Modernization Karelsky Okatysh JSC

Increased factory productivity through modernization of pumping and hydrocyclone units.

Mining and processing plant Karelsky Okatysh JSC is one of the leaders in the iron ore industry in Russia. The company's management is constantly working to improve productivity and improve the quality of the final product, annually modernizing the equipment fleet at all stages of production. In 2014, the plant’s management set the task of increasing the productivity of the first and second intake classifications in 12 sections at the grinding and enrichment site of the Concentrate and Pellets Production Administration (UPKiO).

The management of the Karelsky Okatysh JSC decided to install equipment in one section from each supplier participating in the tender for testing the proposed technologies. Installation and testing of sections was carried out from January to April 2015.

As a result of all tests carried out in 2015, 44 pump-hydrocyclone units (NSCU) were installed in the technological sections of the DOF for the first and second admission, as well as for the preliminary and control classification. The units were equipped with Metso pumps and pipelines, Multotec hydrocyclone batteries, Weg engines and Danfoss Aqua Drive frequency inverters. Installation and commissioning of equipment was carried out by service specialists of Sever Minerals from December 2015 to March 2016.

As a result of the modernization of Karelsky Okatysh JSC, in 2017, impressive results were achieved:

1. The ore and concentrate section productivity has been increased.
2. The specific consumption of grinding balls for ball mills has been reduced.
3. The specific energy consumption for the production of 1 ton of concentrate was reduced.
4. Increased mileage of flowing parts of pumps.
5. Reduced costs for maintenance and repair of pumping positions.
6. In 2017, the management of Karelsky Okatysh JSC set a new task - to improve the quality of the resulting product. To solve this problem, the specialists of Sever Minerals and Multotec proposed to modernize the VV350 hydrocyclones installed at the third and fourth stages.

The proposed technical solution included a partial redesign of the standard VV350 cyclone. The length of the cyclone body was increased using an additional cylindrical section, the angle of the conical part was changed to a sharper one. The upgraded VV350 cyclones increased the efficiency of the preliminary and control classification. The use of modernized hydrocyclones in the third and fourth receptions of the classification led to an increase in the qualitative indicators of discharge in receptions and the concentrate refinement unit as a whole.

Currently, work is continuing to increase the iron content in the concentrate. In April 2019, two new NGCUs were delivered to the enterprise complete with hydrocyclones of a smaller size - 250 mm. The body of the new cyclones is made of steel with a removable rubber lining. Smaller diameter cyclones should increase the content of the finished class in the drain, to ensure finer separation. Currently, Sever Minerals specialists, together with the plant's specialists, are testing equipment and setting up the process.