Stoilensky GOK, Stary Oskol, Russia:

S. A. Napolskikh, CEO, Head of Ore Division
A. G. Lipatov, Chief Mechanic, lipatov_ag@nlmk.com

URALMASHPLANT (UZTM), Yekaterinburg, Russia:
V. O. Furin, Chief Product Manager, Candidate of Engineering Sciences

Institute of Mining, Ural Branch, Russian Academy of Sciences, Yekaterinburg, Russia:
A. G. Zhuravlev, Head of Laboratory of Transportation Systems and Geotechnics for Opencast Mining, Candidate of Engineering Sciences

Primary crushing is one of the critical stages in mineral processing, which governs efficiency and capacity of the follow-on ore pretreatment. Given the present-day activity of Stoilensky GOK toward an increase in production capacity and efficiency, improvement of primary crushing is the first-order condition of the strategic mission accomplishment. This article describes the primary crushing productivity enhancement project at Stoilensky GOK through retrofitting of primary gyratory crushers manufactured at Uralmashplant, which has ensured the annual production output of 38 Mt/yr. The main engineering solutions on redesign of crushers KKD-1500/180, aimed at enhanced capacity and optimization of end product size in the conditions of coarse grinding shopfloor at Stoilensky GOK, consist in optimization of ore feed, intensification of crushing effect and primary breaking in the upper zone of crusher chamber, as well as in improvement of functioning of heavy-duty friction assemblies of crushers. The in-proof test conditions, methods and results obtained after modernization of crushers KKD-1500/180 are presented. The implementation of modernization solutions ensured the hourly efficiency increase from 400 to 5563 t/h at the product outlet width of 180 mm. The grain size composition evaluation proved the product quality improvement connected with stable size and reduction of medium size of the crushed product to d₀₅ = 232.65 mm. As a consequence, it is possible to enhance capacities in the next following stages of medium and fine grinding due to better ore pretreatment quality.

1. Harder J. Trends in the Crushing of Mineral Ores. Mineral Processing. 2016. No. 5. pp. 21–26.
2. Gzogyan S. R., Scherbakov A. V. Improving the quality of concentrates of Stoilensky GOK JSC with the use of magnetic gravity separation. Obogashchenie Rud. 2020. No. 6. pp. 3–10. DOI: 10.17580/or.2020.06.01
3. Midyukov D. O., Umysheva A. A., Chikildin D. E., Smirnov Yu. A. Ore preparation at Talnakh Concentrator with the semi-autogeneous grinding introduction. Tsvetnye Metally. 2018. No. 6. pp. 27–32. DOI: 10.17580/tsm.2018.06.03
4. Akinshin I. K., Bashchenko N. T., Bogdanov O. S. et al. (Eds.) Ore concentration reference book. 2nd edition, revised and enlarged. Moscow : Nedra, 1982. Vol. 1. Preparation processes. 366 p.
5. Lipatov A. G., Turyanskiy Ya. B., Furin V. O., Zhuravlev A. G., Cherepanov V. A. Topical Issues of MRO Management in Implementation of High Capacity Industrial Crushers Manufac tured by Uralmashplant JSC. Gornaya promyshlennost. 2020. No. 3. pp. 73–82.
6. Lagunova Yu. A., Furin V. O., Fedulov K. A. Cone crushers of PJSC Uralmash-Zavod for specific operating conditions. Gornoe oborudovanie i elektromekhanika. 2018. No. 1(135). pp. 27–33.
7. Boiko P. F. Optimization of technical service and repair of equipments at Stoilenskiy Mining and Concentrating Plant joint stock company. Gornyi Zhurnal. 2011. No. 6. pp. 52–54.
8. Andreeva L. I., Vasileva Ya. V. Evaluation of business opportunities for the personnel of mining enterprises. Process Equipment for Mineral, Oil and Gas Industry : XVI International Conference Proceedings. Ekaterinburg : UGGU, 2018. pp. 338–341.
9. Jiayuan Chen g, Tingzhi Ren, Zilong Zhang, Xin Jin, Dawei Liu. Influence of Two Mass Variables on Inertia Cone Crusher Performance and Optimization of Dynamic Balance. Minerals. 2021. Vol. 11, Iss. 2. DOI: 10.3390/min11020163
10. Sinha R. S., Mukhopadhyay A. K. Reliability centered maintenance of cone crusher: a case study. International Journal of System Assurance Engineering and Management. 2015. Vol. 6, Iss. 1. pp. 32–35.
11. Andreeva L. I.,Lashmanov V. A. Increasing the level of normalization of repairing processes using the example of JSC Kovdorskii GOK. Process Equipment for Mineral, Oil and Gas Industry : XVII International Conference Proceedings. Ekaterinburg : UGGU, 2018. pp. 342–345.
12. Boyko P. F., Titievskiy E. M., Timiryazev V. A., Mnatsakanyan V. U., Khostikoev M. Z. Provision of operational life-time period of crushers liners by applying new technologies of their manufacturing and wear-out diagnosing. Oborudovanie i tekhnologii dlya neftegazovogo kompleksa. 2019. No. 5(113). pp. 42–47.
13. Nowicki J., Hebda-Sobkowicz J., Zimroz R., Wyłomańska A. Dependency measures for the diagnosis of local faults in application to the heavy-tailed vibration signal. Applied Acoustics. 2021. Vol. 178. DOI: 10.1016/j.apacoust.2021.107974
14. Zeren Chen, Guoqiang Wang, Duomei Xue, Da Cui. Simulation and optimization of crushing chamber of gyratory crusher based on the DEM and GA. Powder Technology. 2021. Vol. 384. pp. 36–50.
15. Andreeva L. I., Krasnikova T. I., Lashmanov V. A. Reserves of repai r service: standardization of processes. Izvestiya vuzov. Gornyi zhurnal. 2018. No. 2. pp. 61–67.