Mining Institute of Kola Science Centre RAS (Apatity, Russia)

Opalev A. S., Deputy Director for Scientific Work, Candidate of Engineering Sciences, a.opalev@ksc.ru
Alekseeva S. A., Senior Researcher, s.alekseeva@ksc.ru

IGD Kazakhstan LLP (Astana, Kazakhstan)

Bermukhambetov V. A., Director, Candidate of Engineering Sciences, valikhan.ber@gmail.com

This article presents the results of a comprehensive set of process studies conducted both in laboratory and industrial settings aimed at improving the grade of magnetite concentrate produced by an iron ore processing plant in Kazakhstan. In order to align with the current global standards for iron ore products, the plant must improve the iron content (Fetot) in its concentrate from 66 % by weight to at least 67–68 % by weight. The technology upgrade proposed is based on a stepwise process that involves replacing conventional hydrocyclone classification with fine screening and substituting wet magnetic separation with magnetic-gravity separation at the final stage. The integration of fine vibration screening and magnetic-gravity separation ensures high separation efficiency, enabling a phased extraction of high-grade concentrate, recognized as a leading method in mineral raw material processing. The implementation of this updated technology at a section of the plant resulted in the production of magnetite concentrate with a Fetot content of 68 % with a recovery rate of 88.8 %. These results significantly exceed those achieved using the previous technology, which produced concentrate with a Fetot content of 65.9 % and a recovery rate of 86.7 %. Adopting this new technology reduces the circulating loads within each process, increases the energy efficiency of the grinding stage, and eliminates the need for PBM series separators, which have low operational efficiency in the concentrate cleaning process. From a financial perspective, the technology proposed increases the market value of the concentrate by an average of 10–12 %, enhancing the competitiveness of the product.

1. Pelevin A. E. Ways to increase the efficiency of iron ore processing technology. Chernaya Metallurgiya. Byulleten' Nauchno-tekhnicheskoy i Ekonomicheskoy Informatsii. 2019. Vol. 75, No. 2. pp. 137–146.
2. Rudyka V. I. Prospects of direct iron reduction technology in metallurgical production. Chernaya Metallurgiya. Byulleten' Nauchno-tekhnicheskoy i Ekonomicheskoy Informatsii. 2017. No. 11. pp. 14–22.
3. Dorofeev G. A., Parshin V. M. The new concept of resource conservation in the production of steel. Izvestiya Tulskogo Gosudarstvennogo Universiteta. Tekhnicheskie Nauki. 2017. Iss. 1. pp. 58–72.
4. Karmazin V. V., Andreev V. G., Palin I. V., Zhilin S. N., Pozharskiy Yu. M. Development of equipment for the technology of full-stage beneficiation of magnetite quartzite. Gornyi Zhurnal. 2010. No. 12. pp. 85–89.
5. Demin V. V. Improvement of magnetic separation of ferromagnetic materials. Zapiski Gornogo Instituta. 2006. Vol. 167, No. 2. pp. 239–241.
6. Opalev A. S., Marchevskaya V. V. Influence of magnetite grain size on magnetic susceptibility of iron ore concentrates. Fiziko-tekhnicheskie Problemy Razrabotki Poleznykh Iskopayemykh. 2023. No. 1. pp. 161–167.
7. Opalev A. S., Biryukov V. V., Burenina I. V. On the mechanism of selective separation of magnetite-containing products in a magnetically stabilized fluidized bed of a magnetic gravity separator. Nauchnyi Vestnik Moskovskogo Gosudarstvennogo Gornogo Universiteta. 2013. No. 3. pp. 37–48.
8. Buscilio A., Vella G., Micale G., Brandani S. Modeling of magnetic-field-assisted fluidization: model development and CFD simulation of magnetically stabilized fluidized beds. KONA Powder and Particle Journal. 2015. No. 32. pp. 217–226.
9. Espin M. J., Quintanilla M. A. S., Valverde J. M. Magnetic stabilization of fluidized beds: effect of magnetic field orientation. Chemical Engineering Journal. 2017. No. 313. pp. 1335–1345.
10. Opalev A. S., Khokhulya M. S., Fomin A. V., Karpov I. V. Creation of innovative technologies for production of high-quality iron concentrate production in the North West of Russia. Gornyi Zhurnal. 2019. No. 6. pp. 56–61.
11. Opalev A. S., Karpov I. V., Krivovichev S. V. Enhancing magnetite quartzite processing efficiency at Karelsky Okatysh. Gornyi Zhurnal. 2021. No. 11. pp. 66–74.
12. Grinenko V. I., Opalev A. S., Maevsky P. V., Karpov I. V. Improvement of iron ore concentrate quality by gravity and magnetic separation at SSGPO JSC. Gornyi Zhurnal. 2021. No. 10. pp. 81–86.
13. Gzogyan S. R., Shcherbakov A. V. Improving the quality of concentrates of Stoilensky GOK JSC with the use of magnetic-gravity separation. Obogashchenie Rud. 2020. No. 6. pp. 3–8.
14. Moraes M. N., Galery R., Mazzinghy D. B. A review of process models for wet fine classification with high frequency screens. Powder Technology. 2021. Vol. 394. pp. 525–532.
15. Frausto J. J., Ballantyne G. R., Runge K., Powell M. S., Wightman E. M., Evans C. L., Gonzalez P., Gomez S. The effect of screen versus cyclone classification on the mineral liberation properties of a polymetallic ore. Minerals Engineering. 2021. Vol. 169. DOI: 10.1016/j.mineng.2021.106930
16. Jankovic A. Comminution and classification technologies of iron ore. Iron ore: Mineralogy, processing and environmental sustainability. 2ed. Chap. 8. Woodhead Publishing, 2022. pp. 269–308.
17. Vaisberg L. A., Korovnikov A. N. Fine screening as an alternative to hydraulic classification by size. Obogashchenie Rud. 2004. No. 3. pp. 23–34.
18. Ismagilov R. I., Kozub A. V., Gridasov I. N., Shelepov E. V. Case study: Advanced solutions applied by JSC Andrei Varichev Mikhailovsky GOK to improve ferruginous quartzite concentration performance. Gornaya Promyshlennost′. 2020. No. 4. pp. 98–103.
19. Baranov V. F., Patkovskaya N. А., Tasina Т. I. Current trends in magnetite iron ores processing technology. Basic trends. Obogashchenie Rud. 2013. No. 3. pp. 10–17.
20. Korovnikov A. N., Buzunova T. A. Ore slurry classification on a vibrating screen. Obogashchenie Rud. 2018. No. 5. pp. 17–21.
21. Leonov V. Experience of Derrick technologies for mining industry. Mining Report Gluckauf in Russian. 2014. No. 3. pp. 66–70.
22. Pelevin A. E., Sytykh N. A. Fine hydraulic screening for staged separation of titanium-magnetite concentrate. Obogashchenie Rud. 2021. No. 1. pp. 8–14.
23. Dündar H. Investigating the benefits of replacing hydrocyclones with high-frequency fine screens in closed grinding circuit by simulation. Minerals Engineering. 2020. Vol. 148. DOI: 10.1016/j.mineng.2020.106212
24. Pelevin A. E., Sytykh N. A. Efficiency of screens and hydrocyclones in closed-cycle grinding of titanomagnetite ore. Gornyi Informatsionno-analiticheskiy Byulleten′. 2022. No. 5. pp. 154–166.
25. Kosoy G. M., Vinnikov A. Ya. Fine hydraulic screening of ground ores on a multi-frequency screen by Kroosh Technologies: in-process testing. Tsvetnye Metally. 2021. No. 6. pp. 10–15.