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Yekaterinburg, Russia

Nesterov G.S.,Uralmekhanobr JSC | Nesterov A.G.,Ural Federal University
Gornyi Zhurnal

The processes of USSR economics modernization on the threshold of 1920ies and 1930ies has required creation of powerful machine-building production facilities oriented first of all on manufacture of metal-intensive products. Establishment of the metallurgical base (state-of-the-art for those times) that can provide metal supply to the largest national machine-building enterprises, has been considered as mandatory condition for economical development in this direction. Therefore, creation of the large metallurgical works has become one of the most important modernization tasks, while necessity of provision of these works with raw materials has led to the rapid development of mining equipment and technology. Ironmaking has required iron ore with high Fe content. However, in the beginning of XX century most such deposits have been mined out and iron-depleted ores have been used; after their preparation, concentrate with 55-65% iron content could be produced. Agglomeration of iron ore concentrate became thereby the main technological stage in ore preparation, finalized in technological development of sintering, pelletizing and briquetting. Scientific teams - such as Uralmekhanobr, Ural branch of the USSR Academy of Sciences, Ural Polytechnic Institute etc. - have operated in close contact with the producers in the field om improvement of technology and equipment of sintering production. Theoretical grounds of sintering process along whole production route have been developed in order to provide stability of technological processes; the systems of technological control and automatic management have been designed for construction or modernization of sintering plants. It is noted that "Uralmekhanobr" Institute has become at that period the coordinate center in organization of sinter production in the Soviet Union, including development of information control system of product quality. This fact has allowed to realize the system of economical quality evaluation and redistribution of cost of finished product. No important technical solutions in the field of sintering processes could be taken in the USSR without participation of "Uralmekhanobr" Institute, and its role in this ares could be hardly overestimated. Source

Nesterov G.S.,Uralmekhanobr JSC | Gazaleeva G.S.,Uralmekhanobr JSC | Nesterov A.G.,Ural Federal University
Gornyi Zhurnal

The article highlights development of the technology and practice of mineral beneficiation in USSR in 1930-2000. The role of the Uralmekhanobr Institute is illustrated in scientific papers dealing with modernization of processes and technologies of mineral dressing and with higher quality of obtained products; the main fields of activities of the Institute in this area are analyzed. The main attention of the Institute in the 1930s was devoted to the development of mineral processing equipment and technology for nonferrous metal ores, which was conditioned by vital importance of the given trend under conditions of accelerated modernization. During World War II the Institute was the first to develop methods for integrated use of cobalt-bearing raw materials, tungsten and molybdenum ores, tantalumniobic, copper, manganese and chrome raw materials, and nonmetallic minerals. In 1942 processing of niobiumbearing pyrochloric concentrates was started at the Klyutchevsky plant of ferroalloys together with the production of ferro-niobium which had never been produced in USSR up to then. In the postwar years along with the requirement to process nonferrous metal ores and nonmetallic mineral resources, the demand for ferrous metal ore dressing became acute. The Uralmekhanobr Institute was the first to practise research methods in industrial tests and in economic justification of technological test results. In the 1950-60s the Institute created and implemented dressing technologies for different iron ores, based on which such enterprises as Sokolovsko-Sorbaisky and Kachkanarsky Mining-and-Processing Integrated Works were built. Fundamental studies carried out by Uralmekhanobr's scientists enabled for the first time ever in the world practice to develop an efficient processing technology for ferrous metal ores with poor iron content (16 %). This technology initiated construction of the unique Kachkanarsky MPIW. A significant number of scientific and engineering developments of the Institute were priority-oriented and fulfilled for the first time and for different branch enterprises. Dozens of such developments are protected by copyright certificates and patents for invention. Currently the Institute is an independent subdivision of the Ural Mining and Metallurgical Company and fulfills a range of works in such areas as mining, dressing, metallurgy, chemistry, standardization, engineering services, mine waste utilization technologies, etc. Source

Klyushnikov A.M.,Uralmekhanobr JSC | Musaev V.V.,Uralmekhanobr JSC | Orlov S.L.,Uralmekhanobr JSC | Umanskiy A.B.,Russian Academy of Sciences
Tsvetnye Metally

A method for treating laterite ores for nickel recovery was developed utilizing a combination of sulfuric acid leaching, sorption and chemical precipitation as an alternative to conventional pyrometallurgical processing. Pyrometallurgy is becoming less acceptable from economical standpoints for the treatment of low grade laterite ores. Additionally, high capital costs make modern facilities cost prohibitive for the treatment of such poor ores. Results of previous researchers indicated that sulfuric acid leaching is an efficient and cost effective method of treating poor laterite ores. We proposed that leach acidic liquors that contained 1.0-1.5 g/l of nickel can be processed in a following way. The solution had been initially neutralized and nickel was concentrated in solution by means of sorption from hydroxide slurry using amino carboxylic ion exchange resins. Then it was stripped from loaded resin to obtain a strip solution containing about 30 kg/m3 of nickel. Nickel hydroxide was precipitated from this solution that resulted in about 96-98% of nickel extraction from leach solution to the concentrate. After nickel extraction the slurry was further neutralized and purified from impurities of magnesium by filtration that made possible to recycle technological solution. Based on these results a flowsheet was proposed for the treatment of solutions obtained by sulfuric acid leaching of laterite ores from Ural. The research work presented in this paper determined the optimum conditions at which nickel could be obtained at maximum efficiency from the leach liquor according to this flowsheet. As a result concentrate was obtained that contained 35-43% of nickel. This product can be successfully subjected to the subsequent metallurgical processing in a traditional way. Source

Shikhov N.V.,Uralmekhanobr JSC | Shigaeva V.N.,Uralmekhanobr JSC | Nazarenko L.N.,Uralmekhanobr JSC
Gornyi Zhurnal

The article describes test results on dressability of quartz-feldspathic-kaolin raw material from the Bisembaev deposit. The -functions of quartz, feldspar and kaolin versus size are presented. The authors developed the method of stagewise estimation of optimum limit grain size for minerals during separation and offer a draft scheme of dressing. The scheme includes ultrasound treatment to remove fine fractions of kaolin. The Bisembaev deposit ore samples delivered to Uralmekhanobr in 2013 are mainly composed of quartz, feldspar (potash feldspar), mica (potash mica, annite) and kaolinite. Goethite, hematite, ilmenite and hydrogoethite are present. Generally, grains of the minerals are not intergrown but cemented by kaolinite. The samples were more representative for the deposit as compared with the samples delivered in 1974 and 1977. Thereupon, the decision was made to develop a new processing technology for the quartz-feldspathic-kaolin raw material from the Bisembaev deposit. The main objective of the related research was to find the optimum limit grain size for mineral separation. In order to validate the selection procedure for the optimum limit grain size based on the analysis of the functions at the first stage of dressing scheme and to obtain the ultrasound-treated product, laboratory studies were carried out using the suggested size of a limit grain (screen mesh size). The subsequent flotation and magnetic separation yielded saleable concentrates. The check and refinement of the developed scheme proved the validity of the selected limit grain size and the suggested method of stage-wise analysis of the -functions for the quarzt-feldspathic-kaoline raw material from the Bisembaev deposit. Based on the described scheme, the complete processing technology is developed, and the schedule of processing plant project is elaborated. Source

Minin V.V.,Uralmekhanobr JSC | Piankov D.A.,Uralmekhanobr JSC | Kotenkov A.V.,Uralmekhanobr JSC
Gornyi Zhurnal

The article illustrates intelligent use of ventilation air in stopes and development headings. The feasibility of partial re-use of air flow in mine ventilation network is demonstrated. The presented approach should be considered as one of the most significant and promising trends in energy-saving ventilation technologies for large mines with extensional goafs and ramified systems of roadways with low aerodynamic resistance. Based on the many-years experience of other researchers (over 60 years) and their own research findings, the authors have substantiated principles of partial air re-use that allows sustained, adjustable and safe gas, gas dispersoid, thermophysical and aerodynamic parameters of air and mine airing. Five proofs of the described theory and practice of mine design and construction are presented. The article describes the pilot test of the partial air re-use approach in terms of the Berezniki Mine-2, Uralkali JSC, and shows positions and elements of the pilot-plant equipment. Based on the test results, the hard-and-fast terms for unconditional fulfillment are set in the project documentation. Source

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