Опыт освоения магнитно-гравитационной сепарации на предприятиях России и стран СНГ для повышения качества железорудного сырья

The problem of constructing a HIL simulation stand for researching a technological process using programmable logic controller (PLC) "Baget" is described in this article. Issues of modeling technological processes are currently extremely relevant, since modeling is a mandatory stage in the automated process control systems development. An adequate model of the technological process allows debugging and verification of automated process control system algorithms without using real equipment, reducing financial costs and the probability of emergency situations. The HIL modeling method involves partial use of real equipment as part of the model. The inclusion of standard components of the original object in the model does not require detailed mathematical model and at the same time provides a more complete correspondence to the original. Due to using a computer from the original object, the stand software operates under conditions close to the real technological process, which improves the quality of the simulation results. The HIL modeling stand includes the following components: control computer of automated process control system; programmable logic controller PLC "Baget"; simulation computer. The stand for the basic element of an automated process control system allows to speed up the process of prototyping and debugging even in the case of complex systems, because it will be easier to build the entire system from correctly functioning elements. Another advantage of this approach is that the stand is not tied to a specific type of technological process or to a narrow area of production — the stand allows the use of ready-made models, the development of new models, and the inclusion of various function libraries. The simplicity of the stand design with this approach is combined with a full range of functionality. By connecting additional software, you can create more complicated and detaild model. This stand is also capable of serving both for debugging PLC algorithms and as a simulator for maintenance personnel of a real control object, because the stand operator can simulate failures and errors of standard equipment, emergency situations at the control object. Using C and JavaScript programming languages for development ensures portability and ease of expanding the capabilities of the modeling software. The development of complex systems based on HIL modeling allows saving resources and effectively solving assigned problems, therefore the proposed approach to building stands will be in demand in the process of developing an automated process control system based on the PLC "Baget".

The purpose of this study is to develop a new conceptual approach to the modernization of existing industrial operated automated process control systems (IOAP CS) in order to integrate them into the technology of building digital twins and digital factories with minimal expenditure of computing resources and reducing the amount of processed data. To solve this problem, it is proposed to modify existing automated process control systems (IOAP CS) sequentially by automation levels so that the volume of redundant information is reduced in the structures of the levels, as well as predicting the values of technological parameters based on the properties of control objects using artificial intelligence in order to use identical values in automated process control systems (IOAP CS) and in their models of digital twins. To obtain information about technological processes with a low degree of automation, it is proposed to use organizational and technical structures based on the theory of graphs with a finite vertex, reflecting the volume and quality of the products obtained using algorithms based on artificial intelligence tools, which make it possible to predict the result of subsequent ones based on the results of the previous stage, taking into account the accumulated experience, this will enable an expert assessment of the correctness of the technological process to achieve the required product properties and performance of the technological unit. The proposed concept of modification of automated control systems (IOAP CS) for technological processes in operation will make it possible to ensure the transition to building digital counterparts of technological processes with minimal time using available computing resources with minimal loss of the volume of products.

Performance assessment of an innovative precise low-intensity magnetic separator

Recently rock magnetism is contributing to solve many geological problems. There are several types of remanent magnetization. In case of igneous rocks, magnetism arises from thermo-remanent magnetization. When the ferromagnetic mineral grows or changes chemically in the magnetic field under its curie point, it gets chemical or crystalline magnetization. In this paper, application of rock magnetism arising from chemical or crystalline remanent magnetization to economic geology was attempted. In order to achieve this purpose, the Shinyama ore body of Kamaishi iron and copper ore deposits was selected, because it is a typical contact metasomatic ore deposit and is a well exploited one. The Shinyama ore body consists of two iron ore bodies that contain magnetite and several copper ore bodies that contain pyrrhotite. Oriented samples were collected from many localities of the ore deposits systimatically. The direction and intensity of remanent magnetization, the magnetic susceptibility and other magnetic properties of ores were measured. The direction of remanent magnetization of each ore body is as follows. the iron ore…………………………Inclination 90°Down The 2nd copper ore body (closed to the iron ore body)……………{Declination 12°E INclination 48°Down The 4th copper ore body (200m distant from the iron ore body)…{Declination 333°E Inclination 53°Down From the view point of mechanism of magnetization, it is sure that the iron ore body gets the remanent magnetization which, roughly speaking, agrees with the direction of elongation of the ore body; and the 2nd copper ore body gets the remanent magnetization in the direction compounding geomagnetic field and magnetic flux of the iron ore body. By means of remanent magnetization together with other magnetic properties of ores, the direction of elongation of an ore body and the order of mineralization can be predicated.

The article describes features of ore reserves and development of processing technologies at Mikhailovsky MPP. New approaches to disintegration of ore and to improvement of dry magnetic separation of unoxidized ferruginous quartzite are evaluated. The scope of the discussion embraces the process of finishing magnetite concentrate, extracted from unoxidized ferruginous quartzite by wet magnetic separation, using the flotation flow chart in the closed and open circuits, as well as with the reverse cation flotation of hematite concentrate from tailings of wet magnetic separation. The authors present engineering solutions aimed at designing energy-efficient horizontal-grate calcinator MOK-1-592 and the technologies to produce different-purpose iron ore pellets.

Background/Objectives: Due to soaring demand and rapid depletion of high-grade iron ores, lean grade iron ores of India like BHJ and BHQ needs to be utilized through suitable beneficiation techniques. Methods: Banded Hematite Jasper (BHJ) sample of Bonai-Keonjhar belt (BK belt), Odisha, India assayed 35.3 % Fe, 47.1% SiO2 and 0.96% Al2O3 was investigated in respect of mineralogy, liberation characteristics and chemistry to finding out its optimum beneficiation potential. In the present investigation, efforts have been made to characterize the BHJ sample with reference to its beneficiation response. The sample was subjected to various beneficiation operations like Jigging followed by hydrocyclone, two-stage tabling and magnetic Separation. Findings: Mineralogical studies indicate that quartz and hematite are the major mineral phases, whereas goethite, martitized magnetite and clay (kaolinite) are present in very minor amounts. The liberation characteristic indicates that the average band thickness of Iron bearing mineral is of 1680 microns and 80% of the iron bearing minerals are liberated at -105 microns size. The two stage tabling of jig concentrate with desliming gives better outcome as compared with direct tabling of jig concentrate. An iron ore concentrate assayed 64.5% Fe, 5.6% SiO2 and 0.80% Al2O3 with wt% recovery of 23.2% can be obtained from two stage tabling. Another concentrate from magnetic separation of table middling and hydrocyclone assayed 63.2% Fe, 7.2% SiO2 and 0.7% Al2O3 with wt% recovery of 12.4% can be obtained. Novelty/ Application: Here a conventional beneficiation flow sheet is developed with a finding that, in order to beneficiate ore like banded hematite jasper (BHJ), an integral characterization approach is very much essential. Both of the concentrates obtained through the flow sheet assayed 64% Fe, 6.2% SiO2 and 0.7% Al2O3 with a wt% recovery of 35.6% can be utilized as a feed stock for pellet making in iron ore industries. Keywords: Banded Hematite Jasper (BHJ); mineral beneficiation; wet high intensity magnetic separator (WHIMS); jigging; Bonai-Keonjhar belt

Geological aspects, particularly mineralogy and ore genesis of different iron ores have important roles to play in understanding their behaviour during processing and decide suitable beneficiation method for particular type of ore so to produce desired quality end products. The implications of different geological aspects and mineralogical characteristics specific to ore types in mineral beneficiation have been outlined in this paper. Experiments indicated that iron ores, such as massive hard ores, laminated hard ores, fine powdery ore and blue dust ore, do not require complicated processing, however at the other end; sub grade ores, such as flaky, friable, shaly, ochrous, powdery, lateritic and goethitic ores having low iron and high alumina content, require specific beneficiation treatments before their use as direct or as agglomerates in the blast furnace feed. While processing, different ore types need treatment differently for their up gradation. Hence, in addition to the conventional methods of processing such as crushing, screening and washing, advanced beneficiation techniques using concepts of gravity and magnetic separation have found their specific applications for beneficiation of different types of ores, based upon their physicochemical and mineralogical characteristics. Geological setup of the deposits and mode of occurrences of different ore types, physical, chemical and mineralogical characterisation and extensive beneficiation experiments conducted on Indian iron ores have established that quality of lumps can substantially be up graded through simple processing and log washing. On the other hand, for fines ores, Jigging has been found to be the best suitable method. Slime beneficiation requires combination of processes and treatment through hydrocyclones, multigravity separation, magnetic separation and sink float methods, etc. These applications would help not only to recover more values from the inferior grades of iron ores but also to conserve and preserve the natural resources too.

The iron deposits of the Sanpo mine, Okayama Prefecture have been emplaced in Palaeozoic limestone, and are of contact-metasomatic origin genetically related to granitic rocks of the late Cretaceous or the early Tertiary age. It is a remarkable fact that magnetite ores from the iron mine contain appreciable amounts of Sn, ranging from O. OX to O. X per cent.In a series of studies, of which this is the first, an attempt will be made to clarify the mode of distribution of Sn in the ore-bodies, and the manner of the presence of Sn in the stanniferous iron ores by means of field work, microscopic observation, spectrochemical analysis, X-ray diffractometry and electronprobe microanalysis. This first report dealt with the mode of distribution of Sn in ore-bodies and led to the following results:(1) In the central zone of iron mineralization (zone of massive magnetite ore), the Sn content is high as much as O. X per cent order. Whereas the outer zone (zone of magnetite and calcite) at the limestone side decreases Sn content, showing usually O. OX per cent order.(2) At the end of ore-bodies on the underground geological plan map, where iron mineralization is very slight, Sn content is usually low as much as 0.0X per cent order.(3) No definite relationship between paragenesis of main metallic minerals and the Sn content in the iron ores was recognizable.(4) Post-ore dykes of porphyrite did not affect the Sn content of the ore-bodies.(5) Cassiterite showing minute subhedral crystals was optically identified in the iron ore having maximum contents of Sn (No.4-12).(6) The magnetite concentrate obtained by use of magnetic separator showed remarkable decrease of Sn content as compared with the crude ore, and this suggests that almost whole of Sn is not contained in magnetite structure by ionic substitution, but contained in cassiterite and other Sn-bearing crystalline phases.

A study on separation of Mn and Fe from high-alumina ferruginous manganese ores by the carbothermal roasting reduction process

The gasoline blending station is a key unit at an oil refinery, ensuring the production of finished products compliant with modern technical specifications. The purpose of this study is a comprehensive analysis of the technological process and layout of a gasoline blending station operating at an oil refinery in Uzbekistan. The investigation covers the feedstock base, equipment, sequence of operations, automated process control system, and features of enhanced fuel production. The process is based on the compounding of three components-light naphtha, reformate, and butane fraction-followed by the addition of specialized detergent additives to produce QuWatt-branded fuel. A critical factor ensuring consistent product quality is the adjustment of the blending recipe based on real-time laboratory data on the properties of the feedstock components. The analysis confirms a high level of reliability and safety of the unit, achieved through a multi-level system of alarms, interlocks, and automatic regulation, enabling effective control of the complex technological process and the production of gasoline grades strictly in accordance with national standards.

The article presents the results of the analysis of business processes of pasta production. According to the concept of lean production, types of losses during the production of pasta products were identified. Among the causes of losses are a high proportion of unregulated interruptions, cases of incomplete production in a shift, the presence of downtime due to technological equipment failures, and the laboriousness of manual operations. Taking into account the high importance of optimization of production business processes, emphasis is placed on the expediency of using lean production tools to eliminate losses. The standard SCADA system ‒ TRACE MODE with pre-developed functional schemes for processing grain into flour in the cross-platform Ramus system using CASE technologies was used to develop an automatic process control system. The description of the developed automatic control system for the technological process of flour disinfection using the energy of ultra-high frequency electromagnetic radiation is given. The proposed automatic technological process control system using a disinfectant will speed up and, accordingly, reduce the cost of production. a promising method of drying is proposed - with an infrared energy supply, which ensures obtaining a final product with high quality characteristics, reducing energy consumption and shortening the duration of the drying process. The use of silent heating elements will reduce the noise level at the enterprise; Modernization of technological equipment made it possible to ensure: the possibility of producing pasta products of higher quality; compaction of the structure of the semi-finished product and reduction of its fragility, while simultaneously increasing the strength limit of finished products by 20-25%; improvement of consumer properties, as well as sanitary and hygienic indicators of pasta products due to its pasteurization; decrease in moisture absorption and loss of nutritional value during storage.

Comprehensive Utilization of Ludwigite Ore Based on Metallizing Reduction and Magnetic Separation

Efficient enrichment of nickel and iron in laterite nickel ore by deep reduction and magnetic separation

In view of the complicated process of sewage treatment and magnetic flocculation technology, an integrated device for magnetic particle separation and sludge precipitation is designed, which simplifies the sewage treatment process and achieves the purpose of saving electricity and improving sewage treatment efficiency. The optimization of magnetic flocculation technology and energy saving and emission reduction are realized. This project is to realize the process of flocculation sedimentation and magnetic particle separation at the same time. Based on the Halbach array, the magnetic roller is optimally designed, and the cylinder structure is cleverly designed. The intelligent control ball valve collects sludge, and the construction of the designed integrated facility has great social significance.

The study of the material composition, textural, and structural features of skarns and magnetite ores is of great importance for increasing the efficiency of iron ore mining and its subsequent processing and enrichment. In the northwestern Balkhash region of Central Kazakhstan, there is a reserve iron ore region represented by a series of skarn contact-metasomatic deposits: Bapy, Zhuantobe, Karaulken, Akchagyl, Ushtobe, Kiyik, Taitobe, Tomashev, Kyzyl-Sayak, and others. The results of field investigations and laboratory analyses have enabled the characterization of the mineralogical and petrographic composition of the skarns, as well as their material composition and textural–structural features. All these specified characteristics of skarns reflect the stage-by-stage nature of the contact-metasomatic processes of iron ore formation. The skarn formation model at the Zhuantobe deposit developed over several stages: (1) the formation of skarns during granitoid intrusion and the establishment of conditions for contact metamorphism (resulting in iron-poor, barren diopside hornfels and marbles); (2) early skarn stage, during which anhydrous, dark-colored endo- and exoskarns composed of pyroxenes, magnetite, and hematite develop; (3) late fluid–hydrothermal stage, during which hornblende, epidote, calcite, and sulfides (pyrite, chalcopyrite, sphalerite, and galena) form; (4) oxidative supergene stage under near-surface conditions, during which limonite and iron hydroxides form. The conducted comprehensive analysis of the material composition and textural–structural features of iron ores of the Zhuantobe deposit made it possible to establish the influence of these parameters on the technological properties of ores. The performed studies make it possible to more accurately identify promising iron ore zones in skarns and predict the technological behavior of ore during processing.