Belgorod State University, Belgorod, Russia:

S. R. Gzogyan, Senior Researcher
T. N. Gzogyan, Head of Laboratory, Candidate of Engineering Sciences, mehanobr1@yandex.ru

Stoilensky GOK, Stary Oskol, Russia:

M. R. Mryasov, Head of Project Management of Ore Division
V. N. Chakov, Head of Engineering Office

The development and technological advance strategy of Stoilensky GOK (Mining and Processing Plant) includes modernization of crushing and milling facilities. The top-priority objective in this regard is resource-saving based on higher energy efficiency of ore pretreatment. The pretreatment process flow is added with high pressure grinding rolls (HPGR) manufactured by Köppern, Germany. The test subject is ferruginous quartzite from Stoilensky deposit. This is a finely disseminated and very strong rock. Dissociation of metal and nonmetal phases takes place in milling to the size of –0.045 mm. Milling was implemented in three stages, with preliminary size screening of stage III product, which offered a finely milled product with the weighted average size dav of 5.5 mm at the content of size +15 mm up to 2.5 %. Some aspects of the roller technology introduction are discussed, and the main stages of the technology application at the commercial scale are described. The informational measures are selected to compare ferruginous quartzite pretreatment circuits with and without HPGR. Fine milling enhances efficiency of processing by 8 % owing to the reduced size of feed of the head-end mills at the maintained iron ore concentration quality.

1. Gazaleeva G. I., Tsypin E. F., Chervyakov S. A. Ore preparation. Crushing, screening, beneficiation. Ekaterinburg : OOO UTsAO, 2014. 914 p.
2. Varichev A. V., Ugarov A. A., Efendiev N. T., Kretov S. I., Lavrinenko A. A. et al. Innovative Solutions in Iron Ore Production at Mikhailovsky Mining and Processing Plant. Journal of Mining Science. 2017. Vol. 53, Iss. 5. pp. 925–937.
3. Churilov N. G., Kryuchkov A. V., Golovchenko N. Ya. et al. Optimization of ferruginous quartzite pretreatment at processing factory. Gornyi Zhurnal. 2001. No. 6. pp. 57–59.
4. Fedotov P. K. Research and practice of roller-presses in ore preparation. Proceedings of the XXIX International Mineral Processing Congress. Moscow, 2018. pp. 22–28.
5. Revnivtseva V. I. (Ed.). Selective mineral decomposition. Moscow : Nedra, 1988. 285 p.
6. Tsvetkova A., Katysheva E. Ecological and economic efficiency evaluation of sustainable use of mineral raw materials in modern conditions. Proceedings of the 17^th International Multidisciplinary Scientific GeoConference SGEM 2017. Albena, 2017. Vol. 17, Iss. 53. pp. 241–248.
7. Khopunov E. A. Energy and power factors of selective destruction of ores. Izvestiya vuzov. Gornyi zhurnal. 2020. No. 1. pp. 79–88.
8. Gzogyan T. N., Gubin S. L. Roller press–grinder – Case-study of operation at Mikhailovsky GOK. GIAB. 2001. No. 5. pp. 244–246.
9. Dremin A. I., Perepelitsin A. I., Margulis V. S., Solntsev V. I. Grinding and processing test data of nonoxidized quartzite in roller–pressing machine at Mikhailovsky GOK. Obogashchenie Rud. 1996. No. 1. pp. 6–9.
10. Gzogyan T. N., Ryapolov A. N., Gzogyan S. R. Change in structural conditions of ferruginous quartzite under mechanical effects. Current technology and equipment for ferruginous quartzite pretreatment. Change in structural conditions and physical properties of ferruginous quartzite during ore pretreatment. Moscow : Gornaya kniga, 2013. pp. 126–137.
11 . Filin A. E., Zinovieva O. M., Kolesnikova L. A., Merkulova A. M. Prospects of safety control in combination of mining and metallurgy industries. Eurasian Mining. 2018. No. 1. pp. 31–34. DOI: 10.17580/em.2018.01.07
12. Vasyuchkov Yu. F., Melnik V. V. Mining of coal deposit on the base of «Local coal gas electric complexes». Eurasian Mining. 2017. No. 2. pp. 20–24. DOI: 10.17580/em.2017.02.05
13. Harder J. Trends in the Crushing of Mineral Ores. Mineral Processing. 2016 . No. 5. pp. 21–26.
14. Khaymovskiy S. S. Autogenous grinding mill process control practices. Tsvetnye Metally. 2021. No. 3. pp. 38–42. DOI: 10.17580/tsm.2021.03.03
15. Nordell L. K. Porter B. Potapov A. Comminution energy efficiency—understanding next steps. Proceedings of XXVIII International Mineral Processing Congress. Québec, 2016. pp. 1–24.
16. Krasnov G. D., Podgaetskiy A. V., Chikhladze V. V. Modeling breaking process at roller-press. GIAB. 2009. Special issue 14. Mineral concentration-1. pp. 89–102.
17. Hill H., Mainza A., Bbosa L., Becker V. Comparing the ore breakage characteristics of drill core and crushed ore using the JKRBT. Proceedings of XXIX International Mineral Processing Congress. Moscow, 2018. pp. 153–162.
18. Gzogyan T. N., Golovin Yu. I., Tyurin A. I., Gzogyan S. R. Effect of Intergrowth Boundaries between Mineral Species of Ferruginous Quartzite on Ore Pretreatment. Journal of Mining Science. 2017. Vol. 53, Iss. 3. pp. 565–572.
19. Kondratev S. A., Kotova O. B., Rostovtsev V. I. Surfaces and boundaries in the processes of preparation and enrichment of rebellious mineral and technogenic raw: quantum-mechanical concepts. Izvestiya Komi nauchnogo tsentra UrO RAN. 2010. No. 4(4). pp. 53–58.
20. Bengtsson M., Hulthén E., Evertsson C. M. Size and shape simulation in a tertiary crushing stage, a multi objectiveperspective. Minerals Engineering. 2015. Vol. 77. pp. 72–77.
21. Barskiy L. A., Kozin V. Z. System analysis in mineral processing. Moscow : Nedra, 1978. 486 p.
22. Bogdanov O. S. (Ed.). Reference book on ores concentration : in 3 volumes. Moscow : Nedra, 1972. 1302 p.