Kazakhstan's Sokolov-Salbaysk (Соколовск-Сарóайск) mining company now belongs to the "ССГПО" consortium (Sokolov-Salbaysk mining production consortium), which is the Republic of Kazakhstan the largest iron ore mining and processing enterprises, and its products are sintered iron pellets and iron ore concentrate.

Stopes and ore dressing plant was designed by the former Soviet Union mining and industrial enterprises Institute Mihaela Noble Mineral Processing Research and Design Institute in the 1950s. The company designs 26 million tons of ore per year and produces iron concentrate at 65.3%. At present, the annual processing of iron ore is 30 million tons, and the iron concentrate grade is 66.5%.

Mine ore comes from Kacharsk, Saalbaysk, Sokolovsk, Kurkulsk, Bekalinsk, Lomonosovsk, South Kalbaysk and Solsk deposits. The ore reserves of the Saalbaysk deposit are 636 million tons, and the ore contains about 33% of Fe; the ore reserves of the South Saalbaysk deposit are 382 million tons. The Sokolov ore deposit has an ore reserve of 1.2 billion tons and contains Fe 41%, S 2.5% and P 0.1%. The ore reserves of the Kacharsk deposit are 3,957.4 million tons, containing 39.04% of Fe, 0.33% of S and 0.22% of P. The ore reserves of the Kurkukulisk deposit are 82.9 million tons, containing Fe1.41%. The ore is mainly open-pit mining. The main magnetite ore minerals, albite, scapolite, pyroxene and orthoclase, hematite secondary minerals, pyrite, calcite, chlorite, silica, and apatite.

After the improvement of the concentrator, the current concentrating plant adopts 5 sections of fracture and 3 sections of magnetic separation (Fig. 1). The concentrator treats ore 35 million tons per year and obtains iron grade of 66.35% to 66.51% iron concentrate of 15 million tons. The process characteristics of the concentrator are: 1 dry magnetic separation of finely divided products, which can abandon the yield of 16.24%, iron grade 10.00%, iron loss rate of 4.72% coarse tailings; 2 strengthen the crushing circuit, so that The ore size of the ore entering the grinding is reduced to -12 mm; 3 fine screening of the magnetic separation concentrate to improve the quality of the final concentrate. The rough selection process index is comparable to that of Russian mining companies, but it is quite different from the United States, Canada and Sweden. Due to the high hardness of the ore, the mining equipment is worn out, so the equipment maintenance and operation costs are high. Due to the different specifications of the equipment used in the concentrator and the ore of the concentrator are not ore, the process adjustment is difficult. In two stages, fine screening operations are used to select iron concentrates. Reducing the particle size of dry magnetically selected ore from 25 to 0 mm to 12 to 0 mm can increase the processing capacity of the concentrator by 300 t/h. The installation of high-frequency fine screen in the magnetic selection of the first section can improve the processing capacity by 10% to 15% and the iron grade by 1.7% to 2.3%.

Recently, the company has improved the ore quality of the concentrator from the following three aspects: 1 ore for the ore entering the beneficiation workshop; 2 for stabilizing the quality of the fine ore; 3 applying an automatic detection system to control the quality of the ore from the stop to the concentrator. The crushing workshop crushing process was optimized. The second and third sections were crushed by ΚСД-2000Γ-2Д and ΚМД-2200T6 crushers respectively, and the fourth section was made by Merlin RPl09 crusher to reduce the particle size of the crushed product to lO~Omm. In order to reduce the production cost and ensure the iron concentrate grade, the two-stage process of fine concentrate fine screening is optimized (Fig. 1), that is, the quality of the ore is stabilized; the sorting equipment is standardized; the first section is ground. The use of rod mills or ball mills ; the use of screening operations and slurry pump-cyclone automatic control system to complete the grinding circuit; increase de-sludge and filtration equipment ; application of computer detection and process control systems. Applying the new process, the ore processing plant will process 40 million tons of ore per year, with an annual output of 67.5% to 70.0% of iron concentrate, 17 million tons of iron concentrate, and a reduction of 25% in energy consumption per unit.

Figure 1 New process flow of the concentrator of the Sokolov-Salbaysk mining company

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