated open pit-underground mining with mining waste disposal in the worked-out space of underground mines and open pits, highly efficient calculation schemes for studying the stress-strain state of a rock massif during transition from open pit to underground mining with formation of protective barrier pillars, an option with the development of the lower room of stage II under protection of an ore pillar left within the contours of the upper room of stage I, and an option with the development of the lower room of stage II under protection of an artificial pillar made of the consolidating backfill in the upper room of stage I. The stress-strain state of the massif and possibilities of forming internal waste rock dumps when applying integrated open pit-underground mining technologies are studied and substantiated. Transition technologies from open pit to underground mining of iron ore raw materials under the bottom of an operating open pit are developed and proposed on the example of Kryvyi Rih iron ore basin.

Prospects of the Bug mining district as an agglomeration of ore and non-ore mineral deposits for the reconstruction of the national economy of Ukraine in the post-war period

The role and capabilities of Ukrainian geological science, production and investment capital in the reconstruction of the national economy of Ukraine during the war and post-war period are considered here using the example of the Bug mining district (BMD) of the Ukrainian Shield (USh).
 BMD is characterized by an extremely wide range of deposits and ore of minerals relatively close to the surface, among which the most important ones are graphite, iron ore and iron-manganese, nickel-chromium-cobalt deposits, deposits and ore occurrences of gold discovered by geologists and geophysicists for many years. Numerous deposits of building materials and kaolin are also known here. There are prospects for obtaining local agrochemical raw materials based on the development of apatite-containing ores and calcifers.
 The article lists and shows the location of mineral deposits and ore occurrences which arethe most well-prepared for industrial development and investments. The composition of ores and the content of useful substances are given for some of them.
 Two powerful industrial enterprises are located on the BMD square, i.e., the Zavallye graphite factory and the Bug ferronickel plant (currently repurposed for other products). They can be used to process the above-mentioned ore raw materials, with some improvement of technological processes. In this regard, the possibility and practicality of creating two centers (clusters) of integrated mining and industrial development of these useful resources were considered. One of them can be created on the basis of nickel-cobalt and iron ore deposits of BMD with an orientation towards the Bug ferronickel plant. The second center can be created based on the enrichment of iron-manganese oxide ores using the technical capabilities of the Zavallye graphite plant.
 In case of realization of the entire economic potential of the industrial development of graphite ores of the region, Ukraine could become a world leader in this field and receive significant funds to reconstruct the industry disrupted by the war.
 The BMD also meets all the geological and economic prerequisites to become the first region on the Ukrainian Shield for industrial gold mining.

Experimental examination of the chemical-metallurgical roasting process for iron ore raw materials on the fire grate of a roasting conveyor machine

Experimental examination of the chemical-metallurgical roasting process for iron ore raw materials on the fire grate of a roasting conveyor machine

Development of ICP-AES Method for Analysis of Iron Ore Raw Materials

Development of ICP-AES Method for Analysis of Iron Ore Raw Materials

Investigation of the influence of lime content in the charge and its quality on the sintering process of iron ore raw materials

Main objectives of the work was to study the influence of degree of roasting of lime contained in the charge on the sintering process and sinter quality, as well as comparing the impact of changes in the mass fraction of active CaO in the charge by varying degrees of burning lime, and by varying the content of lime in the charge. It is shown that the intensifying effect of lime on the sintering process occurs as a result of a decrease in the content of small classes in the charge. When the lime content in the charge is equal to 3 %, an increase in the degree of lime firing from 5 to 96 % led to an increase in the specific productivity of the plant from 0.96 to 1.87 t/(m 2 · hour). The independence of sintering parameters from the content of active CaO in lime with its constant content in the sinter charge and the decisive role of the content of active CaO in the sinter charge with its constant content in lime are confirmed. A new approach to the production of lime for agglomeration processes is proposed: it should have the lowest cost of the active CaO contained in it.