M Technology, together with its partner M HEAVY TECHNOLOGY Kazakhstan, has completed a project to replace the equipment at two crushing plants in the pre-crushing and crushing section of Qarmet JSC.
Current Situation:
At the existing crushing plant mechanical crushing of iron ore to a particle size of 0–8 mm is carried out.
Preparation of the ore mixture includes:
- receiving and unloading into open stockpiles;
- transportation via belt conveyors through junction houses;
- screening, first and second stage crushing (to 20 and 8 mm respectively).
Crushing is carried out in the ore crushing building by means of cone KMDT-2200, KMD-2200 and HP-400 crushers. The production complex includes three buildings — for the first and second ore crushing stages and for ore screening. To achieve the required fineness of the ore mix the process flow diagram provides for several screening operations with screen meshes of 10×10 mm and 8×8 mm.
Main problems of the Existing Complex:
– A productivity of less than 350 t/h (8 400 t/day) fails to ensure production of a high-quality ore mix required for manufacturing of sinter in the necessary volume.
– The increased content of fractions larger than 8 mm leads to higher solid fuel consumption (by 3 kg per ton of sinter), raises FeO and S content and reduces metallurgical properties of the product.
– Lack of spare parts for KMD-2200 crushers and long manufacturing times (over 180 days).
– Increased electricity consumption and operating costs.
The company carried out detailed engineering and prepared the working drawings for the replacement of equipment in the first and second crushing stages.
Dismantling:
- cone crusher KMD-2200 without drive;
- cone crusher oil station;
- crusher feed chute;
- garage-type screen enclosure;
- vibrating screen;
- belt feeder;
- feeder skid;
- feeder charging chute.
Installation of new equipment, steel structures and maintenance platforms:
- installation of a vibrating feeder under the ore hopper;
- installation of a cone-type crusher;
- installation of a screen;
- installation of new ore chutes;
- installation of equipment maintenance platforms.
Project Objective.
Replacement of equipment in the two crushing complexes will allow:
- production of the required quantity of prepared ore mix for sinter production;
- improving sinter quality through a more stable particle size distribution;
- reducing energy consumption and operating costs.
Current Status.
- Crushing Complex No. 2 (CCR-2) has been fully commissioned;
- installation of new equipment at Crushing Complex No. 1 (CCR-1) is nearing completion.
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