JPRS ID: 8311 TRANSLATIONS ON USSR INDUSTRIAL AFFAIRS

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- JPIt5 L/s3ii _
6 March 1979
_ ~
TRANSLATIONS ON USSR INDUSTRIAL AFFAIRS
CFOUO 3/79)
U. S. ~OINT PUBLICATIONS RESEARCH SERVICE
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BIBLIOGRAPHIC DATA ~epott No, 2� Recipient'~ Atcettion No.
SHEET JPRS L/ 8311
. i~ e ~n , u t it r . epon ~te
TRANSLATION5 ON USSR INDUSTRIAL AFFAIRS FOUO 3/79 ) 6 March 19 79
. 6.
7. Autbnr(i) Performins Or~ani:~tion Repc,
No. ,
9. Performin~ Ord~nis~tion Name ~nd Addre~� 10. Proieet/T~sk/wot~ Unit No.
_ Joint Publicationa Reeearch Service
1000 I3orth Clebe RoBd ' 11. Concnet/G~~nc No.
Arlington~ Virginia 22201
~
12 Spon~orina dr~~nlzuion N~me ~nd Addre~r 1~. Trpe of Repon k Pcriod
Co~eted
Ae above
� t~.
iS. Supplemenary Nae�
16. Abicr~ec~
This aerial report containa information on the developmenC and productivity ~
of the automotive and tractor induatry; chemical industry and chemical
machinery output; electronic and precision equipment; metallurgy and
metalworking equipment; conatruction equipment and building materials.
7. Kcy Nordi and Daumea~ Analy~i~. 17a Deicripeot~
USSR
- Automotive Industry Metalworking Equipment
Agricultural Machinery Economica
Chemical Industry
Construction
Construction Materials
Construction ~quipment
Electronics Industry
Metallur.gy
- 17b. ldentifict~/Open�Ended Termi
t~u COSATI Field/Group 2C~ SC, 7A. 11F, 13C, 13F, 13H~ 13I, 13M
1/. A~a~lability Jtatement 19. Sacuritr Cl~sa (This 21. no. of Psaes
FOR OFFtCIAL USE ONLY. Limited Number of ~`P�"~ 5 3
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Pa e
N A D
�owr r~s�7! ~wCV. ~�ri~ TNlS FORM MAY 8E REPRODUCED v~coNwoc ~~~tt�~r~
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r �
6 March 1.9 79 '
TRA~~SIATIONS ON USSR INAUSTRIAL AFFAIRS
(FOUO 3/79)
CONTENTS PpGE
CHEMICAL INDUSTRY AND RELATED EQUIPMENT -
_ ChemizaCion of~National Economy Discuased in Book
, (PLANIROVANIYE KHIMIZATSII NAROUNOGO
KHOZYAYSI`VA,19~8) 1
_ CONSTRUCTION, CONSTRUCTION MACHII~ERY, AND BUILDING rtATERIALS . ~
Hotel for Forei~gn Olympic Judges Under Construction
- (0. Kedrenovskiy; NA STROYKAKH ROSSII, Nov 78)......... 6
' METALLURGY
Lead and Zinc Byproduct Extraction Advances De~tailed
(A. P. Sychev, et. al.; TSVETNYYE METALLY, Dec 78)..... 13
Nickel Industry's WasCe-Free Production Prospects Evaluated
(T. V. ~ran'; TSVETNYYE METALLY, Dec 78) 1$
Chelyabinsk Electrolytic Zinc Plant's Waste-Frse Production
Efforta Detailed
(S. F. Matveyeva; TSVETNYYE METALLY, Dec 78)........... 2q
Waete-Free Technology Introduced at pobuzhakiy Nickel Plant
(S. P. Kormilitayn, et. al.; TSVETNYYE METALLY,
Dec 78) 31
Losses of Valuable Constituents in Copper Refining Reduced
(N. P. Shubin; TSVETNYYE METAI,LY, Uec 78) 39
Effectiveness of Refining in an I~iD Trough
(B. I. Bondarev, et. al.; TSVETNYyE METALLY, Dec 78)... 46
METALWORKING EQUIPMENT
First All-Union Conference on Product Reliability
(V. Logachev; VOPROSY EKONOMIKI, Jan 79) 51
- a - [III - USSR - 36 FOUO)
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CN~MICAi, INUUSTItY Ar1D R~I.AT~U EQUIPMENT
UUC (54+66]: 338.984 (47+57)
CHEMIZATION OF NATIONAL ECONOMY DISCUSSED IN BOOK `
Mos~~o-,r F`LANIROVANIYE KHIMIZATSII NARODNOGO KHOZYAYSTVA in Rusaian 1978 s
- signed to presa 1 Jan 78 pp 1-7
[Mnotation, Table of Contents and Introduction of bnak edited by
I. V. Rakhlin]
[~xcerpts] Title Page: _
Title: PLAIIIROVANIY~ KHIMIZATSII NARODNOGO KHOZYAYSTVA (Planning
the Chemization of the National ~conomy) .
Publisher: Khimiya -
Place and Year of Publication: Moacow, 1978
Signed to Pre~a Date: 1 January i918
Number of Copies Fublished: 2,900
Number of Pages: 223 _
Annotation:
The book deals with the group of problems involved in n,lanning chemization -
as one of the most important directions in scientific-technical progress.
It states the methodological p:oblems of planning new chemical products and
processes at all stages of their design and use, as well as at different
levels of the hierarchical system (enterprise, association, sector); it
descrihes the mPthodology for drafting ~~rt:prehensive intersecto:ial plans
for chemization of the national economy.
The book wil'_ be useful for a hroad group of workers in enterprises and
organizations of [he chemical industry, as well as for teachers and
student~ at VUZ's.
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~ T~bl~ nf Contenra
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PAItT 1. METHODOLOCICAL PROHL~MS OF PLANNING CHEMIZATION PROCESSES
ChapCer 1. Planning a Unified Technical I'olicy for Chemizaeion 8 -
ChapCer 2. Comprehensive SCage-Type Planning of Chemization 23
ChapCer 3. Comprehensive InCeraecCorial Planning of Chemization 42
Chnpter 4. Planning Chemizaeion on the Baeis of Comprehensive _
Material B~lancea . . . . . . . . . . . . . . . . . . . 60
Chapter 5. Planning the Need for Equipment for Chemization 72
PAltT 2. PLANNING CHEMIZATION OF THE SECTORS OF THE NATIONAL ECONOMY .
Cl~apter 6. Problems of Economic SubstantiaCion of Che Development of
Chemization of Capital Construction . . . . . . . . . . 105
Chapter 7. Planning the Chemization of Agriculture 119
Chapter 8. Planning the ChemizaCion of Everyday Life 145
PART 3. ECONOMIC-MATHEMATICAL METHODS IN PLANNING CHEMIZATION -
Chapter 9. Using Mathematical Modpl Study Methods to Plan
Chemization . . . . . . . . . . . . . . . . . . . . . . 159
Chapter 10. Planning Chemization on the Basis of the Intersectorial
Balance . . . . . . . . . . . . . . . . . . . . . . . . 173
Chapter 11. Economic-Mathematical Model Study of the OpCimum
Planning of Chemization . . . . . . . . . . . . . . . . 196
Chapter 12. Using Economic-Statistical Methods in Planning
Chemization . . . . . . . . . . . . . . . . . . . . 207
- Introduction
- 'Che core of the party's economic strategy at the present stage and in the
long-r.~nge future is. as was emphasized at the 25th CPSU Congress, a further
increase in the country's economic power, expansion and radical updatinR o=
tlie production capital. This poses tremendous tasks for the sectors that
must saciREy the growing demand for metals, fuel, energy, chemical products,
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timher ~ind building m~terinls. * On the bnsis of this, nccelerating and
incre~sing the e�ficiency of chemization of Che national economy becomcs
particulnrly imporCanC.
CliemizACinn of the national economy means introducing, in conformance witl~
Ctie pl~n~ chemical m~eerials and chemical processing methods into all spheres
i of physicnl producCion and everyday life, on Che basis of an accelerated
srowth of Che chemical industry and Che origin and developmenC of new sector~
of i t.
Under eoday's conditions, the proces~ of chemization is made up of elements
such as the development and improvement of Che ma~or sectors of the chemical ~
industry--the material baeis of chemization; continuous development and
introduction inCo all sectors of Che national ec~nomy of new, highly e�fi-
cienr chemical proce~ses and materials; the utmost development of chemical
- and relnted fields of science and technology, as the determining factor in
the creation of new and improvemenC in the qua~,iCy of existing materials,
~s well as the intensificaCion of production processes. Chemization should
be reRarded as a unique means of increasing food and ra~o marerial resources
on a scale that is essentially not achieved by other ineans.
'Cliere ts a~roup of strategic, social, technical and e~:onomic factors that
bri.ng about the accelerated development of production and the usP of chemi-
cnl materials and products, as well as putting industr~al processes into -
operation on the basis of chemical methods. This process is to a certain _
extent ob~ective, for it is b roughC about by the action of the economic -
laws of socialism.
If one traces the history of the development of world technology and manu-
facturing methods, it can be esEablished that the creation and rapid growth
of practically all new sectors are inseparably bound with the use of
improved chemical materials and processes. A number of economical indus-
trial procegses developed earlier are also implemented on the basis of
chemization. The invasion of polymers into technology and everyday life,
swift in its rates and scale, perhaps constitutes one of the most~essential
factors in the fundamental conversion of the material-technical basis of
- modern production that has begun.
The appearance of new c}~emical methods and materials has not only come about
ttirough ttie requirements of technology, In a broader concept, this process
occura due to the effect of the socioeconomic conditions of human life.
inr.rraging effic�iency and accelerating chemization are integrally bound and
depenJ Incr~:asingly on impr.oving its planning. The urgency of solving this
_ ~~roblem is caused not only by the rapidly growing effect of introducing
cliemical products and industrial p:ncesses on the rates of scientific and _
*
"Materialy XXV G"ezda KPSS" [Materials of the 25th CPSU Congress], Moscow,
Poiitizant, 1976, p 42.
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Cechnical progress in Che coneumer-sectors, a change in Che c}ualiCative
structure of production aud many exCremely imporCant nationnl economic
indicatore, but also by the intensive expansion of rhe qcnle and sharply
increasing complexity af Ctie sCructure of the demand for chemical producCs,
the shortage, not yet nvercome, of some chemical materials and the need to
select the most efficient ways to ease it and Che ch~nge in the narure and
directivity of Che interrelations between the consumer-sectors and the
producer-sectors af the chemical output of the C~MA�member countries, etc.
' While in the initial stages, planning the development of chemistry and of
chemiz~tion was based on the frontal development of the entire chemical
industry and other sectors producing chemical goods, in the last decade,
because of the growing complexity of the economic and industrial relations,
- there is increasing importance in comprehensive plans for speci�ic purposes,
specifying the carefully wo:ked-out coordination of the efforts of all the
pnrticipating organizations. At the same time, a great deal of experience
has been accumulated in Che production cooperation of many minisrries and
departments with Che chemical industry, in order to execute these plans.
Practical experience shows that in rhe process of planning the development _
uf the sector it is impossible to take into consideration Che enCire aggra-
gate of factors determining the national economic efficiency of a certain
specific decision, as for example, the all-round chemization of a~ector.
At the same time, the departmental approach to chemizaCion of a aector is
useless and one-sided. Therefore, the disparities arising between the
interests of individual sectors should be overcome in appropriate plans for
the development of the chemical industry and chemization of the national
economy.
Successful compilatinn and execution of the comprehensive plans for chemiza-
tion depend to a great extent on a clear understanding of their directivity
and economic content, of the problems solved by them and of the methodology
and organizaCion for working them out. Under today's conditions, however,
a unified understanding of the content of the comprehensive programs and
plans has not yet been achieved, and the actual definition of "comprehensive
- program" remains quite debatable.
In order to increase the substantiati.on of the plans for chemization, a num-
ber of requirements must be taken into consideration in the process of work-
ing them out. Particularly included among them are:
Ensuring the priority of national economic interests and a major orientation
toward solvin g problems facing the ecQnomic system as a whole;
Raising the degree of comprehensiveness of all the planning calculations
made at various levels and stages, and this assumes more complete coordina-
tion of the plans for chemization with analogous developments in the remain-
ing directions of scientific-technical progress and with other economic
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- processes~ achievemenC of balance in ~he plans for the use, production ~nd -
import of chemical products and ~reater coordination in the use of various
r.hemic~l mgCerisls in individuAl sectors, revea].ing the best proportions
- amon~ the inCerchangeable chemical and nonchemical types of resources, etc.;
Reducing the periods for drawing up the plans and ensuring the possibility
of working out different variants and high-qualiCy corrections for the
. planning deciaions with a view to taking into accoune more fully the con-
ditions of Che period bei.ng planned. ~
This book is the first attempt to state the methodological and practical -
problems involved in comprehensive planning of chemization as one of the
most importanC direcCions in scientific-technical progress. An adequate
planning system should be in xccordance with chemization. So far, however,
in the practical work of planning there is sti11 no system of indicators
tt~at regulate completely enough the procesa of introducing chemical materials
and chemical technology inro the national economy. A.s a result, there may
be a certain lack of correspondence between the planning of the production
and the consumption of the chemical goods. In this connection, particular
_ attention ia paid in the monogxaph t~ working out a system of such indi-
c.ators, to the possibility of usi.ng the intersectorial balance and economic-
mathematical and statistical methods to improve the planning of chemization,
and to the methodological problems of creating comprehensive plans for
chemization at different levels.
The book was written by a collective of authors. The individual chapters -
we�re prepared by:
Gabidullin, V. M.--Chap. 7.
' Ioffe, V. M.--Chap. 11.
Krichevskiy, I. Ye.--Chap. 12.
Palmerovich, D. M.--Chap. 5.
Parksheyan, Kh. R.--Chap. 3.
~ Rabin, M. G.--Chap. 10.
Rakhlin, I. V.--Introduction, chaps. 1, 3, 4. _
Sidorova, N. A.--Chap. 6. -
' Sokolov, 0. S.--Chap. 7.
Fedorov, K. G.--Chap. 2.
_ Shchukin, Ye. P.--Chap. 9.
Yanvarev, V. A.--Chap. 8.
COPYRICt1T: Izdatel'stvo "Khimiya"= 1978
~ 12].51
CSO: 1821
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CON6TRUCTION, CON5TRUCTION MACHIN~RY, AND ~UILbING MATCE2IAL5 -
HOTEL FOR FOREIGN OLYI~IC JUDGES UNDER CONSTRUCTION
Moscow NA STROYKAKH ROSSII in Russian No 11, Nov 78 pp 56-59
[Article by 0. Kedrenovskiy, chief project archiCect]
[Text] The hotel complex of the USSR Sports Committee [SporCkomiteCa] for
housing foreign refere~s during the Olympic Games is being built on Lenin
' Prospekt in quarter 19, southwest. It will be we11 connected in transporta-
Cion respects with the Olympic village and the stadiwu imeni V. I. Lenin
in Luzhniki.
- The choice of the location of the hotel was dictated by the effort to have
- an architectural accent at the location on the prospekt [boulevard] where ~
- rhe perimetral brick buildings of the end of the 1950's have been replaced
by the so-called free planning using fully prefabricated panel houses. In
addition, in the near futuxe construction is to be completed and public
amenities provided over the broad territory inside the quadrangle formed
by the Lenin Prospekt, Ukal'tsava Street, Vernadskiy Prospekt and Kravchenko
Street. This space, ,~hich is a flood plane included in the gathering area
of the Ramenka River has ~ust been builr up with modern residential and
public buildings on Vernadskiy Prospekt, it has been planted and we11 arranged:
a cascade of ponds has been built. After completion of the construction of
the hotel and also the MGU athletic complex which i.s planned alongaide, the
entire territory will be converted to a city park. '
The complex is located deep within the site, 80 meters from the thoroughfare.
- Considering the existing relief, a study was made of the number of Che
terraces dropping in the direction of the park zone. On one of them 3 to 4
_ meters below the Prospekt level, the hotel buildings are located, on another, -
at the Lenin Prospekt level, there is a reception area with a large parking
area for automobiles and buses connected to the local side access to the -
Prospekt. A broad pedestrian bridge and also stairs and a ramp lead to the
main entrance on the fiXst~floor.
- The hote~ building is made up of three independent parts--the basic building,
a restaurant and conference hall with a press center connected to each other
by the first-floor access hall. _
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The baeic 22-etory building exCenda along the Prospeke. In the central
aection the rizalites are clearly expressed. This solution gives the building
the required plasticity, it~will be successfully combfned with respect Co
style with the 19-f loor residenCial towers distinctively shifted in plan
view,
The plain lobby of the hote~ is located on the first floor of the high-rise -
part. It has a registraCion desk, administration offices, portiers,
- aervice office, currency exchange off ice, a poatal substation, and shops.
A four-pasaenger elevator and two cargo and passenger elevaCora and also a
large distribution hall were deaigned along Che axis of the entrance.
In the basement ther~~ is a emall lobby wiCh entrance into which the automobiles -
and buaee will drive. A barber, cloakroom, restrooms, administrative and
management facilities are located there.
The second floor has been seC aside for the directors, the medical aid station,
the domestic servi~e~ combine, the reading room for the hokel personnel.
On ~'~e standard floora there are 431 comfortable rooms, including 160
' sin,,:,: rocros, 191 douule rooms, 48 triple rooms, and 32 semidelux rooms.
They will sleep 750 people. There are facilities for service personnel,
rooms for dryfng and cleaning clothing and footwear.
The halls are used floor by floor with alternation by floors as snack bars,
television gueat rooms or sutomated game rooms, the corridors with residential
rooms are well insula~e.d from the noisy elevator and floor hallways.
All of the roome are equtpped with modern bathrooms in the standard execution
applied in all of th~ Olympic hotels under construction. In the antirooms,
' there are built-in storage closets, and in the rooms, in addition to the
_ usual furniture, there are built-in window seats.
The hotel roofa are designed to be used. Al1 of the passenger elevators will
~ provide accesa to the roof. Open aolariuma and areas under shade are provided
here for rest and exercise. On the roof level on the main fucade side there -
is a glassed in training room which can also be used for billiards and table
tennis. It will be possible to equip a auimner buffet and bar in this area.
The building ia crowned with a five-story tower which houses the machine rooms
fo~ the elevators and va�-;,ous engineering facilities. This raised portion
with a lighted sign Olimpiady-80 [0].ympics-1980] will ~end distinction to
the entire silhouette of the building.
The three-story structures of restaurant'and the conference hall are ad3~acent `
, to the basic building on the parking facade side. ~
In the basement of the restaurant which is connected to the underground
loading platform, there are etorage rooms, refrigeration chambers, a number of
auxiliary shopa and also a dining room for the hotel personnel.
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Placement of Olympic Pro~ecta within tb.e Structure of the City (See Journal
No 1, 1977): 1--Sporta stru~tures 3n Luzhniki: all-purpose hall (No 2, 1977);
,ASU-Olimpiada [Qlympics Automated Control System] build{ng (No 8, 1978); 2--
Olympic pro~ects in Izmaylova: the all-purpose hall (No 3, 1977), the hotel
complex (No 6, 1978); 3--The sports complex on the Mira Prospekt (No 4, 1977);
_ 4--The all-purpose hall in Khimki-Khovrino (No 5, 1977); S--The Olympic
village complex: the master plan (No 6, 1977); the sports cenCer (No 7, 1977);
_ the service center (No 8, 1977); the administrative cenCer (No 9, 1977); the
_ cultural center (No 12, 1977); 6--'t'he sports constructiion complex in Krylat-
skoye: the bicycle path (No 1, 1978); the bicycle track and archery fields
(No 2, 1978); 7--The eques*rian sports base in Bittsy (~10 3, 1978); $--The
main preas center (No 4, 1978); 9--The television and radio complex in
Ostankino (N~ 5, 1978); 10--TsSKA soccer and track and field events on Lenin-
- grad Prospekt (No 7, 1978); 11--Planernaya equestrian sports base (No 9, 1978);
12--International post office on Warsaw H:tghway (No ?0, 1978); 13--Hotel
for foreign referees.
Key: (a) MyCiahchi (g) Kry~.atakoye
(b) Izmaylova (h) Lenin~rad Prospekt
(c) Balashikha (i) Khi mki=Khovrino
(d) Bittsy Ostankino
(e) Michurinskiy Prospekt (k) Sokol'nik i
(f) Luzhniki (1) Mira Prospekt
= The plan view of the first and second floors of the restaurant building
having freight elevators, service and front stairs is identical. Each of
them has its own kitchen units, dining and banquet rooms which seaz a total
of 600 people. The third floor is an engineering room.
S
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'4 ~'.i:: 5 's"ki~'`'W' Z _ .
r R~ ~ ~
_ ; F~ ~
_ S!:a
Genernl View of the Hotel Complex for the Foreign Umpires (Photo from the
Model)
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I
~
; -
_ ~
.
.
,
, -
; ~i
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1
I
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[~ncade of the Highri~e Modern Hotel Cc,~+plex from the Park Zone Direction.
- 'fu ti~c left--restaurant; to the right--cot~Ference hall.
9
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I ~1'
C~C1 ~
~ a
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~ / k k I'(
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Floor Plans of the Hotel Complex: a--First floor; b--Second floor;
I--Reeteurant; II--Conference hall; III--Hotel.
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~o~ n~~ictat, U~~ orrLY
z z
~ 2
2 2
_
/ I ! f ~ f t
2
J ~ 2 z ? i r r ~ ~
- ~ ~
, r t
f ~
G
, Floor Plan of a Standard Ploor of the Hotel for Poreign Refereea:
1--Reaidential roome; 2--Auaciliary facilities and aervice personnel
rooma.
Thie divieion of the r�etaurant into t~?o independent parte. each aith
its own complete production cycle aill make it poe~ible if npceeeary to
keep one floor for people living in the hotel and by ueing an independent
entrance, open the other for the residenta of the city. ~
In the basement of the conference room an entrance hall ~rith cloakroom,
buffet and bathroome~ are planned; on the fireC floor there ie a foyer con-
nected tn the hall of the hotel. a vieaing room for 500 people~ the fncl.lity
for a presidium, and on the second floor, a prees center vith internatiGnal
intervieW area.
In epeciel respecta the complex is a frame-panel type building. Its facades
aill be executed from the etandardized mouated ceramic concrete panels faced
with light glaes tilee. The Windos+s Will have wood-aluminum frames; for the
firet floore there will b~ aluminum aindows; for the acreena on the balconi~s.
shpets Af corrugated aluminum. The baeements of the building and, in part,
the valls of the lover floors. will be faced ~+ith polished granite. The
alua~inum atructural elemente Will also be used in the top in tihe form of
sheda over the utilized ~reas of the roofs.
- Alang vith traditional materials, vaehable aallpapers of various colors~
synthetic rugs~ precioua varieties of wood harmonizing with modern furniture
aill find application in the interior decoration of the rooms and corridors.
The elevator halls aill be faced in natural etone. The ceilings Will be de-
corative-aluminum and acoustic ceilings using Akmigraa tile.
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Thc grc~dte~t artentinn wi11 b~ given to the fini~h dn the m~in lnby of the
hotel whiCh i~ 5 m~eer~ high with open g~lleries on the m~xz~c~ine. The
columns wi11 b~ ~ov~r~d with white m~r61e~ the p~rap~~g nf th~ m~zz~nin~,
wieh ehinly ~awn travpretne, gnd the rear ~r~11, wfiich i~ th~ bg~kgrdund fdr
Che ~uppnrt~ di the pd~rei~r gnd kin~rl~~ will b~ ~ov~r~d Wteh fumed oak; the
~upporCe th~mee.tveg wi11 be mgd~ df fum~d oak with ~rtifieigl l~~eh~r. '~h~
flnor~ will be of m~rblp.
In the r~~tgur~nt mgt~riglg ~r~ ug~d whi~h give th~ inC~rinrg cnmfnrt ~nd
intimgcy. Tha c~lumng gre fgepd wiCh trav~reine. In cnnergse tn thp regt~u-
rent~ the c~nferencp h~11 gnd foyer ai11 be in g eevere gty~le.
'The d~~i~n of th~ hotQ1 wa~ d~veloped at work~hbp Nd 3 df Md~proy~kt-1 guid~d
by L~nin priz~ L~ureat in Architpcture Ye. SCamo. The guthor~ aer~ grchieectg
0. K~dren~vgkiy~ p. Kldknv, ~n~in~~r~ Yu. K~lygdin, L. Krivoeh~in, and
i. zhukova.
~ 'Ch~ hntel Will be b~i1t by con~truction ~dministration Nd 32 (chi~f M. n~lieg,
eecCion ~hief C. Cerehval'd) of Mos~troy-7 Truet of the Ord~r of Lenin
Glavmogetroy. The grructural elenf~nC~ wi11 be in~tglled by construction
~dminiatration No 119 of the prommontazh Trust.
At the preeent time the structures for the 16th and 18th floors, rhe eanitary
engi~eering aad electrotechnical equipment are being inetalled. The fini~hing
wen ,~av~ begun aork.
COPYRIGNT: Izdatel'stvo "~ovetakaya ltossiya", "Na stroykakh Rossii"~ 1978
10845
C50:1821
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. ~o~ o~~icYni. us~ ortt.Y
M~~ALLUR(~Y
LE~D AND ZINC BYPItODUCT ~X'TftACTION AI~VANC~S b~TA2L~D
Mogaow 7'SV~TNYY~ M~TALLY in ~tuegi~n Nd 12, bec 78 pp 2-4 _
(Article by A.P. Sych~v, Ye.p. Sggimbay~v ~nd T.M. Bel'kovg: "Legd ~nd zinc
Indugtry improvee Utiliz~tion of It~w Meteri~l"~
_ (Texr] At ~nterpriseg of Che l~ad ~nd zinc indugtry a gr~gt ~ob ia b~ing -
done on fulfilling the d~cree of the CPSU Central Commitree titled "Regarding
th~ Ffork df Party Org~nixationg af the Uet`-Kamenogorek Lead and 2inc and
Balkhaeh Mining and Metallurgical Combinea on Mobilizing Collective~ for thp
Achievement of High Indicatora for the Thorough Utilixation of lta~? Materi~l." -
The b~~ig of radical improvement~ in the utilization of lead and zinc raw ~
material hae been the improvement of technological procegees in all farms of
convergion. In the lOth Five-Year Plan period conaiderable rrapital hag been
earmarked for the redeeign and retoc+ling of exigting ~nterprieee of the lead _
. a~nd zinc ~ubinduetry, ~rith the renovatinn and modernization of ~quipmeut, -
ahich will make it posaible at a loaer coet to increase the output of non-
f+~rroua metals, to increase labor productivity and to reduce the loee of inetal.
At the pre~ent time 18 elemente and 40 kinda of commercial products are ex-
tracted from lead-and-zinc YaW material. Extraction in metallurgical conversion
equalg on average, in percentgges: 95.71 P~, 94.34 Zn, 83.43 Cd and 84.88 S.
~ M~xample of th~ achi~v~n~nt of high re~ulte in the thorongh utilization of
raa material is the Ugt'-Kamenogorek Lead gnd Zinc Combine, ahere zinc, lead,
suifuric acid and rare mptal production have b~en :ombined succeeefully~ and
_ a closed syetem ha8 been created for the croas proceseing of semifiniehed pro-
ducts in the z~nc end lead branches. In producing commercial oxygen, nitrogen
and argon are a19o trapped. At thia combine are extracted almo~t all cc~mponents
o~ the raW ore arriving for proceeeing and of the industrial products from
other plante, end 26 ktnda of cc~ercial pruducte are produced.
Very hiRh extraction of lead~ 97.45 percent, has been achieved at this combine.
The level of extraction of zinc (96.54 percenc) and cadmium (91 percent) is
also high, although the combine iE behind the Chelyabin~k 21nc Plant aith
regard to theee figures.
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- Conduaive to th~ g~hi~v~m~ttt o~ high r~~uies hae be~n ehe inrprovemene of
proce~ee~ for fuming l~~d ~igg, and improvement o~ th~ indicatore nf th~
emelting ~~cCion on accoun~ of eh~ procee~ing in shaft furnaces of higher~ -
quality ~inter, produc~d with a~ineer p1~nC employing bl~aeing from b~1o~.
A~ th~ regule of Ch~ inerodu~tion of hoe prel~anhin$ of 1~ad c~ke~ aith rhe
pr~cipitation of impuritiee frdm ~nlutione, th~ ~xCrgctinn nf xinc h~g in-
cre~~~d by 0.2 percent, gnd rh~e df cadmium by 0.1 p~ra~nt. Th~ m~et~ry of
on~-et~p 1~aching of mgtt~ with c~unt~rflow w~~hing of zinc c~k~g hg~ reduced
their yield by ~ p~rc~nt ~nd hgs incr~ae~d the extraceion of zinc fram raW
ore by 0.15 p~rcent, and of cgdmium by 0.3 p~rc~nt. Th~ uae of auromatic
- loading eontrol hga incr~ased the efficienay of Wge1z furnacea 3 to 4 perc~nt.
A 1~~ding place among ~inc pl~nte for th~ degr~~ of thoroughnegg in th~
utilixgrion of r~w material i~ hE1d by th~ ~he~yebingk El~ctrolytic Zinc
pl~nt. Here have been gchi~ved th~ higheet indicetors ~ng domegtic zinc
plant~ for the extraction of zinc (96.83 pere~nt) and the thoroughnese factor
for the utilization of rga n~ terial (95.7 percenr). ~
A key tr~nd in improvement of produerinn efficiency and of the thoroughn~gg
of utilixgtion of raw lead ~nd xinc are has been the imprevement of technology
end the enliatmenC for proceeaing of a11 industrial products and production
waste.
A special pl~ce among raa material resource~ has been held by ev~ilable re-
e~rvee of alag from ahaft smelting of lead. The capacitiea of slag-processing
plants have grotm conaiderably in th~ Ninth and lOth Fiv~-Y~ar Plan periodg.
Por ex~mple, g high-eapgcity elag sublimation ~lant has be~n canstructed and
put into service at the Chimkent Lead Plant. In 1977, 86 perc~nt of the
slag from ongoing production was proceesed in an 5hW ~slag sublimation plantj.
In the proceas of ma8tering the plant, there was improvement in the quality
of the sublimates produced in terms af their zinc content. In the firet
quarter of 1978 gublimates contained 56.3 percent zinc. According to the
know-har gained by the Ryeztsvetmet Plant~ the operation of an ShW has eham
that it is poesible to carry out the process ueing natural ges irithout the
uee of a solid reducing agent.
The slag sublimation plant at the Uet'-Kamenogorsk L~ad and zinc Combine has
been reconstructed. The mestery of a mixer-accumulator has b~en conducive
to reducin$ unecheduled downtime of the plant, to reducing cycles, to pre-
ventir.g the pouring of matte into the furnace, ~nd to atabilizing its operation.
Becauee of the improvement of the terhnology for processing slag, the indicatorg
of the ShW have be~n improved and the extraction of zinc in sublimates has been
inereased, equaling 84.5 percent in 1978. But much remains to be da~e for
the purpose of atabilizing the operation of the plant.
At the Achieay Polymetals Combine there has been an increase in the capacity of
the Haelz aection and the ccnnposition of the Waelz burden has been altered
(the percentage of slag hes been increaeed), as the result of Which the ex-
traction of zinc in ilaelz oxidee ha8 increaeed and equaled ab~ut 89 percent
in 1978.
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~ox o~~i~rnt, us~ orn.Y
~xigeing meChod~ of processing gleg do not gQlve ~h~ probl~m of compl~t~ ex-
tr~ction of cdpper and nobl~ meC~ls from it. ~'dr the purpos~ of ~olving the
probl~m of th~ ehorou$h utili~gtion of sl~g, UKSTeK (U~e'-K~m~~ttdgdrgk Le~d
J ~nd zinc Cdtnbin~~ in con~unctinn with VNIIr~veem~t (A1~-Union Sai~neifi~ it~-
~egr~h ~n~Citute of Mining and Non-p~rroug Met~llurgy~ h~g d~velnped g method of
proce~~ing it witihout t~aere, including th~ Wg~lz prdc~s~ and n~gn~tie concen-
eration of th~ clink~r, whil~ pr~ducing gublim~t~~ whi~h wi11 b~ bound for ehe
zinc prdductinn proce~~ for irdn ~nncentr~t~ cont~ining ropp~r and ndbl~ metelg
gnd suitgble for utili~gCion in le~d prnduGei~n, ~nd of g nnnmgg,~eCic clinker
frg~einn repreeenting r~w materiel for the prdduction of building mgterigls. _
The ef�~ctive pro~~$eing of ~int~ring gnd shafti smelting du~e c~negining rarp
~nd trace elementa has b~~n conducive to a cnngidernbl~ exCent to improving th~
degre~ di thordu$hn~es nf the utilization of raw m~t~rial in l~~d producrion.
5eparac~ procesging of ~ pdrtion of rhis du~t he~ been erranged for gt glmost
all plar.tg of the subindu~try. In spite of the fact thgt it has been carried -
out for e long Cime, th~ degree of pxtrgceinn of rare meegl~ from it is still
ingUfficient. It is poasible to carrect the eituation by a more reasonable
digtribution of rare elemente over intermediate producCa.
Of great importence for improving the thoroughnegs of the utillzgtion of raw _
material hgs been the introduction of oxyelectrothem~al emelting of lead con-
centratea ("Kivteet-Te5"), which, togeCher With improving the extractinn of
legd and xinc, will coneiderably improve working sanitation and health con-
ditione and will lower harmful environmental effluents to health standards.
At the pregent time the "Kivtset" technology ha~ b~~n mg~t~r~d at the Irty~hsk
Polymetals Combine. I~or the purpose of proceseing copper-ar.d-zinc concentratea,
the intent ia to redeeign the "Kivtset" unit at this combine, to increase its
output and ensure maximum extraction of zinc and utilization of aulfur-contain-
ing gasea.
- The incent is to introduce oxyelectrothermal smelting of raw lead ore with a
"Kivtset-TsS" unit at UKSTeK, the Dal'polimetall Association and the Elektro-
tsink Plant.
At VNIIt~vetmet ~tudiea and testa on an industrial scale have been made of a
nea method of procesaing storage battery acrap--the KEPAL method. This method
includea mechanized aeparation (concentration by sink-float separation) of
atorege battery scrap with the separation of chlorine and metallurgical pro-
cessing of concentration products ~rith the high extraction of inetals. It
eatiefies modern requirements for Working conditions and environmental pro- -
tection.
8ased on teat results~ a aection for processing storage battery scrap has been
planned and its construction has begun at the Leninogorsk Polymetals Combine.
The degree of thoroughness of the utilization of raa material in ziac production
is determined primarily by an efficient syatem for proceasing zinc cakes.
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.
~OR O~FLCIAL US~ ~NLY
At UKSTeK~ c~k~~ from int~xnal production and a portion o� Leninogorek cak~e
ere proceAeed by the Wnelz method, an impoYtant dis~dvantag~ of which 3e the
produ~rio~ of e~oppar-bearing clinker ponr in copper, gold gnd ~31ver cont~nC.
MoBt promieing i~ the hydrom~eail~~Yqical method of processirig zin~ c~k~~~ which
mak~e it poeeible to extr~eC ~11 ~~..aab1~ eompon~nte in the cloeed cycle of
' xinc end lead plgnCs.
Work~r~ et th~ Lpninogorek z3nc P1er.C in corr3unction with gegncigt~e ~t VNII-
tgvetmet h~ve developpd ~nd carried out hydrom~Callurgical proceseing of zinc
cakee from current production; this hae b~en responsible for g three-percent
3ncrease in the extraction of zinc at thP plant, and a 4.1-percent for cadmium.
With the startup of the high-temperature legching eention for zinc cakes~ all
cakes �rom c~rrent production will be procegged and old dumps will gradually
b~ utillzed. ~
In 1974 gt VNIICSVeCmet was developed end n~egtered on the tnduatrial scale a
technology for combined hydrometallurgical proceasing of zinc cakee and eub-
limatea for the Almalyk Zinc Plant. A pra~ecC for redesigning the leaching
section has been carri~d ouC for the purpose of introduc~.ng this technology
for thp entire emount of zinc cakes from c'~rrent production and of sublimates.
The capacitiee of Waelz furnaces which have been freed will be utilized for
the purpos~ of procesaing slag from old dumpg at the ChimkenC Lead Plane.
The introduction of combined hydrometallurgical processing of zinc cakea and
aublimate~ to the full exCent at the Almalyk Zinc Plant will improve the ex- ~
traction of zine, cadmium, copper and noble metals. -
M analyeis of the operation of lead and zinc enterprises hae shown that they
have at their diapoeal great resources for improving the thoroughness of the
utilization of raw material. Teatifying to this primarily is the considerable
gap in figuree for the extrac.tion of inetals for individual piants. For ex~mple,
the extraction of lead in refined lead~ sublimates and matte ia 2.85 percent
loWer at the Chimkent Lead Plant than extraction in ref ined lead at UKSTsK.
The extraction of zinc from raw ore at the Chelyabinak Zinc Plant is conaider-
ably ahead of figures for other plants.
Enterprises have not been utiliztng to the full extent their opportunitiea
for reducing the loae of inetals and for utilizing sulfur from exhaust gases.
In recent yegre the purification of exhauet gasea has been improved at lead
and zinc plante. For example, URFM-2 bag filtera have been put into eervice
at the Chimkent I.ead Plant and electric aeparatora for cleaning roa8ting gases
at the Chelyabinek Electrolytic Zinc Plant; conatruction hae been completed on �
nev sets of gas purification facilities at the Ust'-Ka~nogorak Lead and Zinc
Combi~ae; and duet trapping systems have been expanded at the Chimlcent le~d and -
Belovo zinc plants.
Together ~,rith the conBtruction of new gas purification facilitiea, much
attention has been paid to improving the level of utilization of dust trapping
units; as a reault. the reeidual duat content of process gases from key con-
veraion proceseea ie being reduced gradually and significantly. But the
16
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~OEt 0~'~ICYAL US~ ONLY
r~aidual dust cnnCene o~ gases is aCill h~.~h at ett~erpriseg auch gs LPK
(Leninogorsk PolymeCgls Combine], UKSTsK gnd Ch5Z ~Chimken~ Lead P1ane].
In evaluating ae n wh~l~ the poesible way~ of reducing dusC and gas effluente
~nd df gehi~ving healChier eir in ehe gre~s nf 1ocgCion of le~d ~nd zinc plgneg,
it ~houLd be mentioned thnt far the purpoee of a full ~olution to Chig problem
it is n~cessary to introduce new metallurgical processes ("KivCset," dugL-
conC~cC, ~Cc.)~ to redesign gnd eMpand duse erapping and gas purification _
eyetemg, and to build uniea for sanitary prepurificaCion of gases.
The maximum utilizaCion of a11 reaources at hand ae plane$ of the lead and -
- zit~c subinduatry, for reducing the loas of valuable componenes of raw ore, _
the introduction of new metallurgical proceases and the improvemenC of exisCing
ones, the modernization and conaolidation of equipment, and the mechanization
and ~utnm~tion of key and ancillary procegses will be condu~.:ive to solving
one of the maior problema aseigned to the country's non-ferrous meCallurgy
industry by the 25th CPSU Congreas, ChaC of further impnoving the efficiency
of the production of non-ferroue metals and the Choroughness of the utilization
of raw material.
COpYRIGKT: Yzdatel'stvo Metallurgiyas TsVETNYYE METALLY, 1978
8831
CSO: 1821
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rs~x~LUR~x
NICICEL INDUSTRY'S WASTE-FREE PRODUCTION PROSPECTS EVALUATED
Moecow TSVETNY3CE METALLY in RuesiAn No 12, Dec 78 pp 7-9 -
[Article by T.V. Gran': "ProapecCe for Creating Waste-Free Production in the
~ Nickel Industry"] _
[Text] The ma~or waste in metallurgical proceasing of sulfide and oxidized
nickel ore ie repreaenCed by slag, relaCively mild aulfur gases from pyro-~
metallurgical converaion procesaea, and ealine diacharge from hydrometallurgical
sectiona.
Waste-free production of nickel can be created on the basis of improving the
operation of existing plants and by using new waste-free procesaing aystems.
In the USSR'e nickel industry the firat waste-free enterprise has been created--
the Pobuzhekiy Nickel Plant, where ferronickel la produced from oxidized nickel
ore by electroamelting, after which it is concentrated by blasting in converters.
The ma~or maes of nickel and iron contained in the raw ore ia extracted in
conunercial ferronickel. The slag produced is cruahed and it is all handed
over to a construction organization for utilization. In addition, total re-
cycling of water is carried out at this plant.
This example has demonstrated Che fundamental feasibility of setting up new
enterprises with a waste-free technology in the nickel industry or in con-
struction.
Ia it possible to improve the technology of existing enterprises, in order that
they might operate without dumps or by producing them to a minimum? For this
it is necessary to cansider ways for and the feasibility of eliminating or
utilizing gases, slag and induatrial waste.
The following are the ma~or ways of raising the level of utilization of sulfur
from exhauat gases from metallurgical production:
- 1. Raising the concentration of S02 in theae gases and ensuring uniformity
of gas stream volumes and conatancy of the S02 content over time, by:
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Developing and introdu~ing a~ exiating eneerprisea new prnc~sses and metal-
lurgical e~chnology equipm~nr, e.g., cou~inuouA conversion uniCe~ auCogenous -
emelting uni~s, eCc., producing concentrated aulPnr gas (10 tio 20 percent S02). -
Improving exisCing prnceasea and equipmenC, such as by usin& ~,mproved sprayer$,
in convertera, involute, for exampie, which W~.ii make it possible tu raise
the concentration of SO in gasea to six percent; aealing ore roasting and
electric etripping furnaces, packing gas fluea, and enxiching the air with
oxygen when converting and roasting in fluidized bed furnaces (in theae the
content of S02 in gases is raiged to about 8.0 percent); inatalling heat re-
covery boilera after the metallurgical unita,~inatead of thinning exhaust gases -
with air for the purpoae of cooling them.
2. Uaing chemical methods of enriching gases poor in SO , for the purpose of
aubaequently procesaing them,into acid or elemental aulfur.
3. Using �high-temperature or catalytic meChods of reduc'.ng S02 with natural
ga6 to produce elemenCal sulfur.
4. Building and putting into service new sul�uric acid c,3pacities, as well as
units for Che byproducC derivation of elemenCal sulfur from gases.
- Long-term plans for development of the subindustry call for raising the
~ utilization factor for sulfur at enterprises which process sulfide ore to
90 to 93 percent, which will be able to be considered a solution to the problem
of utilizing the aulfur from gases at these plants. �
~he problem of procesaing low-aulfur gases at Ural nickel enterprises which
work with oxidized ore has still not found an intelligent solution because of
the low concentration of SO in them, since more than 40 percent of the sulfur
is found in low-content sin~er and shaft smelting gases, for which now only
one engineering solution has been able to present itaelf--neutralization.
Dump slag in the nickel and cobalt subindustry represents a complex multicom-
ponent silicate eystem, containing rock-forming components with an admixture
of moderate amounta of non-ferrous metals and sulfur. _
All slag in the nickel industry comes under the heading of acid slag, and
ite modulua of basiciCy is leas than one.
Slag arrives at the dump in a liquid-molten state or in pelletized form.
' The physical and chemical properties of this slag make it possible to use it -
- as a promising raw matsrial for the production of building materials and pro-
ducCs, such as mineral wool, caet stone products and cast alag ballast. Pellet-
ized slag, being an already considerably crushed product, can be used also ae
a filler for mortar and concrete.
Of the useful properties of this slag, mention should be made of its highly
uniform composition as compared with natural materials used in the silicate
- induetry.
19
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The following xepresent protqising ~xends in the uC~,~,izaeion o~ alag:
u) Production of m3neral wool products (increase ~rom 0.3 to 0.6 percent of
all slag produced in the subinclustry).
b) In pelletized Porm, fox filling mine workinga (increase from three to four
percent to nine Co 12 percent).
c) As rubble for construction and landscaping, and for producing binders
(cement). -
d) F'or Che production of slag pyroceramics.
Aa already mentioned, a promising way to utilize slag is to produce cement from
it. The production of binding materials from nickel industry dump alag has ~
been atudied by the Leningrad Area Institute of Standard and Experimental
Design (LenZNIIEP), Che Leningrad Con~truction Engineering InstiCute, the Lenin-
- grad Branch of the USSR ASiA [Academy of Builders and Architects], the Kola
Branch of the USSR Academy of Sciences, the Noril'skproyekt Institute, etc.
. Studies have shown that slag cruehed to cement finenesa, when hardening promo-
Cers are added to it (lime or gypaum), can serve as a binding material for -
the fabrication of building producCa. Hardening of theae producCs must take
place in kilns or autoclavea. The concreCe types produced have a mechanical _
atrength of 300 to 400 kg/cm2.
- Reaearch and testing along this line are continuing. For example, at the
preaent time the Rezh Nickel Plant and the Yuzhuralnikel' Combine in con-
junction with building institutes are conducting tests on the additian of slag
Co the t~urden in the prod~ction of clinker at the Sukholozhskiy and Novotroitak
cement plants. At the Gipronikel' InstitutQ [State Planning and Scientific
Research Institute of the Nickel, Cobalt and Tin Industry] research work is -
- under way on the electrosmelting of raw aulfide ore into slag suited for the
production of cement to be used in Che preparation of foundation concrete.
For the purpose of solving the problem of the utilization of crushed dump
slag for the production of cement, organizations of the USSR Gosstroy must
develop engineering specifications for the production of binding materials
from this type of raw material and for the production of building pr.oducts
from them. ~
With a favorable solution to the problem of the production of slag cement
- based on binders, it is possible to utilize as muc.h as 60 percent of the dump
slag formed in the subindustry. -
The USSR Academy of Sciences Kola Branch has done extensive research on the
production of caet stone products from liquid-molten slag and has demonstrated
its auitability for pouring large blocks (up to one ton), as well as products
of inedium and amall size (up to 40 kg). As much as 10 percent o� the slag
formed in the subinduatry can be directed for these purposes in the future.
20
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_ ln 1975 at G~.pronikel' Cechnica~. ~nd econom~.c eatimatea were made �or arranging
ror the proceseing and utiliz~tti.on o~E nickel dump s]:ag, which ahowed that
thie type of axrangemenC would be highly e~~ective, and the period for paying
off Che capital inveatmenC would equal about two yeara. _
I:? the Future a aoLution wi11 alao be found to the problem of eltminating
itidustrial discharge. Tl~e most complicated thing here is the processing of
saline industrial diacharge which contains, in g/1, as much as 60 Na+, 90 -
S04- and 20 C1'. Every year many thousande of tons of valuable chemica,l pro-
~ ducta--sodium sulfate and sodium chloride--are wasted with theae. At the
preaent time a technology is being developed for producing commercial producCS,
auch ae sodium aulfate, chlorine and alkal3s, from saline industrial diecharge.
_ A more radical solution is represented by the development of a processing � -
system for the electrolytir. refining of nickel which would not produce saline
diecharge. Thie ia poaeible in principle, and studiea alang this line are
under way.
Refining of raw nickel can also be arranged for by the carbonyl method. Able
to serve as an example of an enterprise with a waste-free technology is the
new INKO refining plant put into operation in 1973, which uses a high-pressure
carbonyl process.
The ma~or raw maCerial for thie plant is the metallic fraction f rom the copper-
nickel matte processing section. In addiCion, nick~el concentrate and commercial
products from ele~trolysis sections are processed at the plant. The raw material
is melted and blasted in rotary converters with oxygen blasted from above. -
The raw material for the carbonyl process is metal granules containing, in
percentagea, 72 Ni, 18 Cu, 3 Fe, 1 Co and S S.
. It can be concluded from the above that, for the purpose of converting existing
nickel plants to a waste-free technology, it is necessary to complete research
on Che enrichment of low-content sulfur gas, to increase dramatically the scale
of production of aulfuric acid, to make arrangemet~ts for sulfur production, to
develop and introduce a technology for processing saline discharge with the
production of commercial salta, and to make arrangements for the total utiliza- _
tion of slag.
An analysis has demonsCrated Che fundamental feasibility of in the future con-
verting exisCing enterprises which process nickel sulfide ore to a waste-free -
technology.
The further development of the production of nickel must be based on the use
of new procesaes making it possible to utilize raw ore completely. The highest
- figures for the thorough?-.zss of the utilization of raw material are prov~ded
- by combination syatems in which hydrometallurgical processes prevail. -
The Mekhanobr Institute [All-Union Scientific Research Institute of Mechanical
Proceasing of Minerals] has developed a process for concentrating Noril'sk ore
while producing a rich ni~~kel concentrate and separating a considerable portion
21
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' FOR OFFICIAL USE ONLY
of thP irott in an independent pyrrhotine concentrate, from which nickel ia also
Co be extracCed. For the purpose o~ procesaing the pyrrhotine conc~nCraCe,
Gipronikel', Gintevetmet (State Scientific Research Institute of Non-Ferrous
Metals], NGMK [Noril'sk Mining and Metallurgical ~om~ine] and a number of
other organizations have develo~ed an oxidative aut~clave leaching method,
which makes it possible to produce a rich nickel sslfide concentrate contain- _
ing 11 to 12 percenC Ni and elemental sulf~ar as a separate pr~duct. Almost
all. the iron will be concentrated in ferruginous dump tailings. A demozistration
has been given of the basic feas;bility of processing Chem inCo high-quality raw
material for ferrous metallurgy.
At Gipronikel', on a laboratory scale a waste-free Cechnology has been developed
for sulfuric acid leaching of sulfide products, which malces possible the utiliza-
_ tion of all components a.,^ording to the following system: non-oxidative liqua-
tion smelting into matte; disaolution of the matte in circulating sulfuric. acid;
processing o~ Che hydrogen sulfide thus produced into elemental sulfur; oxida- -
- tion and hydrolysis of the iron with recovery of the acid formed to dissolve the
matte; processing of the sulfide precipitate of non-ferrous metals with the
derivation of a concer~zrate of precious metals, cobalt, nickel and iron; and
groduction of iron pellets from the hydroxide.
By this system are produced nickel, c~~balt and copper briquets, iron oxide
' pellets or gas reduction iron, elemental sulfur and a concentrate of platinic
metals. The extraction into finished products, according to lab~ratory data,
equals: nickel 97.5 percent, copper 97.6 percent and cobalt 90.9 percent.
Possible is a variant cf this waste-free technology which includes carbonyl
processing of a sulfide cake (obtained as the result of leaching) containing
nickel, cobalt, platinoida and iron residues. The finished products will be
nickel pellets, autoclave copier (as a powder, briquets or rolled metal), _
high-purity reduced iron, and s~ecial materials with a ferronickel and copper-
nickel base.
� The ~ipronikel' Inatitute in conjunction with a number of other organizations
has been conducting other research aimed at increasing the thoroughness of
the utilization of raw maCerial and at creating waste-free processing systems
on this basis. Under the heading of this work come autogenous forms of smelt-
- ing raw sulfide ore G�hich produce concentrated gases, continuous conversion,
_ smelting in furnaces with an immersed jet, into ferronickel, etc.
Under way at the present tima; are a fair number of processes making it possible
to create a waste-free processing system for an enterprise for the purpose of
~ processing sulfide ore. These include autogenous smelting with the production
oF sulfur or sulfuric acid and the total utilization of slag, oxidaCive auto-
clave leaching of a pyrrhotine concentrate with utilization of tailing iron and
sulfur, continuous conversion of matte (also with utilization of Che sulfur),
and carbonyl refining of raw nickel. It is possible to use a hydrometallurgical
system �or processing raw sulfide ore aftsr further improvement of this system
on a semi-industrial scale.
~ 22
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Important factor~ i,n th~ areeeion o~ new weg~e-~ree technnl~gie~ ar~ repr~~~nt~d
by the need ro develop merhod~ o~ utilixing ~~rruginou~ t~iling~ ~nd df prd-
ceeeing el~g, wtt~ch must be solved in combingti.on in inve~tiggttng, pl~nn~ing
and i,mplementing n~w proce~~ing ey~C~mm~.
, COPYRICHT: xzdaC~l'etvo M~Callurgiya~ T5VL7'NYY~ ME~'ALLX, 197g
8831
CSO: 1821
23
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FOCt O~FICIAL U5~ ON`LY
M~TALtUttGY _
_ CH~LYABIN3K LLLC~ItOLYT2~ ZINC PLANT' S WAST~-I~It~B PItODUCTION LI~OItTS D~~AIL~b
Moecow TSV~'TNYYE ME'TALLY in Rueaign No 12, Dec ~8 pp 4-7
(Article by S.F. Matveyev~: "The Ch~lyabinak ~lectrolytic Zinc p~~nt on th~
Way to W~sCe-Fr~e Productidn"j
(Text~ Th~ Ch~lyebinsk Llectrnlytic Zinc Plgnt Work~ mainly nn concentrgtpg
derived from copper-and-zinc ore from the Urals. The diseinctiv~ fe~turee
af Ural concentrat~e ar~: a r~duced content of zinc and cadmium, a high con-
t~nt of iron, copper and sulfur~ a high degree of dieperaion, and a high per-
centage of water eolubip rompounde. The content af ~in~ in concentrates gt
Urgl concentration planta does not exceed SO percent, and in coacentratee at
the Cayekiy and Uchaly concentration plants, 45 to 46 percenC.
The high iron content in concentrates and its close structut~al relationehip
to zinc are the reaeons for the low aolubility of ~inc in ro~ieting producte;
this dramaCically complicaees hydrometallurgical proceasea; increases the
output of zinc ione~ complicates their proceseing. ~ind incregaes the conaumption
of fuel and auxiliary materials. But the plant hae, achieved notable auccesa
in recent yeare in improving the thoroughnese of t'ne utilization of raW material.
The auccesaea of the plant'e team have been the coneequence of the system
ahich hae been formed for organizing production, repreeenting a combination
of technical. organizational, ecoaomic rind sociopsychological meaeurea. This
system embracea all eubdivielons and services of the plant which in one way
or another have been promoting the efficient utilization of raa material.
The fotlot,iing are the main ],inea along ~+hich the thoroughnees of the utiliza-
tion of raw material is being improved:
1. Improvement of extraction by the use of advanced technological procesaea
and improved equipment, by the mechanization of labor intenaive ~obs, by the
automation of the monitoring and control of technological processes, and
by improving Working condition~ and production standarda.
2. Enlisting in the processing of inetal-containing materials production
- waete~ al8o~ including from dumpe of past years, as well as Waste from other
non-ferroue metallurgy enterprisee and allied industries.
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/
I~'OR nFI~ICIAt, U5g OAtI.Y
3. Improv~m~nt of produ~t quality by rpd~cing the ge~n~igt~d metgl~ in pro-
ductg ~rid by ~~gr~g~ring eh~m i~nto commadity produate.
4. InCroduction of environm~nCal protection meg~ur~~.
Roa~ting ie on~ of rh~ moet impnrtgnC formn of conv~r~ion in Che productiun
of zinc.
Th~ cdneCruceion gnd ma~tery of a h~ghly m~chanized gtorag~ f~cility for cdn-
C~ntretee heg mad~ it pogeibl~ to convert eo cont~in~riz~d tr~n~portarion of
eoneenergt~e, there has be~n g con~ider~ble reduction i,~ th~ lde~ of concentrgteg
on th~ way end in the p~rform~nce of logding gnd unloa~3~ng operationa, and
labor coetg for these op~rations have glso been lawer~d.
The key trend in the improv~ment of the rogsCing proce~~ it~~1f in recent
y~Ar~ hns been an increae~ in eh~ uni~t cepactty of "fluidized bQd" furn~cpg
ae the result of ueing oxygen. Th~ ~fficiency of roaettng furngc~s haa be~n
rais~d 35 pprcent, ther~ h~~ bpen a coneidpr~ble r~duction in the content of
~ulphidee in rogeCing praducte, and th~ dir~ct extr~ction nf zinc hgg increased. _
A r~duatinn in Ch~ output of zinc cakea has made it pop~ible to procees in
addition cakee from reeerves from paet yegre.
Improvement o~ the deeign and of the utilization of ~l~ctric eeparetora ha~
reduced loasee of valueble components ~+iCh ga~~s in th~ ro~~ting converaion
p~ocee~ to 0.02 percent of the total zinc charg~. _
The utilization of o~cygen ia roa8ting zinc concenCrgtee and the recongtruction
of aulfuric acid production by converting exieting sqetemg to th� system of
dual contact and intermediate abeorption have been reaponaible f~~r poaitive
results with regard tr~ maetery of the proceseing of gasea with a high SO2 con-
tent, with a corresponding growth in capacity ai.thout increasing th~ number of
operating pereonnel. Thie has been conducive to improvement ~n the extraction
of eulEur into sulfuric acid and Co healthier air.
One n~ore syetem wae redesigned according to the dual contact sqstem in 1977.
It has been operating in the autothermal mode with high ratings. The content
of S02 in exhauat gasea has equaled a total of 0.01 percent ~rl.th 99.6 to 99.8
percent convereion. Full completion of the redesign of sulfuric acid production
ie planned in 1979.
The incrpase in the percentage of Ural concentrates in the raw material being
proceseed has eerved as aa impetu4 tos+ard modifying the aqstema and modes of
leeching roasting producta and cleaning golutions.
Studiea made in con~unction with VNIltavetmet (Al1-Union Scientific Research
Inetitute of M'~ning and Non-Perroue Metallurgy~ have demonatrated the feasi-
bility of emp]oying a one-etep leaching system and cownterflosr Washing of zinc
cakes.
Up until recently, cleaning copper aad cadmium from aolutions aas carried out
ar the plant in two ete~s, using a~?timony salte~ as activating additiona, vith
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~OR U~NLCIAL U3L~ dNLY
g f~irly l~w ~~nsumption ~f zin~ dugE (~bnut 34 e~ 35 k$/t+~n nf zinc). ~hi~
d~d not prnvid~ eh~ rpquired d~gr~~ di tho~roughnea~ tor ~1~~ni~n$ ~ulution~
~nd did no~ prnvide fur ~~p~rgtion nf ehe c~ment d~pngit derivpd ineo copp~r
~nd ~~dmium.
In 1976, in catt~un~tidn t~r,tth VNIltsvetmet, was introduced a three=step gygcem
_ for el~enin~ zinc goiutiona of impurl~i~~, ~rieh the ~eparntion of the major
amount of copp~r ~nto cnpper ~~k~ in th~ f3r~t c1~~ning ee~p. 7'h~ qu~lity
of n~uCra1 aolutione w~e th~r~by i~nprov~d.
- The cone~nt of impuriti~~ in the c~~~ned ~olutioa w~g r~duc~d consid~r~biy,
whict~ i~ obviou~ frdm th~ folioai~ng dat~, in mg/1:
1975 Pivc monthg, 197p
Cu 0.10 0.06
Cd 2.73 1.1
~1i 0.43 0.26
Co 1.8 0.63
There hae been a reduction in the output of copp~r-and-Cadmium c~ke gnd the
content of cadmium in it hag been incregeed, which hag made it poaeible to
improve the technology for proceseing copper-gnd-cadmium cake w~hil~ producing
coam?er~igl copper cake.
The mastery of three-step cleaning haa created an opportunity for introducing
a xanthate-free system for aeparating cobalt. According to this syatem, the
concentration of cobalt takes place during the cementational precipitation
of cadmiwa~ and cobalt is aeparated from the procese aith eolutione ~or the
production of hydrous zinc eulfate. The use of expensive and highly toxic
ethyl xanthate is completely eliminated and lossea of zinc and cadmium are
reduced.
Conducive to improvea~nt in th~ thoroughneas wit?1 which raw material ig t~eing
utilized have been improvement and intensi`:....:.:.,.. o~ ~�C Waelz process for
zinc cakes. The high content of iron in them (27 to 30 percent) hae cauaed
intenae elag incrustation in Waelz furnacea. Since 1975 oxqgen hae been
eupplied to furnaces~ and the autput of furnaces has reached 94 to 95 tona
of burden per 24-hour period. The full effect from this measure can be gotten
only after eliminating the elag incruatation phenomenon.
In the converaion procesa for Waelz oxidea there has been a considerable re-
duction in the loas of zinc and of cgdmium, especially, with lead cakea, as
the reault of the introduction of oxidative high-temperature preleaching of
the lead cake and continuous "inverse" leaching of the Waelz oxide.
Much useful arork has been done it~ the conversion of rare metals. The most
important are the selective precipitation of rare metals, the use of a more
active reducing agent. and improvement in the electrolyaie of indium. As
n result, the extraction of indium from ~iaelz oxide during the last five
26
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~nit d~t~tCIAL U~~ ONLY
y~~r~ h~e b~pn in~re~~~d by more th~n 5.d perCent, ~nd ~t ehe pr~~~nt tim~
it i~ 1f1 ~a ~0 pereent (gb~oluC~) high~r th~n ~e oeher dam~~ti~ ~in~ pl~ntg.
A11 indium i~ being produc~d wiCh th~ ~t~t~ ~mblem df (~uglity, -
A~ombingeion of indu~~rigl engin~~ring m~agur~g ~~rri~d aut in e4~e ~l~~frd-
1y~i~ eecri~n (in~tell~ei~n of ~dd~tion~i el~~cralytic G~il~, m~~h~ni~~~idn
of Cleani~~ ~ludg~ frnm ~e~le, ~tc.) h~~ mad~ it pna~ibl~ t~ improv~ eh~
quelity of zinc pre~ipie~?ei~t~, ea r~ige the y~eld of inetal in pig zinc, and ~
r~ rpduCe iog~~~ of it ~n dro~g gnd m~].ting log~.
~'he r~~u1t~ ~f th~ p18nt's vnrk on impr~ving eh~ ~xtt~~tian af vg1u8b1~ com-
pon~neg ~r~ eh~r~ct~riz~d by th~ follenring dgtg, in per~~nr~geg:
~xtrartion 1971 1975 pive monthg, 197g
zn 96.0 9G.64 ~6.8g
Cd 90.42 9b.64 91.36
In 7~.0 75.3 76.38
5 ~9.14 g~.67 8~.g9
Litili~~tidn df gulfur 92.54 94.64 9~.57
Thordughne~s of u[i1iz~=
tidn ~f gulfur 94.7 95.4 95.57
a Univ~r~~lly r~cognized ig the ngtinnal econami~ import~nce of p~ocegsing pro-
duc[lon waste and of ~~v~loping and intr~ducin~ a~~e~-fr~~ t~ch~telbgi+~a1 pro~
c~ege~. Thie ob~ective hgs become the d~termining ane in the p~ant's work.
'Phe improvement in the quality of roaating product~ gnd inten~ification of Ch~
Waelz procese have made it posgible to get up the proceeging of c~kee from
dumpe of paet yeara. The procesaing of eludge from cleaning facilities hae
be~n eet up.
A production system has been developed and introduced for proceseing chemical
industry waete containing 40 percent zinc in carbonate form.
In conjunction wi~h the Glredmet [State Scientific Regearch and Plar~ning
Ingtitute of Rare Metals), an original syetem has been created for processing
semiaonductor material aaste, including the extraction of indium. Gallium is
being extracted by the aorption method from indium production Waete.
The plant ie close to creating a Waete-free production procese syatem. '
Meaaurea far the improvement of the thorough utilization of raW material have
been carried out by the plant in close alliance ~rith environmental protection
ob~ectives.
Baeed on the revieion of gll technological procesaes, the opportunity has beea
created of eliminating the disposal of inetal-containing solutiona into the
seWer eystem and of utilizing them ~n technological procesaes. As a r~sult,
the total diapoeal of contaminated Waste ha8 been reduced conaiderably, and .
- purification facilities put into eervice in 1974 have been only 40 to SO per-
cent loaded.
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~btt 0~'~IG~AL U5~ ONLY
~n nper~tion gt th~ pi~nt ~re ehr~~ Cio~ed w~t~r ~ir~ul~tidn gy~temg: in
eh~ ~uifuri~ ~c~d pradu~eia~ proc~~~; for eh~ purpo~~ af ~xeingui~hing the
~l~g in th~ Wg~1x furn~~~; end far eh~ purpo~e of can~r~l cooling of th~
~inc ~lectrc~lye~. r.~~y~ling nf a~ter hag been intredu~ed in m~ny ~~ctiong.
_ ~h~ eat~i ci~cul~tion af a~e~r ~e rh~ p1an~ ~qu~lg 96.5 p~rCenC~ On],y 3.5
percent of the wate~ ueed fo~ technological neede ie di~pos~d df gft~r p~r~limin-
~ry thnrou~h cl~enin~ ~o th~ t~xtmum p~rmi~~ibie ~on~~ntr~eion~, for r~~~gvdir~
fnr bu~in~~~ gnd ~v~rydgy pu~rpo~~~~
'1'h~ pi~n~ ~ouid conv~rt to 100-p~rc~nt r~cycling df w~e~r, if g f~vdr~bi~ ~a1~-
~idn Were found tn th~ problem of ~l~~ning ahi~rin~ from a~gte a~e~r.
In tierent yegre Ch~ plgnt h~~ be~n gr~gtly inv~lv~d in thig prc~b~~m, in
codp~ration aith T~Nliolovd [C~ntr~1 Sc~~ntific lte8~grch In~tie~Ce of Tin),
K~zm~khenobr (Kax~kh In~titut~ of M~chanization of Proceesing~, th~ Azerbaydzt~,,an
SSR Acad~my of 3ai~nce~ in~titu~e of P~trochpmi~gl Produre~, th~ Ural Ins~itut~
of Waod Technology, ~nd th~ Ch~lyabin~k Branch of VObGYed (All-Union Scientif ic _
tt~g~grch ingtitut~ of W~~er 5upply, S~~r~r~g~, Hydrdlogical Structur~g gnd
Hydrogeology~. But th~re hag ae yet been no gucce~g in d~v~loping gn ~fficienr _
ey~tem For th~ eepAration of chlorine with th~ uCilization of chlorid~ pre-
aipitaCes.
Conducive to h~alrhier gir havp been the redegign nf ~ulfurie gcid production,
improve~nr of th~ gyetem for removing�dust from metallurgical production pro-
c~es gagee, th~ introduction of unit-by-unit overhauling gnd the eealing of
~quipm~nt, and strict monitoring of th~ obaervance of technological cycles.
In the purificatian of gaee8 from the drying of lead and zinc cakes, and in
the unit for producing hydroue ~ulfate in fluidized bed fut:nace~, percuasion-
type gcrubb~r~ (SUD'g) have bpen operating eucceasfully, the use of ahich has
m~de it possible to reduce the content of precious duat in these gases from
1 to 2 g/nm3 to 0.1 to 0.2 g/nm3.
A high degree of removal of ~Jaelz oxide has been achieved with bag filtera.
_ The duat content in exhauat gaeea has not exce~ded 12 to 17 mg/nm3.
A highly difficult problem hag turned aut to be the purification of ind~;ction
furnace gaeee in the remelting of zinc. ~iith the introduction of rotar~~ cy-
clone dust separatora in this convereion proces~, all metallurgical production
gases aill be aubjected to duet removal.
The improvemenC of product quality has alao had a conaiderable influence on
improvement of the thoroughness of the utilization of raw material.
The reduction in the content of impurit~~s in commercial producte (cf. table)
teatifies to the great 3ob done by the plant's tesm along this line.
An objective evaluation of the plant's job in improving product quality is
represented by the output of producta w'_th the State Emblem of Quality.
28
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~OK O~f~ICIAL U5~ d@fLY
in 197b ~0.4 p~ra~ne af nil pruduce~ bore thp ~mbl~m of Qu~l~ty, ~nd in 197~,
61~73 p~r~en~.
tt~duction in Cont~nt of ~mpuriti~g i.n Commeri~~l Prdduce~, in percentgge~
7'yp~ of Profluct ~ri Cd
i976 1977 1976 19~7
Clinker 1.49 1.42 - -
~.~~d cak~ 8.8S 7.6~ 0.22 0.17
Copper cek~ 8.13 ~.51 b.4 0.32
Cl~gn~d ~olution,
~ng/1 - - 2.13 1.63
Succ~ese~ in improvemene of the thoroughne~g of th~ utilization of raw maCerlgl
chp rianr hav~ been dve not only to th~ arowth in the technical l~vel of
produrtion, but ~l~o to the preciee formulaeion of organi~~tiongl work.
The plant has made exterisiv~ use of inform~tinn on the know-h~a of domeetic ~rid
foreign zinc p1~nC~ gnd ~nterprise~ of alli~d indu~tries.
A comparative analyeie i~ regularly made of a11 technologic~l indicators of
plante, the reaeona are found for the plant'e lagging behind with regard to
individual ind~~atore, and meaeureg are developed fc~r ~liminating the lag.
Queatione releting to Cechnological diecipline and to reducing the loss of
valuable componenta are diacusaed in daily selective operation~ meetinge
vith aection procega engineere. In compulsory monihly meetings of ehift
foremen for all production prace~see and of eection procesa engineere, a
deteiled analyeis ie roade of the month's Work resulta, vi.th�reports by
foremen and proceae engineere~ and euggestiona for improving figurea are
_ diacuseed.
Questions rel~ting to reducing the loes of valuable compoc?enCs nnd to improving
the thoroughness of the utilization of raw material have found reflection in
eyatema for paying workere, in a milieu of socialiet competition. _
The Flant extracta from complex multicomponent raw material 12 elementa and
11 typee of product~. The cost of producing byproducts equals 23.4 percent
of the total output of commercial producta.
But the plant's opportunitiea for improving the thoroughne8e of the utilization
of raw material have been far from exhauated.
The follosring are the mosr important ob~ectivea of the lOth Five-Year Plan
period:
Mastery, ~rith an experimental unit, of a technology far processing co~ercial
copper-and-zinc products from Ural concentration planCs. The solution to this ~
important problem will expand the plant'e raa material base conliderably and
vill increaee the extraction of copper and zinc for the subxnduscry as a Whole.
29
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_ ~bR O~~IC~A~, U3~ ONLY
Compl~?tian ~f th~ r~d~~ign o~ thp ~ulfuric ~~id producCion prnc~ge, by converC-
ing ~il sy~C~ms to ehe eyet~m o# d~~i coneaet of g~~e~ with ineerm~diat~ ~?b-
~orpCion.
Cott~truction of on~ mor~ Waelz furnac~, for the purpo~e enabling the pro-
c~e~ing o4' all currettt a~k~~ gnd cak~~ from dumpg of pg~t ye~re, with g
growth in th~ production of zinc.
Improv~ment of ~y~tems far proce~ging ~inc c~keg gnd W~~1z oxides.
Mod~rnizgCion of filCering equipmenC in hydrnmetgllurgicgl eection~.
~ Improvement of t~~ leaching technology, and other meaeurea.
COPYRIGt1T: Izdatel'stvo Met~liurgiya, TSVETNYYE METALLY, 197g
8831
CSO: 1$21
30 _
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_
~~k UH'FI~IAL USL dNLY
M~TALLUitGY -
UUC: 669.243.052~
WAST~-~'ItBE TECHNOLOGY INTRODUC~D AT I'OBUZH5KIY NICK~L pLANT
Moscow TSV~TNYY~ METALLY in Rueeian No 12, Dec 78 pp 9-13
(Article by 3. P. Kormilitayn, V. D. Linev, A. Ye. Surochkin, p. Onishchin,
and V. A. Nechipoxenko: "Adoption nf Waste-Free Procese gt the Pobuzhekiy
Nickel Plant"~
(TexCj The Pobu~hskiy Nickel Plant (PNZ) in Kirovogradskayg OblaeC wenC into
oppretion in 1913, receiving iCs raw materials from a local oxidized nickel
ore body. The p1anC employe reduction electro~melting of the ore into
- ferronickel in place uf reduction-sulfidi.zing amelting of ore into matte,
which ia traditionally utilized in this country.
Selection of the emelting procesa proceeded from the poesibility of increasing
comprehensivaness of ore utilization by the commercial recovery of subatan-
tial quenCitiea of iron in addition to nickel and cobalC. A positive in- _
fluence was also exerted by auch factors as the poesibility of total elimina-
tion of utilization of ahort-supply metallurgical coke, procesa aimplicity,
and the possibility of producing stack gases which do not contain sulfur
dioxide, that is, producing leas environmental pollution.
The process employed at PNZ (Figure 1) includes the following: preparation
of matzrials for smelting and charging, roasting the charge in rotary tube
. Eurnaces, smelting of the hot matte in large-capacity electric furnaces,
ladle refining of the obtained crude ferronickel from sulfur with molten
soda, then from silicon and chromium in a vertical oxygen converCer with
dinns (acid) lining and from carbon, phoaphorus and residual silicon, sulfur
and chromium in a aimilar converter with magnesite-chromite (baeic) lining.
After the product is poured into 30-50 kg ingota, the metal is reduced with
ferrosilicon and aluminum. Poor ore of the following content, in Fercen-
tages, is proceased:~.o _ ~I~ >~.e >i=i'i'
~~d-a~e Ti_s;3" ~ -
a = p
0,10 0~~ o,~
. o~~-~~
o, o~ o.o~ o, ~ ~
~ ~0 ~ o~ 0
1~0 0~10 0.16
~tl~ ~1~ . � i~0~1
Table 1.
Chemical Compoaition of PNZ Commodity
Output, r (numerator according to
Technical Specifications 48-3-59-15,
denominator actual content)
_ Key�
� 1. Ferronickel -
2. Refined
3. Carbon
4. Foundry
S. Grade
32
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,
- ~0[t 0~~'YCTAL USL ONLY
~'2 .
10 ~y,y~~ nwNr'~"n~ro"~a~y~. , ' , � ' -
_ '~C ~ t . .
~
_ ~ ~ 19 J ~6 ~r~~
m~R ~wqew~dNe~?h
enyMVn~nrnrqra.eN~~ ' N~ Q ~
N 1
� ' ws i! "e~+~p �a
n~ev l8
11~ 10 f - .
. ~ ~ a .
. aw I m~?-a c~i~~~ 20
~~r~
~ . ~ ~
16 ~ � r_>_
raa~r16 j n.
i
i� '
~ a~?,~,r~. 21 �
_
� 20__ J ~e
w,~~
2~,~'i~,`~ 23
/RM'~t/NII~OY MMCJfIl1//~I
~iRure l. Diagram of Procesaing of Oxidized Nickel Ore at Che Pobuzhskiy
Nickel ~1ant
_ Key: �
1. Tube rotary furnace 13. MagneCic aeparation reaidue
- 2. Bucket car 14. Sand
3. Ore heating furnace 15. Cruahed rock
4. Ladle wiCh molten soda 16. Slag
5. Slag car 17. Ferronickel
6. Converter wiCh "acid" 18. Magnetic concentrate and
lining aecondary waste
7. Converter with "basic" 19. Slag to building materials
lining production
8. Ladle with molten aoda 20. Soda slag
9. Casting machine 21. Magnetic aeparation
10. Ore 22. Magnetic concentrate to
11. Limestone convertera
12. Anthracite duet 23. 51ag reaidue to ore storage
24. Oxygen
It ia important to note that the content of trace impuritiea in the ferro-
nickel which are harmful for ateelmaking (Sn, Sb, Pb, Zn, and othera) is
two thirds to half that in grade 1 steel scrap utilized in steelmaking.
At the present time the following, in percentages, is being recovered from
ore refined into ferronickel at PNZ: SS Ni, �70 Co and 50 Fe. Nickel
recovery is more than lOX (abe.) higher than at Ural planta smelting ore
33
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~OEt O~~ICrAL US~ nNLY ~
- into matte~ An estiim~te of compreh~naiv~nea~ o� ueilization ie given for
the average cr�nposiCion of PtQZ oxidized nickel ore (Table 2) for two cases:
- smelting of Chis ore ineo ferrottickel end maete procese emelting~ obtaining
metallic nickel and nobalt.
Table 2. Iteeul.te of Calculaeion of Comprehenai.venesa o� UCilization of
Ore et PMZ
~
1 N~.,~~~.. 3 "
2 % ~ w ~ye
T~:aaa~n~c~u~ upr~eri ,
NI Co P~
4iloor~wAdT~o p~mrr~pou~� ' ~
SNOro mtpporrM~~~ A6 !e 60 A6
fipor�opcr~o ~~Y~nara�
cxrs NNK~~~ r KoO~n?r~ T6 ~4 - 64~4
611~oMS~oACT~o Art~llroro a~ ee 70 7~.1
m PDorex~n� . . . ~ . . . .
Key:
1. Proceea varianCs 4. ProducCion of refined ferro-
2. Recovery nic~Cel
3. Comprehensiveneas of ore 5. Production of inetallic nickel
utilizaCion, x and cobalt
6. ProducCiott of foundry ferro-
nickel _
Installation of an efficient dust-Crapping ayatem w~is provided at PNZ.
Tube furnaee gases are dry-cleaned, while gasea from the electric fur-
nacea and converters are acrubbed. Tube furnace duat ia return-cycle.
Table 3 contains figures on the gae scrubbing system employed on the
principal metallurgical equipment, their preaent achieved working ef-
ficiency, and compoaition of waste gases.
In all case; gases e~ected into the atmoaphere conCain lesa than 0.3 g/nm3 of nar-
ticLlaee:~, whic; is lower than the maximum allowed by health atandarda. ~
The plant operates with fully recirculating water aupply and has two
water cycles: conditionally pure, and dirty. In the first cycle (857: of
the entire water balance) water used to cool the components of inetallurgi-
cal furnacea and inatallationa (cooling water ~ackets and coolers of
electric furnaces, electrostaCic eprayera and tuyerea of converters~ -
oxygen station equipment) ia cooled in a cooling tower prior to recyclin~ and
ie subjected to chemical aoftening and stabiliza[ion. The second cycle
services the wet scrubbing systems. All water contaminated by nickel-con-
taining duat is collected and aent to a thickener. The upper drainoff from
_ the thickener, after cooling in the cooling tower, is recycled. The lower
drainoff is clarified in settling ponds and then cooled, while soiid aus- -
pended matter ie collected in these ponds and periodically (oace every
34
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_
�
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- Table 3. I'NG G~e Scrubbittg SyeCems and Chemical Composi~ion o� Gases
~~ecCed InCo Ctie ACmoephere from Che principal MeCallurgical
~quipment
1 2 . 3 4 Ca~r~r r~~os,
~~e ~ r ' S ~
a~iri wNrir~ii Cs~~~ rnoo~~nrra K~
, ~ CO E~
. ~ , , . . kq . , , y~x
b
T~yMMwa~~r Ll~taouw ~nn~pal 9Y~7 I b,l~~I~.d 0~0~4 6~1-14~6
b tk-in~xtpo~r~Mrp~ ~~03 O,Od~ I ll,l
t1
s~.r,pona...a.� 9onoo~om.e~nu~ ~ua oO.~a ~~,s-~o~~ � o-e.9 a~a_~9~1 0-1,7
,~w Na aoA~YOKpYQ cKpY6� 1~3 , 8,~- ~.6 ~
. . dep~,ryp8ynehrn~~
~uonpowu~r~ar- ~ ' _
7 KaOnlotA~ait~a? . .
1
IWrr~ptop~ .K~e� BoAoopom~ertiA ~~~a 0,!-a.e o-0,~ 1e-10,a 0.0~4
aob crrAw~ p~~pr� :oA^Ty96ylIfYTNY~ , Q~4 O.OS ~0� 1
- ~rpo~~rr~ g ~a~onpoau~r~n?-
K~nnearAUirr~a~ 07.76 -
sxo~iro~~aeta~A
i 12 1-~~0.6 0.9-1.9 I~s-70.4 0.00
A~Otr~poup~ � 'T~ 0~3~ 1J~6
9 ~ . ~ . ' � �
.
� ii ~~easH~~-~~t~p~u roaq~tTputrl~ s s~ar~~~ruu-eptA~~a ia~ar~a. � . �
~ Key : ~
1. Metallurgical equipment 7. Electric smelting furnacea
2. Gas ecrubbing process 8. "Acid" refining stgge con- -
3. Gas acrubbing efficiency, ~ verters
4. Composition of gasea, 9;* 9. "Basic" refining stage con-
S. S02 (according to figures verters -
of the State Scientific 10. Cyclone dust separators, -
Resesrch Inatitute for In- electrostatic precipitatora
dustrial and Health Gas 11. Sprinkler-containing gas
Purification) duct, wet scrubber, turbulent
6. Tube furnaces gas scrubber, steam tran
12. Sprinkler-containing gas duct, .
turbulent gas scrubber, s team
_ * In the numerator concentration in- trap
terval, in the denominator average
values
2 or 3 years) removed, in the summer, and fed to the start of the process
to be refined together with ore. Thanks to the closed water circulation
- cycle~ additional fresh water is required (7.1X of total conaumption) only
to replace evaporation losses.
35
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_
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~liminntion of discharge of harm�ul po1luC~nCs inCo the air and waCer ;nade
it possib].e Co locaCe Che p1anC in the ceneer of a settled, fertile fa~rm-
ing area. Since the plant has been in operation there has not been reaorded
a eingle ineCance of adverae effect by the metallurgical producCion on the
ecology of the plant's environmenC. ~
The work force at PNZ, togeCher with apecialisCa from the Gipronikel' In-
sCiCuCe, have expended a considerable effort to increase metal recovery
and Co develop a waste-free technology.
5tudy of the nickel requirements of the nation's economy led to the necea-
sity of designing and installing a process for produc3.ng new grades of
ferronickel with increased carbon, silicon and chromium content, and cor-
respondingly increased the number of customers. It is preferable to utilize
carbon ferronickel Co produce a large number of grades of low-and medium-
alloy steels, while �oundry ferronickel is extensively employed in machine
- Coo1 building for producing higr-quality iron castings (see Tab1e 1).
'Clte process for producing new kinds of ferronickel has made iC possible
either partially or totally to eliminate oxygen conversion and acidification
and requires only additional soda treatment. Thia results in a 7-20% in-
crease in recovery of iron and a 0.4-4% increase in nickel and cobalt
_ recovery, and in addition operating costs are reduced. Utilization of
silicon, carbon and chromium sharply increases the comprehensiveness of
ore processing (see Table 2), which reaches al~mosC 74% with utilization of
ferronickel to produce foundry metal.
Efficiency of production at PNZ has improved substantially since installation
of the process for refining secondary nickel-containing metallic waste in
_ oxygen converters. The process takes place autogenously with the excess
heat in the acid-stage converters, hvat generated by the oxidation of
silicon and chromium. From 95 to 96% of the nickel and more than 70% of
the iron is recovered as commodity out:put. The volume of processing of
secondary materials can reach 35% of �he crude ferronickel by weight with- '
out disturbing process conditions. In practical ~erms consumption of
secondary metal waste has steadily decreaseci from 1973 through 1977 (from
22.5 to 7.9%), and the plant sees substantiail reserve potential in this
regard. We muat note that in processirig such nickel-containing waste in
matte converters at other nickel enterprise;i, the iron is eritirely. lost.
A magnetic separation unit was installed and put into operation at the
plant~in 1977 for final recovery of ferroniclcel inclusions trapped in con-
verCer and soda slags (Figure 2).
The magnetic concentrate, recovered with the aid of a magnetic disk, over-
head electromagnet and an electromagnetic sheave, contains 1-3% Ni + Co and
is returned to the com~erters for processing, while the separation re~ects
are utilized in ore electrosmelting, replacing a portion of the limestone.
The introduction of magnetic separation and complete cycling of converter
and soda slage made it posaible to increase start-to-finish recovery of -
36
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~Ok Ut~'~ICIAL U5L ONt~Y
R 1 �
2 ~t~t0%/ I
/~OArt1
' r~~IMN
~ IIJ~~eJe~t+?~d s~tRn er~rc~t ~
' W
~~lvs,~e~
Meme~ 4 e~�i 5
~
d+tOnw
,~�~?r?otMa�~rd 6 ~
Ikt~+vrm?~ , r?RO/
i ~nn
g Aa,?Redo~
~ q~r~~u~e
, . , �
9 an
. ' ~ ~?nw
,i~ann~~
m~ LO
I'k~
MW~
. .,plaow 12
- N~~"r?~r 11 .
Figure 2. Cunverter Slag Magnetic Separation Proceg~ Ui~grgm
Kev: -
1. Slag 7. Magnetic product
2. Jaw cr~sher 8. Roll crushing milt -
3. Overhead electromagnet 9. Screen
- 4. Metal acrap 10. Electromagnetic drum
5. Toothed-roll crueher 11. Magnetic producta
6. ~lectromag~et ehpave 12. Rejects
Ni + Co by 1.~7 and to reduce irrecoverable losses of these metala by 0.8X.
At the present time full-scale testiag is in progre~s on final proceseing
of n portion of molten converter slage in elecCric ore smelting furnaces,
bypassing magnetic separation.
in 1977 the plant began productian of construction crushed rock and sand of
electric mel[ing waste slaga. Slags containing 0.06x Ni, lOX Pe, 52x Si02 _
and 22X Ca0 in molten form are hauled to the slag ysrd. As it cools do~m~
the slag layer is aprinkled with water, which causes it to crack and split,
so that the pile can be worked with excavators. Jaw crushing and acreening
the slag produces good-quality crushed rock for road eonstruceion, con-
forming to GOST 5578-65, and sand. The material is of the folloWing size:
-7U+40 mm; -40+20 aun; -20+5 mm, and -5 mm. Sincc this unit went into opera-
tion all slag produced in electric ore amelting has been utilized~ follow-
inq processing, i~ construction. Since that time the production process at
PNZ has been practically totally waste-free.
37
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~Olt O~~tCIAL U5~ dNLY
Minim~l rpquirpd capiC~L outl~y~ help~d gchi~v~ guch ~ r~pid inCOrporgCion
df ging proc~~~ing with ~ Compgretively eimple equipment and proc~~g
~rranq~mpnt.
A~~ording tn ~tudi~~ ~ondu~C~d gC th~ L~nit~gr~d CnngCructiott ~ngine~ring In-
~titut~ gnd confirm~d by Che op~r~ting perfurmgnc~ of ~~emi-full-~c~le
uniC wiCh ~n output C~pgC~CY df 80 Con~ per dgy, ~emene of grad~~ 16U-2d0
ig obt~in~d whpn Che ~1gg ig ground e~ -U.nS mm ~nd wtCh Ch~ ~ddition of
15-20z ~~Civ~ting agent (pdrtland cement, 1im~, etc). ApproximgCely
604~000 tone of nement can b~ produ~ed ~nnuglly from PN~ slggs. At the ~gme
tim~ remaining ferronickel inclueione can be recov~red by magnetia or air
gepar~ti~n in th~ proce~~ of grinding the g1ag~.
Wdrk i~ to be continued in the fnllowing gregs in order ta achieve further =
increase in the compreheneivenese of utiliz~tion of raw maeeriale and to
increnee plgnt prof itability:
incregse in irdn recovery, primarily by increa~ing the percenCage
share of foundry ferronickel production;
_ the eearch for Weys to obtain useful employment of cobalt contained
in the ferronickel;
organization of cement production baeed on electric melCing slage;
recovery of ferronickel incluaions from the elags.
COPYRICHT: I2DATEL'STVO "METALLURGIYA", "TSVETNYYE METALLY", 1978
30 24
CSO: 1821
, 38
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I
~l~Et d~F'ICIAL U5~ dNLY
MLTALtU1tGY
~ UDC: 669.33.052
LOSSES OF VALUA$LE CON5TITUENTS IN COPPER REI~INING REDUCLD
Mo~cow TSt1~1'NYYL M~TALLY in Ruseian No 12, Uec 1978 pp 19-21 .
[Article by N. p. Shubin: "Lossea of Valuable Componenta Iteduced at
UrelelekCromed' Combine"]
(Text] A campaign to reduce losaes of v~luable component~ at all atages
of production, more compreheneive utilization of raw maCeriale and develop-
~ent of production without waste hae become one of the leading trends in
efforts to improve the economic effectiveness of this enterprise.
Efforts by the combine's work force are concentrated in the following areas. _
Imrrovement in the proceas of beneficiation of Gumeshevskaya ore. At the
end of 1976~ after the ore was played out at the Pyahminskiy Mine, the -
concentration mill was fully converted over to procesaing of Gumeshevskaya
ore, which aharply differs in character from the ore previously procesaed.
The people at the combine, working together with scientists from the
Unipromed' Institute, designed and in 1977 incorporated an improved process -
of concentrating Gumiehevsk~ya ore under full water cycling conditions.
The diagram in Figure 1 includes bulk flotation, fining of bulk concentrate, -
with subaequent separation of copper and iron aulfides and magnetic separa-
tion of bulk flotation residue.
Following are the ore flotation reagent and process figures:
Size yield 0.074 mm, percentage of ore ...........60-65
- Size yield 0.014 mm, percentage of bulk concentration ...........85-90
Buzyl xanthate consumption, g/t:
~ bulk rougher flotation ...........35-40
check flotation ..................25-30
- copper check flotation 8-10
Foaming agent conaumption, g/t:
bulk rou~er flotation ............15-20
check flotation 5-10
Lime consumption on copper concentrate second cleaning flotation, kg/t...4-5
39
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~OE~ n~~ICIAL U5~ ONLY
oi
~ ' ' !A VtMt/d 2
~ A's~tand~o~ nsqv~ 3 ~
4 ~v ~n m 5 ~ '
6 tr?wc~rw
mMC~ Noi~wn,,va~
ar~s 7�
= S 8 Mtai?m~m~vn
_ ~pi,wn~ooa? .
4 ~ 1 9 Qereo~w-r.~k-rmN
lOl~~ vmoqrs ;~ro~
d
Q ~p'~,~11 -
~ Pa imar
~ M S ~ ~,?pivqennt~ 1,~
~ , ~
13 a~?emveMVe ~
~I~eNCvai N a~ amo w
14 a
_ � 4 ~rA � ~ 5 x~c~co,w
6 tiwrcm~von y~nr ~iwnpv~m? ~raoyv~
~sw S .~16
.
IOlMdQ1/M0I IdqAOqfAI 17//~'pN((nyq?~
~ .
~Aonwr 5 Il~i~9,arogan~o,rrlg -
_ Figure 1. Gumeshevakaya Ore Concentration Process Flow Diagram
Key:
1. Ore 10. Second cleaning flotation
2. Grinding 11. Mi.ne backfilling
3. Bulk flotation 12. Bulk concentrate
4. Concentrate 13. Fining
5. R~sidue 14. Copper rougher flotation
6. First cleaning flotation 15. Check flotation
7. Magnetic separation 16. Residue (pyrite concentrate)
8. Magnetite concentrate 17. Concentrate (intermediate product)
9. Final rejects 18. Copper concentrate
40
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~d~ d~'~ICtAL US~ ONLY �
In order Cn increnge extraGeion nf ir~n frdm bulk finegtion regidue, gn
improv~d PllM-pp-gb/zSU ~epgrntor (wieh semi~dunt~rflc~w b~th) w~~ in~eglled
in pl~ce nf Che ~xi~Cin~ P~M-2 mggn~riG sep~r~tdrg.
- Uuring Gh~ p~rind nf e~gCing Ch~ new prdc~g~ ~rr~ng~menC, Ch~ En1lc~wing
wer~ obeain~d from dre cdntaining 1.15~ Capper, up Co 7% gulfur ~nd 3~
~Q3n4~ copp~r cdn~~ntr~te with 22.6~ copp~r, with 8g.25~ copp~r r~cov~ry;
pyrit~ coc~c~ntraC~ wieh r~cnvery of >SOY 5, ~nd iron cdnc~ntrat~~ with -
recovery of >619' ~e.
If we eongider that th~ mi11'~ fingl re~ecCS are uged gs chegp mine beckfill
material, the existing proces~ of cone~ner~Cion of Gumpghevgkgya nre mey
- constitute a pdgieive ~x~mple in the dev~lopmene of wgste-fr~e produCCion.
'~he process was adopt~d wiChduC cnpital ouClgyg and withnuC subgtaneial
re~rrengement of equipment, which made it possible to put the new prncess
into operaCidn in a very short period of time.
5eCting up producCion of refined nickel sulfate. Prior Co adoption of
the new procesa, in the production of Copper gulfate nickel was recovered
in copper-nickel salts and crude nickel sulfate, which were shipped to
nickel plants in the form of production process Cailings.
The people aC the combine came up wiCh a process of obtaining commercial
nickel sulfate of grades NS-1 and NS-0, according to COST 2665-73, from
crude crude nickel sulfate containing (percentages): 18 Ni; 0.5 Cu; 0.1 Fe;
0.2 HZSO4.
The process of obtaining refined nickel sulfate (Figure 2) includes the
following: washing out crude nickel sulfate from sulfuric acid, dissolving
it (concentration Ni 100-110 g/1), cleaning copper and iron from the
solution with separated chalk, and solution filtration. Cake from the
filters~ composition~ in percentages: 9.0 Ni; 0.5 Cu; 0.1 I~e; 80 (CaCOg+ -
Ca04)) is ahipped to nickel planta~ and the refined solution, following
acidification with sulfuric acid to a conc~ntration of ?-5 g/1, ie evaporated
(nickel concentration 200 g/1), cryatallized (at 26-28�C) and, following
centrifuge separation from the mother liquor, ia shipped to the customer.
T'iie mother liquor (120-135 g/1 Ni), afCer 20 cycles, is flame-evaporated Co
obtain nick~l salts, which are shipped to nickel plants. Commercial produc-
tion of refined nickel sulfate began in 1978.
Adoption of an installation for processing refining furnace cobbings by the
tlotacL.n method. Formerly copper and the noble metals in refining furnace
cobbings were shipped as production waste to copper smelters for further
processing.
Recovery of copper and noble metals from the cobbings was unsa[isfactory,
particularly in processing refractory chrome-magnesite cobbings,as a
result of difficulty in marketing them.
41
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_ ~ox o~~~ctar, vs~ arrLY
_ I ed~ti ~wRr~.arT~~ 1
� ~ ~ ' ,
3 ~'aw~A?~rmn, '
a
~o, ~ 4
. ~S NMN~ RO
t/AR0 OM~'IA~11N1~0 6
~ ~
AUK ~ Mr �
~ .APS/dxl~ , ,
Poevn 9 _
RM~or ,?~Na~ 1p.
~irpa Aar~w 11 ~
, '
~?~rr~ 12 .
~ ,K,~, 13
~+~14 ~ 15
~ 16
Meaa~17
Figure 2. Process Flow Diagram for Obtaining Refin~d Nickel Sulfate
Key:
1. Crude nickel sulfate 10. Acidification
2. Washing 11. Evaporation
3. Condensate, ateam, air 12. Crystallization
4. Dissolving 13. Centrifugation
S. S~eparated chalk~ steam, air 14. Nickel sulfate
6. Copper and iran removal 15. Mother liquor
7. Filtration 16. Flame Evaporation
8. Cake for nickel plants 17. Nickel ealts
9. Solution
The people at the combine designed and ingtalled a aystem of concentrating
refining furnace cobbings by the flotation method (Figure 3).
- 42
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~Olt O~~i~tAL U5~ dNLY
1
Z l~
t~11~lMNl '
r Or'MNMOM MI~INOM A0~lO ~
M4
" t etMOavoR Nt ~r oa~e n~ 5
� ~r ~r M 6 4 0
ov~ Mo~
7
Kiw~f A~Me~ $
~ e w 4 -
~ ~ ~ M~
- A~'~'nw~r 10 ,
Figure 3. process ~low Diagram of Conc~ntr~tion of Refining Furnace Cobbittgs
K~y:
_ 1. Cobbinge 6. Concentrate
2. Cruehing and grinding 7. Cleaning flotation
3. Firet copper rougher g. Check flotation
� flotation 9. Copper conc~ntrate
4. Residue 10. I~inal re3ecCs
S. Second copper rougher
flotation -
~ollowing are cobbings flotation reagent and process figures:
Size yield 0.074 mm, r ...............75
Butyl xanthate consumption, g/t:
first rougher flotation ..............240
second rougher flotation .............180
- check flotation ......................120
Pine oil conaumpt~c+n, g/t:
first rougher ri~~--rton ..............45
secon~d rougher flota�on .............30 _
check flotation ......................30
Lime conaumption in first rougher
flotation, g/t .......................1-2
Wt~en the cobbings concentration procesa Was in full operation~ the obtained
copper concentrate contained >25X Cu with recovery of >90~ Cu.
Refining furnace cobbings are presently being processed at the plant on a
regular basis~ and they are adjusting the process to optimal concentration
43
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~dEt d~~ICIAL US~ ONLY
~1
/ ,?tn~e~r ~
, 3 ~ e Md~
4 ~rseed Rean~
w~adW ee~eNn;detnanxbirq~$
~ rK~eeNe " �t M0`~' , -
~0q~' 6 d~e.+a g
1~+'n,ae~o~?t~
- ~AM
AI1t /Mla/ 8 ' ~'~M?~
/'~i?eq
M/A /710 ,r~Atll~1~/ ~ 1~
�I /N YY A'O 1~. , '
Mer~?n,~ a~,~po~rar 13
12 I
,
~ M~ 14 ,+~'e ~ 16 -
~rrr
Pigure 4. Mednogorek Converter Slag Concentration Procees
Key:
1. 51ag 9. Butyl xanthate, 20 g/t,
2. Three-stege crushing pine oil 20 g/t =
3. Grinding 10. Second copper rougher flota-
4. Sizing tion
5. Butyl xanthate, 100 g/t 11. I~iret rec~.eaning
6. Pine o~il~ 30 g/t 12. Second recleaning
7. Firat copper rougher 13. Magnetic separation
flotation 14. Copper concentrate
8. Concentrate fining 15. Iron concentrate
16. Final rej ects
conditions. At the same time they are atudying Ways to process other
metallurgical aaste material by the flotation method.
Adoption of all the above-enumerated measures at the coIDbine has made it pos-
sible to achieve exceltent indices in ore concentration. to set up addi-
tional production of pyrite concentrate~ t o increase finished copper yield,
_ and to set up production of refined nickel sulfate.
At the present time eavings of more than 400,000 rubles have been achieved
from adoption of these meaeures~ aad savinga will increase to 800,000 rubles
When equipment to obtain refined nickel eulfate, etc is producing at full
designed capacity.
44
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~OIt d~~ICIAL U5~ dNLY
nC inter~~t nr~ rha r~sule~ df fu11-~~g1~ ea~t~ on Mednogor~k eonv~rt~r
slag Cancener~tion by th~ flotation meChod (I~igur~ 4), conduct~d in 1966
~t Ch~ Pyehma Conc~ntr~tion Mi11.
As g reaulC of th~~~ fU11-~c~l~ t~~tg~ 745 Cong nf ~l~g w~~ proceg~ed, con-
taining (percentag~g): 1.S Cu; 2.2 S; 45.S
Wh~n th~ sl~g wgs ground tn 88~ giz~ n.074 mm~ and wirh ~ butyl xanthate
nonsumption of 120 g/t and pine nil congumption of 50 g/t, they obCained
a copper concentraCe contgining 12~ Cu, with 72~ copper recovery, and iron
product (withouC r~cleaning) at 50.3~ wieh 42.29: r~covery.
It would evidenCly be expedi~nt Co proce~g locally, at conc~ntrgCion mills, _
metnllurgical prnduction wast~ of this type on hand ~t ~nterpriget~.
COPYEtICHT: IZDATEL'STVO "METALLURCIYA", "TgN~TNYYE METALLY", 19~8
3024
CSO: 1~21
45
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METALLUROY
UDC: 669.715t621.74
EFFECTIVENESS OF A~~'INING IN AN MHD T1t0UGH
r
Moscow T3VETNYYI: METALLY in Ruesian No 12, Dec 78 pp 66-68
~Article by B. I. Bondarev, I. V. Shvetsov, and V. D. Miehchenko: "In-
veetigation of EffecCivenese of Refining in an MHD Trough"j
(Text~ Degaesing of ine1CS ie extensively employed for obtaining semi-
finished producte of aluminum alloys. However, staCic (without forced
_ mixing) degassing of large quanCities of inetal in a mixer is insufficiently
effective as a reault of the effect of inetalloatatic preseure.
Employment of acCive mixing of a melt during degaesing in a mixer makes it
possible to achieve a subaCantial decreaee in poroaity volume. In partic-
ular, typical porosity values Vp in D1 alloy 540 mm diemeter ingota are
equal to 0.2-0.3X, and no appreciable decrease in ga8 content (G) is observed.
The reeults of an inepectiott of ingote cast with employment of atatic
degassing (numerator) and with refining by traditional methoda (denominator)
are ae folloWS:
(1) M.Kv�rprc*n~ .
ei+u . . . . . � . . . t 11 1Jt tV
0.1~ 0.f4 0.f9 0�14
~2~ T� e~y100 ~ Alt. s.T ~f b~;
(3) Ko~RawetT ,misM -
Ya�Ken~6..�f. 1.� i.~i i.~s
,~aw......... 3.a~ ~,~8 3;a- i:sr
% . . , , . , , , 0.64 o.ei o.~a o.~o
3;di 3~ 3.T _
e.,., . ss.~ s~..
Ti,3 ts.~ ii
~i
Key:
1. Macrostructure, points 3. Ultr,asonic oacillations attenuation -
2. G, cm2/100 g ~actor, db/cm
_ Mixing tak~s place not eo much due to an increase in the mass transfer of
hydrogea during movement tosiard the eurface by the lo~rer layers of the melt
ae it occurs as a result of flotation of oxide inclusioas containing
hydrogen bubbles of a negative radius of curvature. As a consequence of
moc+e comp~]ete r~val of oxides, Which include coolecular hydrogen, ia a aharp
decreage ia poroeity volume ae a result of canaiderably decreasictg the number
of centas of pore generation.
. 46
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It wa~ previdualy ~hdwn thnC in che prnces~ df gCnCiC d~gg~ging, dxide
in~lueione are "activated" in the lower ~gy~r~ nf the meltil Ch~t i~~
n?dl~cul~r hydrdgen i~ rclnne~d in ~he e~pillnry eh~nn~elg nf nanmet~lli~ in-~
~1u~i~ng. Thi~ tnke~ p1a~~ und~r ~~ndieiong of redu~~d pr~ggur~ and thE
d~cr~e~~ in hydre~en ~nlubility Cau~~d by iC, Co v~1u~g law~r Ch~n ggg
content in rh~ invegtigat~d m~1t bndy. A compgri~nn nf hydragen (H) edntettE~
porosity gp gnd grgin gi~e (d) d� ingnt~ dbC~ined with emp~dym~nC of
tr~dttie~n~l r~fining meChndg in a melCin~-casCing unie, gtgeic d~g~,~ing
in a mix~r gnd de~ag~ing with fore~d mixing with a g~g-dyngmic pump
(GDN) confirm~ ehe ph~nomendn of "activaeion" of oxide~ in g mplt during
degagsing (~ee tgble).
Quality df 540 mm Uigmeter D1 A11dy Ingot~ It~fined by bif~~r~nt M~Chods
(typical valueg)
~
M
~1') $ yt ~ (5)
P~~~rNpo~~~~~ M
a' . ~i
Tvut�a�o~.o.~2). . ~o oat~~ oos~ t-tt
~oii~~i ~ IA 0 1!- 0/- tt-ttt
E, i ~ 5, e
Te xe, t nep~r~m~
.~..~r rAH.(4). . o i~- o s- tt-tv
3, b,~
Key:
1. Refining 4. 5ame, with gas-dynamic pump
2. Traditional mixing
3. Static degasaing S. Points
On~ important consequence of "activation" of oxides is appearance in the
melt of additional pore formation centere, which leads to a decreas~ in
the cricical hydrogen c-~~ant values, beloW which poroaity does not develop.
With an identical volun~e ~f porosity in degassed metal, it is easential to
achieve higher degre~s of ga~ removal th~n in undeg~ssed metgl. Poro~ity
of ~ndegas~ed metal provea to be somewhat greater than dega~eed metal with
identical hydrogen content. It Would seem expedienrZ to perform refining
in auch a manner that additional centers of pore generation do not form in
the metal. Diaperaed oxides remaining in the melt, which do not contain
molecular hydrogen, behave during hot Working as normal intermetallide solid
phaeea~ and defects are not formed in the ingots and in deformed semi-
manufactures.
One of the possible Ways to improve the quality of castings and deformed
semimanufactures is refining in an mhd trough With employment of inetallic
gas abaorbera and multilayer filtr~tion through gauze filters. For com-
pnrison With other refining inethods We cast 540 mm diameter ingots of D1
nllay at a rate of 26 tmn/min at 700�C (ingot aald height 180 mm) With the
melt processed in an mhd trough (Figure 1). A gas absorber aas placed in
the trough channel. Folloaing degassing~ the melt is filtered through a
gauze filter.
47
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,
~ 1 -
~
~
i
~ � r
~ ~ r .
r ~ r `
rr `
I ~
F~gur~ 1. Ingot C~~ting bi~gram
Key:
1. Mix~r with melt 4. Spout WiCh filt~ring d~vice
2. 1~Mb trough S. Ingot mold
3. Pesnage c~ith degaeeing 6. Ingot
dpvice
Th~ melt uas ?repared in a gas furnace, tregCed with flux in an elactric
mixer, fed through th~ mhd trough pasgage into a epout and then through a
gpout plug inKo a distribution screen eituated in the ingot mold. The melt's
caet~lloatatic head at the level of the epout~ provided by the mhd trough,
- rune to 0.5 m. The trough paeeage conCains a degaeeing device, the prin-
cipal component of Which is a getter.
~?,x
~l �
i
~ a relative elongation
~ ' and reduction,
~ x ~S specific viscoeity;
~7 ~ ( ) refining
- ~~~--~~-o-~ by traditional methods;
~ refining in
an mhd tYOUgh;
' c--s,~x--~,
~G?~'/~
~ ~
{9
~�~D ~ 410171~ ~
Figure 2. influence of Refining in an l4iD Trough on Plasticity of Ingota
, a~ Ai~gted Temperatures
48 `
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l~c)It ctl~ l~ I f; I AI, II;;I; ~)NI,Y
A reculi~~rity o~ the dynumicg nf movcmettt nf ehe mele in ~~n inclined mhd
trough li~~ in thr_ E.~Ct th~e ehe low~r lnyers of the mele in ehe rrough gre
d i~pl~c~d u~,wurd by m~ans nf electromagn~tic forceg, while the upper layers
digplgc~ downwnrd uttder the effeCr of gr~vity; ehis inC~nsifieg inC~r~ctinn
between me1C nnd gGtter due to repe~eed cdnC~cC. It~diseribueion nf hydrogen
beCween molt~n metal ~nd g~tter engur~~ extrem~ely Low end hydrogen cantent
in th~ me1t. 7'hc ~chi~ved d~gree nf deg~ssing c~n be varied ~croes a bro~d
r~~n~e by the qu~nCity of getter ~nd ies surface area. AC the same time, as
hydrogen p~sges from the melt into the getter, the latter partially dissolves,
with iC~ contenC in the melt incregsing to d.01~. Thp deggssed me1t, under
meC~11v5C~tCic h~nd up eo 0.5 m, enCers th~ filter d~vic~, the princip~l
- compnnent df which is n double-layer~d gguze filt~r with 0.6 x 0.6 mm mesh.
T1~e regult~ of comparnCive exnmineCion~ of ittgots ~CtesC Co Che high ef-
~ectivenegs df refining in nn mhd trdugh:
P~~~n~pouM~~ (HJ��~ ew~/100 r M~ fl�~ a n~~s~~ Y. M~~cpoctPYKrYp~ ~6~
~Z~ Tp~p~q~or~o~ ~~~4-O.Jf
. ~96-0.~ 0~6-0.8 Bers~oe~Kpynroroi~ps~
8 MP �eonce ~~I~-O.fA . 8
A ~ ~3T-0,1j ~ ~~4-0.~ P~~MO~epeu.fA06ya~pN1~ ~ ~
rlb~~ u~nr~Q1tTD~~~ MQf:~ 6 6anno~-p~cTpi~ MiKtNY~A~NYl1. . .
~ B~sen~tene pe~yn?r~r~ onpeAeneH~~ wqopoA~ MlTOAOY nepwro ny~~p?K~, ~
fll/YlN~TlA!-YlTOAOY ~~K1'yYN01'0 NsfplO~. ~
Key:
1. Refining 6. MacrosCrucrure
2. 'Crnditionnl 7. L~rge-grain zones
3. In an mhd trough 3. Uniform, globular
4. Points 9. 1 point no etching; 5 points
S. Relative maximum etching ~
10. The numerator contains results of
determining hydroger. by the firsC
bubble method, and the danominator -
by the vacuum heating method
One Import~nt fe.~ture oE deqaavtng with a metallic getter is the removal
c~f IiydroKen witt~out its eransition to a mole~ular state, which excludes the
possibility of "actlvation" of oxide particles and an increased tendency
_ uE tl~e me1C toward vaPorization. No porosiCy was detected with deep etch-
In~; of test ir~;ots. A no less significant advantage of this method ~he
C;~ct [hat one obt:~ins a uniform structure which does not require ~I;:~ em-
ploymen[ of additional modification with master alloys. The getter, dissolving
tn the melt, gradually passes into the crystallizing ingot. Thus there oc-
c:urs continuous modif ication of the melt, which has grester effectivenes::
tl~:~n modification in the furnace and mixer.
in rl~~stic ch~rnceeristics, at hot working temperature (Figure 2a, b), in-
- };ots with refining in an mhd trough possess a clear superiority over
traditional methods of refining. The increase in plasticity is connected
no[ only with a decrease in gas content but also removal of oxide inclusions
, during Eiltration tl~rough a double 0.6 x 0.6 mm glass gauze filter.
49
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Summnrizing the nbove, we can noCe Chat refining in an mhd trough by the
getter degassing method and mulCi3.ayer filCration is a promising trend
in seeking to solve the problem of incre~sing metal purity. Refining in
gn mhd Crough is equal in effecCivenesa Co degassing in a mixer and can
_ be recommended for extensiv~: commercial adoption.
- FOOTNOTES
1. B. I. I3ondarev, I. V. Shvetsov, G. V. Cherepok, et al, in Che book
"Metnllovedeniye i Cekhnologiya legkikh ap].avov" [Physical Metallurgy
and Technology of Light Alloys], Moscow, Nauka, 1976, pp 24-29.
2. V. I, Yakovlev, G. A. BalakhonCsev, B. T. Bondarev, et al, TSVETNYYE
_ MI:TALLY, No 1, 1974, pp 64-67.
COPYRIGHT: IZDATEL'STVO "METALLURGIYA", "TsVETNYYE METALLY", 1978 -
3024
CSO: 1821
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~ok oNrtcrnt, ust~ oNt.Y -
?ta:rnt.w~~ts~tKc, ~.~ut:~r~i:N~r
I~ IR5'I' ALIrUNtON CONI~'CR~~ZC~ ON I'120UUCT n~LIABILITY
Moscow V()~'itOSY CKc2NOMIKI in Rug~ian No 1, Jan ~9 p 27
(Art[cle by V. Lo~achev: "Reli~bility of t~nufacturing Processes ~nd Im-
~~rovcment of rroduct ~u~litY"j -
('f~xrl '1'lie }~'Irst All-Union SciettCific-Tect~niC~l Cnnference on the problem
of Itrlt;~bllity ~f Production Complexes (using the m~ychine building branches
_ :i~;;in ex~rnnle) wn~ hcld in Uf~ in 5eptember 1978, organized by the All-Union
f:~unril oE ScientiEic and Technical 5ocieties, Che U55R CounciL of Ministers
St:~te Comm[ttee on StanJ~nrds, the U5SR Ministry of Iligher and 5econdary
S~~ecializeJ ~clucntion, the Bashkir CPSU Oblast Cocranittee, the Central Board
of the Scientific-Technical Society of the Machine Building Industry, and
the R~~shkir Oblast Council of 5cientific-Technical SocieCies, ~t the Ufa
Avintion tnstitute imeni 5. Ordzhnnikidze.
i';~P~~r:; nn tlie Eollowing topics were discussed at the conference: forming of
- ~~u:ility and reliability indicators for products and manufacturing processes;
- rrliabiltty of a production complex as a complex dynamic system; standardiza-
tion in tt~e area of reliability of production systems; comprehensive evalua-
tion of level of technological reliabiliCy; methods of quality and reliabili-
ty control; metrological aspects of.the problem of reliability, etc.
'1'he "Principal t)irections of U~veloprnent of the USSR National Cconomy in
197fi-i980" and the laW "On Che State Plan of Uevelopment of the USSR National .
E:conomy in 1976-1980" devote considerable attenCion to improving product
~~u:~ltty ;~nd reli.~bility .hnd increased production efficiency. Production
rc~m~~lr.x~~G, which r~re desiRnated for manufacture of products at all stages, -
~Iic~ulJ enSUre st.nblc formation of all product parameters, that is, possess
:i I~i~;li dey;rcr of reli.7bility. 5oviet science and production have achieved
~~ert;~ir. retiults in ~nsurin~ reliability of Cechnological or production com-
plexer;. Advanced manufacturing processes are extensively utilized, various
tync~~ of control :ind monitoring of production are used to fmprove quality
rind tit.~bility of manufacturing processes, and automated production control
~ystemx a~5 well .~s comprehensive product quality control systems are being
(ncorp~rated. New areas have be:en developed: evaluation of technological
_ reli~b[lity of equipment, strengthening technology, and technological suc-
cesRton.
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~0~ O~~ICrAL U5~ ONLY -
Neverth~el~a~ muCh ~till remning tn be dntte in ehi~ nr~~. Th~ manufnreuring
prnc~~s n~ ~ complex dyn~miC gygCpm h~~ noC been ex~min~d frdm Che po~ition
oE reliabiliCy. There i~ ~ lark of ineehodg nf opeimizarinn ~f this proc~~s,
~nd Erc~qu~ntly Gogt~ rise when securing ~ high degree nf r~l3abiliey df
manufaceured productr~. MeChad~ df deC~rmining seandarda nttd predicting
_ epligbility indi~eg for proCe~~ eq~ipm~nC hgve be~n in~uffiCiently el~bor~Ced,
m~Chodb of testing production ~dmplexe~ hav~ been ~Candgrdiz~d, gnd ther~ i~
nd plnbornred ~ygtem of m~nuf~cCuring prnce~g reli~bil~ir~r ~nnCrdl.
' 'Che cnnf~er~ttCe edngidered th~~ follnwing egsential for succesgful ~CCOmpligh-
m~nt the tngks nf gppeding up scienCific ~nd ee~hnoingical progregg gnd
nn thi~ bnBig increa~ing produCeiviCy, improving qualiCy and relinbiliCy of
mnchine building producC~: in deCprmining prittcipnl dir~~tions in the ere~
of incre~~ing r~t.i~bility nf praiuction compl~x~s, a r~commendatidn should
be qiv~n to Che US5R Acgdemy of 5ciencpg, USSR Coun~il of Mini~C~rs 5rate
CnmmiCtee on Stand~rd~ nnd the SC~te CommitCee of Che U55K Council of
Mini~ters un Science and Ter.hnnlogy, branch mini~tries and ~gencies Cd per-
, fnrm reseF~rrh ~tudieg for Che purpose of optimal resoluCiun of scientific
.~nd tecl~nical problems in the area oE reliability; it should be recommended
tt~nt the USSIt Council of rlittisC~rs State CommitCep on 5tandards draft
dir~ctive m~t~ri~ls nnd methods recommendutions determinin~ el~bnration and
;~doption oE stnnd~rds on reliability of production complexes in machine
building. 13r~nch ministries and agencies, base organizaCions and leading
institute:~, with participation of relinbility .gervices at enterprises and
scientific-technical society organizations should be instrucCed to draw up
yet of stand~rd~ and technical-standards documents pertaining to calcul~-
tion :?nd evaluation of the reliability of producCion complexes in develop-
In~ new manuEncturing processes and operations; optimization of engineering
decisinns on the basis of criteria of reliability of production complexes
:ind product reliability; production complex reliability control; prediction
_ oE reliability of manufacturing process equipment and production complexes;
evaluation of the physicochemical state and stresses on surface layers of
machine parts; st~ndardization of Cests for reliability of production com-
plexes; struin hardening in machine building; collection and processing of
inform:~tion on operational reliability of production complexes and produced
t tc~ns, ~tc.
Col'YItIC;i1T: t`datcl'stvo "Pravda", "Voprosy ekonomiki", 1979
lU24 '
CSc); 1821
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