LLC UMMC Holding

Verkhnyaya Pyshma, Russia

LLC UMMC Holding

Verkhnyaya Pyshma, Russia
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Panshin A.M.,LLC UMMC Holding | Matyukhin V.I.,Ural Federal University | Kozlov P.A.,ZINC Inc | Matyukhin O.V.,Ural Federal University
Tsvetnye Metally | Year: 2015

Conventional division of working space of rotary furnace on processing zones (drying, sulfate and carbonate decomposition, material recovery (reaction zone), oxidative and clinker cooling) allowed to establish peculiarities of heat and mass transfer processes under conditions of counter flow movement of charge and gases. There were determined the regularities of changes in temperature of gaseous medium and materials in working space of heating unit, depending on ratio of specific heats of charge flow and gas flow components. Progressive increase in heat capacity of the flow is observed during the gas transfer in working space of rotary tube. Peculiarities of specific heat changes of materials flow depend on intensity of heat and mass transfer processes development in separate technological zones. The heat capacity of material flow increases in drying and reduction zones due to development of endothermic processes, and values of this characteristics are reduced in oxidizing and cooling zones. The most intensive development of heat transfer processes occur in the zone of charge preheating and formation of heat carrier flow (Wm < Wr). The least intensity of heat exchange with formation of high-temperature gas flow is observed in oxidizing furnace zone. Considering peculiarities of thermal compression of bulk materials, there were defined the intervals of their solid and liquid phase sintering, indicating conditions of intensive development of rotary furnace process without breaking of high temperature annealing conditions. Rotary furnace process of ore components occurs mainly in the solid phase sintering mode, which determines the minimum diffusion difficulties for the development of recovery processes with maximum output of zinc.


Panshin A.M.,LLC UMMC Holding | Viduetskiy M.G.,Ural Federal University | Kozlov P.A.,ZINC Inc | Ivakin D.A.,ZINC Inc
Tsvetnye Metally | Year: 2015

Chelyabinsk Zinc Plant carried out the pilot tests of technology of flotation removement of sulfur from zinc cake on pilot pneumatic flotation machine CFM-180. A key principle of operation of pneumatic machines CFM is pulp oxygenation with finely dispersed air bubbles in ejector, which reduces flotation time and increases its selectivity. Technological scheme of testing includes basic flotation of original cake, control flotation of chamber product, and two cleaner flotations of froth product. In comparison with mechanical flotation machine, the following indicators increase during flotation of zinc cake on CFM:-initial feed performance (by 4 times);-sulfur recovery into flotation concentrate (by 1.4 times);-silver recovery into flotation concentrate (by 1.2 times). The washed chamber product (0.06% of sulfide sulfur and 2.98% of sulphate sulfur) and foam product (18.1% of sulfide sulfur) were obtained during testing. Results of laboratory studies of flotation products' processing are presented. Flotation and zinc cake washing can reduce zinc cake output by 20-25%, which allows to increase the processing volumes of oxidized imported raw materials by Waelz-process. Processing of chamber flotation product (zinc cake with low sulfur content) by Waelz-process can improve the Waelz kiln performance and reduce the coke breeze consumption. Foam product can be used as a sulfidizing additive under independent processing of copper plant dust with zinc, lead and tin extraction into fumes. On the basis of the carried out tests, there was realized the project of processing site of zinc cakes by flotation on the basis of industrial machines CFM-600 and CFM-1400.


Prodanov A.N.,LLC UMMC Holding | Tyulkin A.P.,LLC UMMC Holding | Zoteev O.V.,Russian Academy of Sciences
Tsvetnye Metally | Year: 2015

This article considers the possibility of reclamation of waste borrow excavations, connected by water tunnels with functioning underground mines and rock refuse. There was made a conclusion that application of ordinary pulp with low weight persentage of solid component is irrational for this purpose, because it leads to the sharp increasing (by far and away) of water inflows into the underground mine. Application of dehydrated concentration tails is the most optimal, which makes possible the sharp decrease of costs for reused water swap and load reduction for underground mine dewatering. Waste dehydration by various design filters to the cake state is possible only with low amount of products or appreciated value ores. It is more reasonable to use paste thickening technologies with high volumes of low and average value ore processing (more than 1 mln t of ore pre year). Using such technologies allows not only optimize the costs for return of reused water with absence of working-capable slip road to open-pit, but, in some cases, to dispose free water losses from reclamayed excavations. At the same time, risks of volley pulp break and flood of underground excavations with pulp are excluded because of high viscosity of paste thickening products. Using paste thickening products for reclamation of open pits, connected with underground mines by large channels, requires the construction of solid straight arch system, intended for high pressure, for the protection of functioning underground excavations. There is also required the organization of removement of free water, sent into the open pit bowl due to atmospheric precipitations, drainage of underground waters and paste product runout.


Panshin A.M.,UMMC Holding LLC | Kozlov P.A.,ZINC Inc | Terentev V.M.,ZINC Inc
Tsvetnye Metally | Year: 2014

Disturbances of zinc concentrates' roasting process in fluid-bed furnaces of modern plants are related to change of chemical composition and physical properties of concentrates. Thermodynamic possibilities of sulfide zinc concentrates' oxidizing reaction were studied and defined for fluid-bed furnace conditions. Definition of technological parameters of roasting is necessary for definition of speed of sulfide zinc concentrates' oxidizing reactions. Kinetics of oxidizing reactions for the solid body - gas system in laboratory fluid-bed furnaces was investigated. Dependence of oxidization ratio on the particle size of original product was defined together with optimal size of concentrate particles, where the oxidation speed is limited by the quantity of feeding oxidizing substance. There were shown the reasons of the furnaces operation declination during the roasting of fine zinc concentrates. There was made a conclusion about the negative influence of the small size particles' predominance in the fluid-bed furnace on roasting process. Roasting products with minimum content of sulfides can be obtained by controlling of grain fineness of the calcine in fluid-bed furnace during roasting. There are presented the recommendations for changing of technological parameters of roasting for industrial furnaces. © Designed by: "Ore and Metals" Publishing House, journal "Tsvetnye Metally", 2014.


Panshin A.M.,LLC UMMC Holding
Tsvetnye Metally | Year: 2014

Ural Mining and Metallurgical Company (UMMC) unites Russian mining, metallurgical, metal-working and building industry enterprises into one processing chain. Inclusion of enterprises of various industry branches into UMMC influence area allows to unite and coordinate the enterprises' activities, beginning from ore mining to manufacturing of a wide range of value-added products.


Vasilev E.A.,LLC UMMC Holding | Rudoy G.N.,LLC UMMC Holding | Savin A.G.,LLC UMMC Holding
Tsvetnye Metally | Year: 2014

There was carried out the assessment of presence and state of cumulated and modern dumps of overburden rocks, substandard ores and wastes of concentration plants of UMMC enterprises. Special attention was paid to the tailing dump of concentration plant of Gai Ore Concentration and Processing Enterprise with the highest volume of cumulated floatation tailings and considerable reserves of valuable components. The tailing dump mapping was carried out for obtaining of information about distribution of valuable components in this technogenic formation and preliminary assessment of reserves. During technological exploratory research on gravity and flotation concentration and hydrometal-lurgical retreatment of tailings and their concentration products, the preference was given to the flowsheet, including cyanide carbon in leach process. Although application of conventional intensifying chemical methods of sulfide minerals decomposition and extraction of finely disseminated gold before cyanidation (pressure oxidation, oxidizing roasting and bacterial leaching) helps to increase end-to-end gold recovery (up to 74.5-85.2%), it is more than likely that they will not make profitable application of these methods. JSC "Pokrovskiy rudnik" (included in the "Petropavlovsk" group of companies), in scientific collaboration with JSC "Irgiredmet", carried out continuous pilot tests of cyanide treatment of old pyrite tailings of Gai Ore Concentration and Processing Enterprise in closed mode. The results of laboratory research were proved by pilot tests, and extended economic evaluation of the process is being conducted.


Panshin A.M.,LLC UMMC Holding | Shakirzyanov R.M.,LLC Uraltsink | Izbrekht P.A.,ZINC Inc | Zatonskiy A.V.,ZINC Inc
Tsvetnye Metally | Year: 2015

This article gives an overview of the main production development trends at Chelyabinsk Zinc Plant, including all stages of the process. There are considered the activities, which were implemented or are planned to be implemented in calcination shop, leaching shop, complex of zinc electrolysis, Waelz shop, sulfuric acid shop and hydrometallurgical shop. There is shown the connection between all carried out improvements with increasing of environmentally friendly production. In 2014, a record amount of zinc (about 183 thousand tons) was produced by the enterprise. About 15 tons of copper plant dusts were involved in the processing. The second large-dimensioned rotary kiln (4 m diameter, 60 m length) was built. Capacity of new water circulation of the sulfuric acid plant was up to 5000 m3/h, which allowed to increase sulfuric acid production reliability during operation at maximum loads. Current density during cadmium electrolysis was increased from 70 to 90 A/m2. Currently, capacity of Chelyabinsk Zinc Plant is increased to 200 thousand tons per year of commercial zinc production. The site if charge preparation with capacity of about 100 tons per year for rotary kilns is developed. Technological regulation is worked out and a project of hydrometallurgical plant expanding for increasing number of Waelz oxide processing is undertaken. There is carried out the preparation for construction of pilot plant of zinc cake flotation, using flotation machine CFM. Technology of industrial wastewater treatment to produce a commercial product in the form of halite and Glauber's salt is tested on the pilot plant. For the first time, this technology is implemented for zinc production, with a prospect of provision of 100% return of drains into the production.


Fatkhutdinova O.A.,ZINC Inc | Panshin A.M.,LLC UMMC Holding | Zatonskiy A.V.,ZINC Inc | Kozlov P.A.,ZINC Inc
Tsvetnye Metally | Year: 2015

This paper discusses the results of research, carried out on pilot zinc production waste water treatment unit. The first stage of the pilot trials is chemical treatment of waste waters (using reagents) and their concentration on reverse osmosis unit. Deficiency of sulphurous zinc materials shows the need to engage recycled material in processing. During recycling process, secondary raw materials are cleaned from impurities derived by sewage. Chlorides, sulfates and sodium fluorides are the main impurities removed by sewage. Standard limestone technology of waste water treatment does not give the possibility to remove the foregoing soluble impurities from waste waters. Return of waste waters to the process is not possible owing to the harmful effect of sulphates, chloride and fluoride on the process of zinc extraction. Developed technology of waste water treatment allows to use the purified water in industrial production and direct the concentrate acquired from reverse osmosis to evaporation. Optimal conditions and parameters of the following processes are defined:-chemical treatment of waste water (adding reagents): pH=11.3-11.6; residual hardness-less than 1.0 meq/l; heavy metals precipitation degree-93-98,9%;-ultrafiltration: transmembrane pressure-0.6 bar, partition coefficient-85%; filtration rate-375 l/m2h; filtrate turbidity-0,6 NTU;-reverse osmosis: concentration of soluble salts using two stage reverse osmosis (in the concentrate) is 2.27 mg/dm3 (48-52 bar at the pressure on the first stage, and 60-64 bar at the pressure on the second stage), total concentration of salts in permeate is 27.4 mg/dm3.


Kozlov P.A.,ZINC Inc | Panshin A.M.,LLC UMMC Holding | Vyatkin V.N.,ZINC Inc | Reshetnikov Yu.V.,ZINC Inc
Tsvetnye Metally | Year: 2015

This article considers the possible methods of processing of copper production dusts with extraction of Zn, Pb and Sn. Urgency of processing of these raw materials at zinc plants is defined by exhaustion of natural reserves of Zn ores, increased amounts of cumulation of defined zinc-containing product in copper industry, and solving of ecological problems. Waelz-processing together with other oxidized Zn-Pb-containing materials and Waelz-oxide processing are the existing dust processing technologies, which solve the problem of Zn extraction in solution and Pb extraction in solid product, required for pyrometallurgical technology. Taking into account economic reasonability of Sn extraction from copper production dusts, the task of this metal transfer during processing in concentrated product is still urgent. On the basis of the data of chemical and phase analysis of copper production dusts, and research of thermodynamic and kinetic parameters of pyrometallurgical processes, there is developed the technology of selective extraction of Zn into solution for hydrometallurgical processing. At the same time, Pb is extracted in concentrated product with its content of 40-50% and extraction rate of 95-99%, while Sn is extracted into product, containing 10-20% of this component, with extraction rate of 60-64%. Technology includes the pyrometallurgical stage-roasting of raw materials with Pb removement in sublimates and cinder hydrometallurgical processing stage. Pb is transferred in sulfide form for efficient distillation. There are given the data about technological parameters of roasting and content of obtained product. Extraction of Zn and Sn in cinder is 90% and 70-75%, respectively. Sublimation rate of Pb is 98-99%.


Panshin A.M.,LLC UMMC Holding | Reshetnikov Yu.V.,ZINC Inc | Ivakin D.A.,ZINC Inc | Geraskin V.V.,ZINC Inc
Tsvetnye Metally | Year: 2015

Chelyabinsk Zinc Plant developed the technology of processing of zinc-, lead-and tin-containing copper industry dusts, including the following stages:-pyrometallurgical stage-calcination with addition of sulphidizer, flux and reducing agent to the product, where lead is removed from the product with transfer in processed sublimates, while zinc and tin stay in cinder;-hydrometallurgical stage-high-temperature leaching of cinder, where zinc, iron, coper, etc are extracted in solution with obtaining of tin-concentrating solid residue. There is considered the hydrometallurgical stage of obtaining of tin-containing concentrate from cinder with low content of lead (less than 1%). There is shown the low extraction of zinc in solution and absence of selective separation of tin and lead with acid sulfuric-acid dust leaching without application of pyrometallurgical stage. Three-stage leaching (similar to the technology of hydrometallurgical processing of Waelz-oxides, existing in Chelyabinsk Zinc Plant) and one-stage high-temperature leaching were researched for obtained cinder. Three-stage product leaching is low-efficient, because it requires many equipment and does not provide the required concentration of tin in solid residue. About 98% of zinc, contained in cinder, more than 95% or copper and iron is transferred in solution during the high-temperature product leaching by waste zinc electrolyte with addition of sulfuric acid (t=80-90 °C, concentration of H2SO4 is 160-170 g/dm3). Obtained solution is required for application in technological cycle of zinc plant. Solid residue contains 14-21% of tin, which allows to use it at tin enterprises.

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