Environmental protection of a coal-mining region

Research objective is to substantiate the relevance of mining transition to eco-friendly technologies of subsurface use. Methods of research include analyzing theory and practice of environmental technologies application and carrying out a multifactor experiment. Results. An efficiency criterion for mineral resources extraction technologies is proposed that involves reducing the effect made by the by-products of mining and processing enterprises on the state of the environment. The problem is considered of minimizing the environmental damage from storing silt coal in dumps and storages by utilizing their components. The mechanism of environmental pollution has been formulated. Aspects of metal recovery from beneficiation tailings in a disintegrator mill are investigated. A reduced threat to living matter is predicted by implementing the concept of radical waste-free processing of substandard mineral raw materials. The need to improve the processes of crushing, fine grinding, and classification of minerals in mills to reduce the waste of coal production, harmful to the environment, is noted. Conclusions and scope of the results. Deteriorated conditions of mineral deposits development raise the risk of man-made impact on the environment in coal-mining regions. The global human population grows resulting in increased resources production to respond to resource needs. The growing threat to living matter can be reduced by radical measures, the non-waste processing of substandard mineral raw materials being the priority. The research results can be helpful in the development of deposits of solid metal-containing technologically exposed ores

Integrated study on obtaining oxide pellets from brown iron ore

Introduction. Currently, the main raw materials for the production of cast iron and steel at metallurgical plants are iron concentrates obtained from magnetite (ferrous) quartzites, titanium-magnetite, and skarn ores. The existing technologies for processing these types of ores, which mainly include separation processes based on magnetic properties, size, separating of equally falling grains, and surface wettability allow us to produce both ordinary iron concentrates and high quality ones. The use of such schemes in the processing of brown iron ore does not allow obtaining high rates of mineral concentration. One of the methods for processing this type of ore is a roasting-magnetic scheme, which allows converting weakly magnetic (non-magnetic) forms of iron into strongly magnetic ones. Research objective is to develop the mode of magnetizing roasting of brown iron ore, technology of concentrating of the burn-out product in order to obtain iron concentrate and oxide pellets. Methods of research. The duration of heat treatment of the charge consisting of iron ore from the Abail deposit and coal from the Ekibastuz deposit and the required mass fraction of solid carbon contained in the coal are determined. Technological studies of the roasted product were carried out in order to obtain a concentrate with a mass fraction of iron at least 67%. According to the developed technology, a batch of iron concentrate was developed in order to obtain and study raw and oxide pellets. Results. The modes of magnetizing roasting of brown iron ore from the Abail deposit and cooling of the roasted material have been developed. A scheme for mineral processing of the roasted material has been developed in order to obtain a concentrate with at least 67% of iron mass fraction. The process of obtaining strong raw and roasted pellets from iron concentrate is studied. Conclusions. The developed mode of magnetizing roasting of the charge consisting of coal and ore from the Abail deposit makes it possible to obtain a roasted product with a degree of magnetization of 93%. The using of desliming of the roasted product makes it possible to remove magnetic floccules from the processing that reduce the concentrate quality, and to obtain a concentrate with a mass fraction of iron of at least 67% in the last stage of magnetic separation. From the iron concentrate, it is possible to obtain oxidized pellets with a strength of at least 200 kg/pellet at temperature of pellets firing of 1325 °C.

Assessing the possibility of using dry concentration for oxidized pegmatite and granites at the Kedrovoe feldspar deposit

Introduction. Feldspar raw material is a natural source of silica, alumina, and alkali metal oxides. Each type of feldspar is distinguished by its applications and concentration methods. The main effective method of feldspar raw material concentration is flotation in the course of which the majority of harmful impurities are separated. However, this method is rather costly due to flotation reagents purchase, tailings ponds organization and maintenance, etc. Research relevance. Feldspar dry concertation technologies are promising in terms of resource-saving but uncommon. So, the development of a dry concertation technology for feldspar raw materials seems highly relevant. Research objective is to study the possibility of employing dry concentration technology to process feldspar raw materials at the new Kedrovoe deposit Methods of research. Laboratory equipment of JSC Uralmekhanobr was used for the research, namely centrifugal crusher DC-0.5; centrifugal deflection mill; laboratory-scale cascade classifier; dry electromagnetic separator SMS-20M ITOMAK, and tribo electrostatic separator. Results. The trials confirmed that it is possible to process Kedrovoe feldspar raw materials by dry methods and effectively use centrifugal crushing and grinding as preparation of raw materials for concentration. Feldspar concentrate with a mass fraction of Fe2O3 – 0.30%; SiO2 – 69.42%; Al2O3 – 17.36%; K2O + Na2O – 11.84% has been obtained, which meets the specifications. Conclusions. The technological studies confirmed the possibility in principle of using feldspar raw material dry concentration for oxidized pegmatite and granites of the Kedrovoe deposit at the processing plant of Malyshevskoe Ore Management JSC. Saleable feldspar concentrate has been obtained.

Mine surveying technique and steel storage tank base deformation removal

Introduction. Vertical steel tanks are extensively used in oil fields to hold crude oil and other liquids. Their construction requires continuous surveying control. However, measurement procedures, data processing, and deviations and documentation correction are not universal and cannot be applied for tanks with a capacity of less than 3000 m3. Moreover, the process of correcting the detected bottom irregularities is poorly substantiated and intuitive. Research objective is to improve the as-built survey accuracy and reliability of the low-capacity steel tank bottom, substantiate the minimum height of its irregularities, increase the objectivity and productivity of measurement processing, develop an unambiguous method for time-predictable correction of bottom irregularities, and substantiate the optimal contents of its relief’s as-built scheme. Methods of research. Geometric leveling for the bottom profile survey failed to provide adequate accuracy and was therefore replaced by the method of trigonometric leveling. A method has been developed for determining the deviations of the existent tank bottom profile from the design position by means of algebraic actions with surfaces of a topographic order. The accuracy of determining the smallest height of bottom irregularities has been estimated under the tacheometric survey. A method has been proposed for controlling the correction of tank bottom irregularities based on evaluation calculations of bottom deformations by the finite element method. Research results. All the development results are exemplified by a specific production example. It was found that for a full completion of work, two iterations of tank bottom irregularities correction are enough. Methods of optimal design for the facility’s as-built schemes are presented. Conclusions. A simple, accurate, low-cost, productive, and time-predictable method of mine surveying, mathematical processing and correction of deviations in the tank bottom profile has been developed. This technique reduces the construction period and increases the operating time of the facility.

Determination of horizontal stress orientation in the areas of the Tomsk region

Introduction. The World Stress Map project proves that horizontal stress orientation determination is a global task essential for the majority of geomechanical calculations. However, there is scant data on stress orientations in the territory of Russia at the moment. The task is therefore highly relevant. Research objective is to determine the orientations of maximum and minimum horizontal stresses by separate areas of the Tomsk region and build a map of horizontal stresses. Method of research. The basis for determining the orientations of horizontal stresses is the theory of drilling-induced fracture and borehole breakouts occurrence. The maximum stress orientation coincides with the drilling-induced fracture orientation, whereas the minimum stress orientation coincides with the borehole breakouts orientation or is perpendicular to the maximum stresses. Results. Research results are compiled in a summary table containing mean orientations of horizontal stresses by areas and a map of horizontal stress orientations. Conclusions. A summary map of maximum horizontal stress strike azimuths has been constructed. The stresses are of similar orientation in every well under consideration, except for a well in the North-Shingin area. The average value of maximum horizontal stress orientation has made up 337° northwest and 157° southeast.

Kinetic criteria for evaluating the performance of roller-cone drill bits

Research objective is to work out a method of evaluating the performance of roller-cone drill bits by kinetic criteria. Introduction. It is difficult to determine the absolute criteria for the performance of rock cutting tools. Therefore, the relative values of wear resistance of the cutting structure of roller-cone bits and their relative mechanical rates of drilling are adopted as process criteria. Methods of research. The calculation and analysis of kinetic criteria for evaluating the performance of drill bits have significant differences. Taking them into account is important when studying various modifications of rock cutting tools. The set of kinetic criteria gives a picture of the relative performance of the bit using the model of the well bottom close to the real one. The set of kinetic characteristics (criteria) is conventionally called the kinetic datasheet of the drill bit. The key points of constructing an analytical model of the drill bit operation on the deformable well bottom have been considered. Scope of results. This technique provides for a comparative evaluation of roller-cone drill bits of various modifications, allows for finding feedback, i.e. searching for the appropriate combination of geometrical parameters of the rock cutting tool according to given kinetic characteristics. The versatile approach intended for use in the study of the performance of rock cutting tools allows the most complete and accurate evaluation of the influence of one factor or another on the final result.

Numerical modeling of open pit ventilation when varying the location of the dust and gas cloud

Research objective is to estimate the effect of bulk explosion location and the initial height of the dust and gas cloud on open-pit natural ventilation time and the level of air contamination of the upper edge of the open pit down the wind. Methods of research. Computer modeling of aerodynamics and gaseous component transfer in the 2D geometry is carried out with the COMSOL software. To calculate the aerodynamic characteristics, the approximation of the incompressible fluid with the standard k–ε turbulence model was carried out. Gaseous component distribution was modeled using the numerical solution to the convection-diffusion equation of contaminant transfer. Numerical experiments under the fixed initial concentration of the gaseous component and the speed of the incoming wind flow have been carried out for three locations of bulk explosions and six values of the initial height (from 70 to 420 m with a step of 70 m) of the dust and gas cloud. Research results and analysis. Spatial distributions of the model’s aerodynamic characteristics and contaminants gaseous component when reaching the maximum permissible concentration in the modeled area have been obtained. The estimated time of the open-pit natural ventilation and the dynamics of the open-pit upper edge air contamination dynamics down the wind have been analyzed. The complex and diversified nature of open pit ventilation for various locations of bulk explosions has been recorded. The undulating character of contaminant loss has been predicted (with different heights of peaks) conditioned by the presence of vortex formation in the open pit. Conclusion and scope of results. For the recirculation scheme of ventilation, the situations with the bulk explosion locations shifted to the windward edge of the open pit are the longest. It has been shown that the reduction in the dust and gas cloud lift does not always ensure the reduction in the contamination level at the upper edge of the open pit down the wind.

Developing the technology of associated gold recovery when concentrating copper-pyrite ore

Research objective is to address an up to date task of developing the technology of associated gold recovery from complex ore. Object of research is the gold-bearing copper-pyrite ore. Gold was recovered in laboratory conditions with the use of gravity methods of mineral separation. Research tools. Rational modes of machinery operation have been determined through mathematical planning of experiments including the obtained results processing by mathematical and statistical methods. Methods of research. Gold was recovered in the grinding-classification circuit based on a seriesinstalled short-cone hydrocyclone, a jigging machine and a shaking table. Research results. The developed jig mode differs from the existing ones by the closed-circuit of jig machine chambers: from the feed of the second (in the direction of the light fraction travel) jig chamber, the light fraction (tailings) and undersize product – fraction with the increased content of accessory minerals (rough concentrate) are separated. The rough concentrate in the second chamber is directed to the first chamber of the machine, where the finished jig concentrate is obtained in the form of an undersize product. The light fraction moves from the first chamber to the second and is removed from the machine through the tail board. When fine-tuning the heavy fraction of jigging on a shaking table, it is recommended to mix 1/2 part of the initial feed of the tables with the rough concentrate isolated from the other 1/2 of the original feed. The new jigging mode and the scheme of concentration on the tables provide an increase in the gold content in the initial feed of the apparatus, which is the reason for a decrease in gold losses with the tails of the gravity circuit. Research relevance. Gold recovery increment by 4.77% was obtained due to the use of all three recommended scientific and technical measures, namely sands concentration in a short head cone crusher on a jig, switching the jig chambers to a closed circuit, and jet motion of concentrates on shaking tables. Scope of the results. The results should be applied when concentrating ore containing free (amalgamable) gold, as well as gold-bearing pyrite.

Formally proving whether the software implementation of models applied in instrumentation and control systems conform to the specified requirements

Research objective is to study the possibility to formally validate whether the model’s software implementation meets all the specified requirements of the systems, the model of which can be represented in the form of finite-state automata. Research relevance. At one of the first stages, the development of software for instrumentation and control systems provides for the creation of the system model. The model is based on the terms of reference, specification, and various a priori information. Most of the models for engineering systems in the modern mining industry (conveyor systems, ventilation systems, etc.) can be described in terms of the finite state automaton model. Such a model can be applied to solve diverse tasks. The next step is to implement the model in whole or in part. In this context, the task arises to determine the model’s software implementation conformity to its initial description. Results. One way to solve the task is to formally prove that the software model possesses the properties which are provided in the specification (description) of the initial model. By the example of the mine conveyor system, the paper illustrates the application of the method which consists in the software implementation of the corresponding finite-state automaton model, forecasting whether the model possesses the properties through theorems and their subsequent proof by applying special software. Conclusions. Formal methods of specification, development, and verification of system models’ software implementation together with other methods make it possible to improve the quality and reliability of solutions under development.

The influence of flushing fluids rheological properties on rock breaking efficiency when drilling wells by pellet impact drilling method

Introduction. Pellet impact drilling method which is basically the destruction of rocks by blows of pellets, has been studied by many researchers. Despite this, the rheological properties of the drilling fluid used in pellet impact drilling have not been investigated yet. All bench and field tests were carried out using service water. The use of a drilling fluid with a higher viscosity than water has the potential to expand the field of application of pellet impact drilling. Therefore, it becomes urgent to study the effectiveness of destruction of rocks when using flushing fluids with different rheological parameters. Objective of this research is to investigate the efficiency of rock destruction in the process of drilling wells using the pellet impact drilling method at various rheological parameters of the drilling fluid. Methods of research. A scaled laboratory bench was used in the research. The bench was a closed system of circulation of the drilling fluid (drilling mud). The solution was prepared separately on a high-speed mixer. The main part of the bench was a scaled pellet drill bit located in a simulated well. After the experiment, the destructed rock volume and the rheological parameters of the flushing fluid were measured. A series of experiments was carried out with a gradual increase in the viscosity of the flushing fluid. A biopolymer (xanthan gum) in various concentrations was used to thicken the flushing fluid. Drilling fluid rheological parameters were measured using an eight-speed rotary viscometer and a Marsh funnel. Results. For the first time, a relationship has been established between the efficiency of rock destruction during pellet impact drilling and the rheological parameters of the drilling fluid used. It was found that with an increase in the concentration of biopolymer and an increase in viscosity, at first, there was a significant increase in the volume of drilled rock per unit time, and with a further increase in concentration, a gradual decrease occurs. Conclusions. The results obtained expand the field of application of pellet impact drilling. The reliability of predicting the drilling speed is improved depending on changes in the properties of the drilling fluid. Based on the results, recommendations were made for the selection of the optimal parameters of the drilling fluid, depending on the drilling conditions.