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Yagudin R.A.,Uchalinsky Mining and Processing Integrated Works JSC | Yagudina Yu.R.,Uchalinsky Mining and Processing Integrated Works JSC | Emelianenko E.A.,Magnitogorsk State Technical University
Gornyi Zhurnal | Year: 2014

A few decades ago, the copper-and-zinc ore concentration was a process flow of ore preparation and cleaning operations resulting in production of marketable copper, zinc and, partly, pyrite concentrates. Efficiency of mining and metallurgical technologies is governed by rational and multipurpose utilization of mineral resources and on scientific-and-technical approach to handling problems in integrated development and conservation of mineral wealth. As early as mine planning stage, all process characteristics and features of ore should be taken into account, for the first turn, the ore material constitution that complicates in the course of mineral extraction. The aim of this research was to investigate the material constitution and process properties of pyrite copper ore treated at the Uchalinsky processing plant, and to study rational approaches to this ore dressing. The main goal of the ore dressing is production of high quality copper and zinc concentrates at high yield of the related commercial components. However the problem is complicated by some factors. The difficulties of concentration of pyrite copper ore at the Uchalinsky processing plant are conditioned by that the copper-zinc-pyrite ore occurring in the South Ural formations can greatly differ in the material constitution and process properties in different areas of the same deposit due to different genesis and degree of subsequent meta-morphism and owing to intricate and tight intergrowth of sulphides unlocking of which requires very fine grinding; for another thing, the flotation properties of copper sulphides and zinc sulphides activated by copper ions are very close in the discussed ore. Thus, the complex material constitution, fine intergrowth of sulphides and barren rock, high content of water-soluble copper, zinc and iron sulfates as well as development of colloform varieties prone to overgrinding characterize the ore as rebellious. In flotation the aggregates of copper, zinc and iron sulphides go to tailings, and unlocking of these aggregates requires hydrometallurgical methods. Currently, aimed at the integrated approach to pyrite copper ore processing based on the positive experience gained in steam-and-pressure leaching of copper concentrate, the investigations are carried out into the steam-and-pressure leaching of tailings and copper-and-zinc middlings.

Akhmediyanov I.Kh.,Uchalinsky Mining and Processing Integrated Works JSC | Grigorev V.V.,LLC Shakhtostroitelnoe Upravlenie | Krasavin V.P.,Uchalinsky Mining and Processing Integrated Works JSC | Danilov O.N.,Uchalinsky Mining and Processing Integrated Works JSC | Kalmykov V.N.,Magnitogorsk State Technical University
Gornyi Zhurnal | Year: 2014

Since the capacity of the existing tailing pond of the Uchalinsky Mining and Processing Integrated Works has been depleted, the problem of finding new sites for tailings storage in the industrially developed region is solved by way of using the stripped area of the Uchalinsky open-pit mine scheduled for completion in 2015. The huge stripped area (150 million m3) offers a room for tailings storage for a long term (40 years) and simultaneously allows addressing issues of land reclamation. Analysis of the prevailing mine-technical situation and the lack of experience gained in tailings stockpiling in combination with underground mining operations showed impossibility of tailings storage in the stripped area of the open-pit mine without pre-thickening in view of the numerous hydraulic connections between the open-pit and underground mines and due to high permeability of the tailings. Aimed at finding optimum parameters of the artificial mass made of tailings placed in the bowl of the open-pit, physico-mechanical properties of slurry were studied, namely, porosity modulus of deformation, internal friction angle, viscosity, spreading and their relationship with the basic influencing factors that allow estimation of such properties of the tailings mass as its moisture content, density, deformation and water loss. On this basis, the following design solutions have been developed: -construction of a protective pillar 109 m thick to prevent the thickened product from entering underground roadways; -generation of a drainage system including underground water drainage, water discharge holes and filtering screen; -construction of watertight partitions to seal off underground roadways. The use of the stripped area of the open-pit mine allows pruning payment for waste emplacement by 44 RUB/t and saves 274 MRUB/yr.

Akhmetov A.A.,Uchalinsky Mining and Processing Integrated Works JSC | Akmurzin R.K.,Uchalinsky Mining and Processing Integrated Works JSC | Zagretdinov A.N.,Uchalinsky Mining and Processing Integrated Works JSC | Tankov M.S.,Uralmekhanobr JSC | Dik Yu.A.,Uralmekhanobr JSC
Gornyi Zhurnal | Year: 2014

Under conditions of significant reduction of ore-containing fields, maintenance of planned annual ore output required to extract ore from a dividing ore pillar. Under order of technical management of the Uchalinsky Mining and Processing Integrated Works JSC, specialists of the Department for Mining Science of the Uralmekhanobr JSC developed "Guidelines on Mining Sequence and Geotechnology on Sublevel 240/270m in the Dividing Ore Pillar in the Molodezhny Deposit." It was decided to withdraw mining with caving due to high quality of ore and to carry out extraction of ore reserves in the dividing pillar, both in the bottom and sidewall of the open-pit mine, by room-and-pillar mining using solidifying backfill. The mining sequence was two-stage: The first stage was extraction of bottom reserves (in the ore pillar below the open-pit bottom); The second stage was extraction of sidewall reserves (in the ore pillar in the north-eastern pit wall). The recommended system for extraction of the sidewall reserves is the room-and-pillar mining with solidifying backfilling using high-production drilling and handling machinery. This is first of all connected with the optimum indexes of ore loss and dilution in the room-and-pillar mining with backfilling. In extraction of the sidewall reserves using backfill, it was decided to make an artificial combination pillar.

Baranov S.V.,Uchalinsky Mining and Processing Integrated Works JSC | Goltsov V.V.,Uchalinsky Mining and Processing Integrated Works JSC | Sharipov I.Kh.,Uchalinsky Mining and Processing Integrated Works JSC | Semiryakov V.B.,Uchalinsky Mining and Processing Integrated Works JSC | Kotenkov A.V.,Uralmekhanobr JSC
Gornyi Zhurnal | Year: 2014

Currently Uchaly deposit represented by a steep lenticular continuous sulphide ore body is mined with the combination of open and underground methods. In the South pitwall (South lens out) beyond the ultimate pit limits, the geological ore reserves amount to 90 thou t. At the stage of depletion of the open-pit mine, it was decided to extract the said geological reserves. It was required to find a technology such that to prevent from the pit wall caving, mine safety inhibition, loss of reserves and significant dilution of the extracted ore. The satisfying technology was developed-the extraction site was divided into two mining stages: the first stage was above Level 300m and the second stage was the Level 300-340m; mining was carried out with open chambers toward the open-pit mine. Stage I ore was stepwise broken toward the compensation chamber 34-3yu, preliminary mined-out without backfilling on Level 300-340m (steps 1-4), and toward the open-pit mine (steps 5-6). Ore handling was executed by remote-control load-haul-dumpers in haulage roadways in the chamber 34-3yu. After stage I ore had been extracted, the adjacent rock mass partly lost its stability, and the unbackfilled chamber was filled with caved rocks from lower benches of the open-pit mine. On the whole, the pit wall retained its stability. Stage II ore extraction in sublevel of Level 300-340m (between the stripped area and the chamber 34-3yu filled with caved barren rock) involved a protection pillar set at the interface with the barren rock. The ore was stepwise (steps 1-2) broken toward the open-pit mine and handled by the remote-control load-haul-dumpers. The ore in the protective pillar at the caved barren rock in the chamber 34-3yu was broken at the final step (step 3) by a directed blast toward the open-pit mine. Thus, the South lens-out reserves were extracted with keeping the south pit wall in stable state.

Baibulatov F.R.,Uchalinsky Mining and Processing Integrated Works JSC | Larionov A.V.,Uchalinsky Mining and Processing Integrated Works JSC | Zakharkin P.I.,Uchalinsky Mining and Processing Integrated Works JSC | Muslimov M.B.,Uchalinsky Mining and Processing Integrated Works JSC
Gornyi Zhurnal | Year: 2014

Productivity enhancement in modern conditions is impossible without high-tech management techniques. Development of applications of basic technologies and their introduction in operating production extends their range of use. In this regard, advances of information technologies have furnished them ascendancy in the production control. The Department for Communication, Automation and Informatization provides all business and control units of the Company with the required information and enables control over the entire flow process. For instance, for more efficient use of the transportation system, the Uchalinsky Mining and Processing Integrated Works has introduced the motor-vehicle transport monitoring technology. In the main building of the processing plant, the centralized system of flotation section VI automation and analytical control ASAK-3 informs the processing plant personnel on the parameters of flotation at intermediate levels and allows the operational control of the beneficiation process. Introduced in 2020, the innovative automated energy resources monitoring and registering system (ASKUEN) enables the centralized technical and commercial stock record of trade effluent and service and drink water, as well as heat and gas in subdivisions of the Company. The wireless communication Wi-Fi introduced in the mines of the Company maintains communication with the surface dispatcher control during the working shifts. In the railroad workshop of the Company, the multifunction communication has been installed and the production loudspeaker communication (PLC) has been modernized. The Convention Hall in the Company's administration building has been equipped with the videoconferencing system (Tanberg).

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