National University of Science and Technology – MISIS, Moscow, Russia:

T. I. Yushina, Acting Head of a Chair, Professor, Candidate of Engineering Sciences, yuti62@mail.ru
I. O. Krylov, Associate Professor, Candidate of Engineering Sciences
V. S. Valavin, Director, Director, Romelt Innovation Scientific and Education Center, Doctor of Engineering Sciences
P. A. Sysa, Engineer, Candidate of Engineering Sciences

This is the end part of the article published in Gornyi Zhurnal No. 6–2017.

The authors report the results of the research into processibility of waste of Kamysh-Burun Iron Ore Plant with a view to obtaining an ironore product for Romelt process. The findings of the excessive experimental research are presented. Sample KB (dump of the plant) contains much phosphorus and, thus, needs preliminary dephosphorization. Such feed stock is suitable for higher standard metal conversion after magnetic treatment with prewashing in drum scrubber washers. Sample VCh (Verkhne-Churbash old tailings pond) is exceptionally rebellious. Gravity, flotation and weak-field magnetic separation are inefficient in this case. The authors illustrate the expediency of calcinating–magnetic treatment for iron hydroxides during calcination readily go into magnetically recoverable form when series-production equipment is used. Advantages of the two-stage high-gradient magnetic separation on polygradient separators are also demonstrated. The top layer of waste at Verkhne-Churbash tailings pond is essentially dephosphorized. Magnetic treatment of this material increases the iron content of concentrate up to 20–21%, which allows using this concentrate as an additive to batch mixture in smelting of the conversion product after processing of bottom layer material of the specifi ed tailings pond. Magnetic treatment of the Verkhne-Churbash tailings pond bottom material produces iron concentrates with the total iron content up to 58% at the content of phosphorus round 2%. It is possible to reduce the phosphorus content by blending of the material from the top and bottom layers of the tailings pond. Blending at a ratio of 1:1 will enable production of a concentrate with the iron content of 40% and phosphorus content of 1%. Sulfur is not found in the tailings. So, the tailings are suitable for application of ROMELT process with the preliminary three-stage magnetic treatment and discharge of produced material with the iron content under 5%. The smelter residue will be slug applicable in construction. Beneficiation of the iron-bearing waste of the plant using conventional magnetic separation techniques is inefficient. Extraction of particles –0.4 mm in size at the yield of 73% will allows for a product with the iron content of 58%. The content of phosphorus of this class particles is expectable at the level of 2%, which is less by 25% than in the overall volume of the product. In this fashion, in order to prepare waste material for smelting using ROMELT process, it is recommended to apply gravity-and-washing technology with the extraction of particles –0.4 mm in size and additional blending aimed at dephosphorization. Smelting will produce metal (pig iron) and slug applicable in construction. Radioactive and other unwholesome elements are not found in the Kamysh-Burun Plant waste.
The authors appreciate participation of E. V. Khalueva and V. S. Katasonova, students of the MISIS College of Mining, in this research. The studies have been supported by the Ministry of Education and Science of the Russian Federation, within the framework of the Federal Targeted Program on R&D in Priority Areas of Advancement in the Science and Technology of Russia for 2014–2020, Unique Identifier RFMEFI57814X0049.

1. Yushina T. I., Krylov I. O., Valavin V. S., Sysa P. A. Producibility of iron-bearing materials from industrial waste of Kamysh-Burun Iron Ore Plant using Romelt process. Gornyi Zhurnal. 2017. No. 6. pp. 53–57.
2. Romelt process : monograph. Ed.: V. A. Romenets. Moscow : “Ore and Metals” Publishing House, 2007. 359 p.