Russian steel and iron ore major Metalloinvest participated at the Uzbekistan International Mining Forum (UIMF 2021) held 3-4 November in Tashkent. During the ‘Digital Mining: Mining Industry Modernisation – Digital Development’ session, the company’s experts shared their experience in implementing advanced technologies at Metalloinvest’s enterprises.
Rinat Ismagilov, Director of the Mining Production Department, noted that the company’s Qualitative Change Strategy to 2032 is a response to new challenges such as increasing competition and stricter environmental requirements, among others. Metalloinvest’s most significant investment projects are aimed at increasing sales margins, improving operational and managerial efficiency, and sustainable development.
The company is changing the mining patterns of its open-pit mines by switching to cyclic flow technology. The construction of two phases of the crushing and conveyor facility at Andrey Varichev Mikhailovsky GOK’s open pit mine will enable an operational cost reduction of 5%. Implementation of cyclic flow technology at Lebedinsky GOK’s open pit mine will reduce mining costs by 18%. Both these projects involve innovative high angle conveyors.
Completion of the construction of the concentrate beneficiation facility at Mikhailovsky GOK and implementation of the concentrate flotation technology at Mikhailovsky GOK and Lebedinsky GOK will make the company the third in the world to attain a similarly high concentrate quality, with 71% iron content and 1-1.5% silicon content.
The reconstruction of blast furnaces at Mikhailovsky GOK, Lebedinsky GOK and Alexey Ugarov OEMK will reduce energy costs by 3-7%. A plan for the reconstruction of HBI-1 Plant at Lebedinsky GOK has been developed, the implementation of which will result in a 10% increase in productivity through the introduction of oxygen injection. A new HBI plant in Zheleznogorsk and a fourth HBI unit at Lebedinsky GOK are currently under construction. Both projects have completion dates in 2024-2025. Total HBI production will increase from 4.6 to 9 Mt per year.
Rinat Ismagilov said: “Our integrated projects to raise concentrate quality, refurbish blast furnaces and produce HBI are setting the stage for a change in the traditional pattern of steel production. The use of briquettes in electric furnaces can reduce direct and indirect CO2 emissions by up to 50% and energy consumption by 35%. We are not merely talking about green metallurgy; we are fully implementing these technologies at our enterprises and helping our partners and customers to reduce their environmental footprint.”
Digitalisation of key production processes is one of the key areas of modernisation at Metalloinvest enterprises. The company implements mining information systems at Mikhailovsky GOK and Lebedinsky GOK, as a result of which the mining department located in Moscow will be able to monitor and manage mining operations jointly with the enterprises in the regions, from the distribution of short-term tasks to the medium- and long-term assignments.
Previously, a mining management system was implemented, with dump trucks and excavators linked by a single automated system, allowing to direct machinery to the right area. Overall, this has resulted in an increase in open pit mine productivity of around 11%. Drilling productivity and speed have been increased by 5-7% by equipping drilling rigs with automated systems.
Drones have been introduced for surveying works. Presently, the visualisation quality and detail obtained through this method meet all surveying requirements. Rinat Ismagilov stressed that implementation of such ambitious projects is not possible without investment in staff development. In the current environment, raising the level of professionalism is increasingly one of the key factors of business success.
A new BELAZ dump truck with a carrying capacity of 240 t, has been engaged at the open pit mine of the Andrey Varichev Mikhailovsky GOK (part of Metalloinvest) to transport ore and rock mass. The new powerful equipment received its own name, ‘Yubileiny’ (‘Jubilee’), to mark Metalloinvest’s 15th anniversary. Igor Kryukov, Head of the Motor and Tractor Department at Mikhailovsky GOK, said: “Yubileiny is the tenth vehicle with a 240 t capacity at Mikhailovsky GOK. These powerful dump trucks, in tandem with our excavators with 18-25 m3 buckets, comprise a highly efficient production process for the extraction of iron ore.”
The new truck combines a high capacity with comfort and ease of use. The 2,500-horsepower diesel engine and electronic controls provide a high power-to-weight ratio, boosting the speed of the truck as a result, while the on-board computer controls the vehicle’s parameters. A high level of safety is ensured by rollover protection systems, automatic fire extinguishing, tyre pressure gauges, video monitoring, an alarm device warning against approaching high-voltage cables and OKO fatigue detection system.
