Severstal iron ore mining division Karelsky Okatysh said on December 27, 2021 that it is well advanced in implementing the largest project in the history of the operation – it is applying cyclical-flow technology in the mining complex – specifically an in-pit crushing and conveying (IPCC) system referred to as the CPT for which the total investment amounts to 11 billion rubles. The expected economic effect in cost savings is two billion rubles a year. In parallel with this, the environmental footprint of the mine will decrease: carbon dioxide emissions will decrease by 9,500 t per year. Also, the project will create 127 new jobs.
Some 70 Mt of rock mass per year will be the throughput of the IPCC system. Of this, 20 Mt are ore and 50 Mt are overburden. The launch of the complex is scheduled for 2023. The CPT includes two main crushing and conveying transport complexes for ore and waste overburden, as well as a dry magnetic separation (SMS) unit. The rock mass will be transported by dump trucks along optimally short intra-pit routes. Crushed ore and overburden will be lifted to the surface by inclined belt conveyors. From the pit perimeter the ore will go to the transfer and storage warehouse, and the overburden – to the dump. The use of conveyors instead of dump trucks will reduce the cost of transporting the rock mass, as well as reduce emissions of exhaust gases from heavy equipment into the atmosphere.
The CPT equipment is largely being supplied by thyssenkrupp which told IM that the project includes three IPCC crushers – notably one of these is an innovative ERC® eccentric roll crusher which has a low-wear design and durable components to enhance efficiency. The Karelsky Okatysh ERC has a capacity of 1,000 t/h and will be used for crushing of low grade ore. The high grade ore line comprises a gyratory KB 63-75 semi-mobile plant with related conveyor and stockyard equipment with a capacity of 4000 t/h. Finally, a gyratory KB 63-130 is handling the in-pit waste crushing at a capacity of 8,000 t/h; along with associated conveyor and spreader.
The main equipment arrived at Karelsky Okatysh in 2021. Components were supplied from Turkey, China and Germany. Due to the transportation of bulky spare parts, the federal highway had to be blocked. The mining company says construction of the complex is proceeding according to the schedule. St Petersburg-headquartered Lenmontag is the general construction contractor for the CPT. “I would like to note the high professionalism of my colleagues. This year, we have completed a large amount of work: we have completed the construction of an ore warehouse, assembled a conveyor, a stacker, and now it is being commissioned. We also built the main step-down substation, started the installation of the spreader and preparatory work for the construction of crushing complexes,” comments Anton Vlasov, the Project Manager of the CPT.
Karelsky Okatysh is one of the leading and modern iron ore mining complexes in Russia. It produces 20% of Russian iron ore pellets and is located in Karelia in the northwest of Russia. Mining operations have been carried out since 1982 on the basis of the Kostomuksha deposit, which includes ferruginous quartzites, crystalline shales of various compositions and felsites. In March 2007, mining and processing of iron ore from the Korpangskoye deposit began then in 2008, the company received a license for exploration and processing of ore reserves at the Yuzhno-Korpangsky block. The main consumer in the domestic market is the Cherepovets Steel Mill, also part of Severstal. The products of Karelsky Okatysh are also exported.
