Honestly, I didn’t even think that I could get into such a place and see everything with my own eyes. Not everyone smiles at such a chance, but I got it and today I will tell you about it. About how iron ore is mined, how it is turned into HBI (and what it is), and how ready-made steel products are made from it.
Today, especially for the community, a report from the Lebedinsky Mining and Processing Plant and a story about what happens to the ore after it enters the plant.
First, let me tell you about the quarry itself. Lebedinsky GOK is Russia's largest iron ore mining and processing enterprise and has the largest iron ore open pit in the world. The plant and quarry are located in the Belgorod region, between the cities of Stary Oskol and Gubkin.
View of the quarry from above. It is really huge and growing every day. The depth of the Lebedinsky GOK quarry is 250 m from sea level or 450 m from the surface of the earth (and the diameter is 4 by 5 kilometers), The groundwater, and if it were not for the work of the pumps, then it was filled to the very top in a month. It is twice listed in the Guinness Book of Records as the largest quarry for the extraction of non-combustible minerals.
Some official information: Lebedinsky GOK is part of the Metalloinvest concern and is the leading iron ore producer in Russia. In 2011, the share of concentrate production by the plant in the total annual production of iron ore concentrate and sinter ore in Russia amounted to 21%.
A lot of all kinds of equipment work in the quarry, but the most noticeable of course are the multi-ton Belaz and Caterpillar dump trucks.
In a year, both plants included in the company (Lebedinsky and Mikhailovsky GOK) produce about 40 million tons of iron ore in the form of concentrate and sinter ore (this is not the volume of production, but already enriched ore, that is, separated from waste rock). Thus, it turns out that on average, about 110 thousand tons of enriched iron ore are produced per day at two mining and processing plants.
This kid transports up to 220 tons (!) of iron ore at a time.
The excavator gives a signal and he carefully backs up. Just a few buckets and the giant's body is filled. The excavator once again gives a signal and the dump truck drives off.
Belazs with a carrying capacity of 160 and 220 tons were recently purchased (until now, the load capacity of dump trucks in quarries was no more than 136 tons), and Hitachi excavators with a bucket capacity of 23 cubic meters are expected to arrive. (Currently, the maximum bucket capacity of mining shovels is 12 cubic meters).
"Belaz" and "Caterpillar" alternate. By the way, an imported dump truck transports only 180 tons. Dump trucks of such a large carrying capacity are new equipment that is currently being supplied to mining and processing enterprises as part of Metalloinvest's investment program to improve the efficiency of the mining and transport complex.
Interesting texture of the stones, pay attention. If I'm not mistaken, quartzite is on the left, iron is mined from such ore. The quarry is full of not only iron ore, but also various minerals. They are generally not of interest for further processing on an industrial scale. Today, chalk is obtained from waste rock, and crushed stone is also made for construction purposes.
Beautiful pebbles, I can’t say for sure what kind of mineral, can someone tell me?
Every day, 133 units of the main mining equipment (30 heavy dump trucks, 38 excavators, 20 burstanks, 45 traction units) work in the open pit of Lebedinsky GOK.
I certainly hoped to see spectacular explosions, but even if they took place on this day, I still would not have been able to penetrate the territory of the quarry. Such an explosion is done once every three weeks. All equipment, according to safety standards (and there are a lot of them), is removed from the quarry before that.
Lebedinsky GOK and Mikhailovsky GOK are the two largest iron ore mining and processing plants in Russia in terms of output. The Metalloinvest company has the world's second largest explored iron ore reserves - about 14.6 billion tons of international classification JORC, which guarantees about 150 years of operating life at current production levels. So the residents of Stary Oskol and Gubkin will be provided with jobs for a long time.
You probably noticed from the previous photos that the weather was not good, it was raining, and there was fog in the quarry. Closer to departure, he dissipated a little, but still not much. Pulled out the photo as much as possible. The size of the quarry is certainly impressive.
Right in the middle of the quarry is a mountain with waste rock, around which all the ore containing iron was mined. Soon it is planned to blow it up in parts and take it out of the quarry.
Iron ore is loaded right there into trains, into special reinforced wagons that take ore out of the quarry, they are called dump cars, their carrying capacity is 105 tons.
Geological layers by which one can study the history of the development of the Earth.
Giant machines from the height of the observation deck seem no more than an ant.
Then the ore is transported to the plant, where the waste rock is separated by magnetic separation: the ore is crushed finely, then sent to a magnetic drum (separator), to which, in accordance with the laws of physics, all iron sticks, and not iron is washed off with water. After that, pellets and hot briquetted iron (HBI) are made from the obtained iron ore concentrate, which is then used for steel smelting.
Hot briquetted iron (HBI) is one of the types of direct reduced iron (DRI). A material with a high (>90%) iron content obtained by a technology other than blast furnace. Used as a raw material for steel production. High-quality (with a small amount of harmful impurities) substitute for cast iron, scrap metal.
Unlike pig iron, no coal coke is used in the production of HBI. The production process of briquetted iron is based on the processing of iron ore raw materials (pellets) at high temperatures, most often by means of natural gas.
You can’t just go inside the HBI plant, because the process of baking hot-briquetted pies takes place at a temperature of about 900 degrees, and I didn’t plan to sunbathe in Stary Oskol).
Lebedinsky GOK is the only HBI producer in Russia and the CIS. The plant started production of this type of product in 2001 by launching a HBI production facility (CHBI-1) using HYL-III technology with a capacity of 1.0 million tons per year. In 2007, LGOK completed the construction of the second stage of the HBI production plant (HBI-2) using MIDREX technology with a production capacity of 1.4 million tons per year. Currently, the production capacity of LGOK is 2.4 million tons of HBI per year.
After the quarry, we visited the Oskol Electrometallurgical Plant (OEMK), which is part of the Metallurgical segment of the company. In one of the workshops of the plant, such steel billets are produced. Their length can reach from 4 to 12 meters, depending on the wishes of customers.
See a sheaf of sparks? In that place, a bar of steel is cut off.
An interesting machine with a bucket, called a bucket wagon, slag is poured into it during the production process.
In the adjacent workshop of OEMK, steel bars of different diameters, which have been rolled in another workshop, are turned and polished. By the way, this plant is the seventh largest enterprise in Russia for the production of steel and steel products. In 2011, the share of steel production at OEMK amounted to 5% of the total steel produced in Russia, the share of rolled products also amounted to 5%.
OEMK uses advanced technologies, including direct reduction of iron and electric arc melting, which ensures the production of high quality metal with a reduced content of impurities.
The main consumers of OEMK steel products in the Russian market are enterprises in the automotive, machine-building, pipe, hardware and bearing industries.
OEMK steel products are exported to Germany, France, USA, Italy, Norway, Turkey, Egypt and many other countries.
The plant has mastered the production of long products for the manufacture of products used by the world's leading automakers, such as Peugeot, Mercedes, Ford, Renault, Volkswagen. Bearings for these same foreign cars are made from some products.
By the way, this is not the first time I notice women - crane operators in such industries.
At this plant, almost sterile cleanliness, not typical for such industries.
Like neatly folded steel bars.
At the request of the customer, a sticker is glued to each product.
The heat number and steel grade code are stamped on the sticker.
The opposite end can be marked with paint, and tags with the contract number, destination country, steel grade, heat number, size in millimeters, supplier name and package weight are attached to each package for finished products.
These products are the standards by which the equipment for precision rolling is adjusted.
And this machine can scan the product and identify microcracks and defects before the metal gets to the customer.
The company takes safety very seriously.
All water used in the production is purified by the most recently installed state-of-the-art equipment.
This is the plant's wastewater treatment plant. After processing, it is cleaner than in the river where it is dumped.
Technical water, almost distilled. Like any industrial water, you can’t drink it, but you can try it once, it’s not dangerous to health.
The next day we went to Zheleznogorsk, located in the Kursk region. It is there that the Mikhailovsky GOK is located. The photo shows the complex of roasting machine No. 3 under construction. Here pellets will be produced.
450 million dollars will be invested in its construction. The enterprise will be built and put into operation in 2014.
This is the layout of the plant.
Then we went to the quarry of the Mikhailovsky GOK. The depth of the MGOK quarry is more than 350 meters from the earth's surface, and its size is 3 by 7 kilometers. There are actually three quarries on its territory, this can be seen in the satellite image. One large and two smaller. In about 3-5 years, the quarry will grow so much that it will become one big single one, and possibly catch up with the size of the Lebedinsky quarry.
The quarry employs 49 dump trucks, 54 traction units, 21 diesel locomotives, 72 excavators, 17 drilling rigs, 28 bulldozers and 7 motor graders.
Otherwise, ore mining at MGOK does not differ from LGOK.
This time, we still managed to get to the plant, where iron ore concentrate is converted into the final product - pellets..
Pellets are lumps of crushed ore concentrate. Semi-finished product of metallurgical production of iron. It is a product of enrichment of iron-bearing ores by special concentrating methods. It is used in blast-furnace production to produce pig iron.
For the production of pellets, iron ore concentrate is used. To remove mineral impurities, the original (raw) ore is finely crushed and enriched in various ways.
The process of making pellets is often referred to as "pelletizing". The mixture, that is, a mixture of finely divided concentrates of iron-containing minerals, flux (additives that regulate the composition of the product), and hardening additives (usually bentonite clay), is moistened and pelletized in rotating bowls (granulators) or pelletizing drums. They are the most in the picture.
Let's get closer.
They are dried and fired at temperatures of 1200 ÷ 1300 ° C on special installations - firing machines. Roasting machines (usually of a conveyor type) are a conveyor of firing carts (pallets) that move along rails.
But in the picture - a concentrate, which will soon fall into the drums. 
In the upper part of the calcining machine, above the calcining carts, a heating hearth is located, in which gaseous, solid or liquid fuels are burned and a heat carrier is formed for drying, heating and calcining the pellets. There are roasting machines with pellet cooling directly on the machine and with an external cooler. Unfortunately, we did not see this process.
Roasted pellets acquire high mechanical strength. Roasting removes a significant part of the sulfurous contaminants. This is what the finished product looks like.
Despite the fact that the equipment has been in service since Soviet times, the process is automated, and it is not necessary to control it. a large number personnel.
And by tradition short video about how ore is mined at Lebedinsky GOK and how HBI is made.
Thank you for the invitation to the production of the representative of the company "Metalloinvest" Alexander Bulanov. And thanks to everyone who overcame this not easy for the reader LJ post).
Click the button to subscribe to How It's Made!
If you have a production or service that you want to tell our readers about, write to Aslan ( [email protected] ) and we will make the best report, which will be seen not only by readers of the community, but also by the site How it's made
Subscribe also to our groups in facebook, vkontakte,classmates and in google+plus, where the most interesting things from the community will be posted, plus materials that are not here and a video about how things work in our world.
Click on the icon and subscribe!
September 28th, 2015
I have been living in Stary Oskol for more than 30 years, but only a few days ago I had the opportunity to visit a quarry, which is located very close to the city. But he is twice included in the Guinness Book of Records as the largest quarry in the world among non-combustible minerals and the largest quarry in terms of explored reserves of raw materials.
Lebedinsky Mining and Processing Plant (LGOK) is the largest company in Russia in the production of iron ore raw materials for the ferrous metallurgy and is one of the ten largest enterprises in the world for the extraction of iron ore and the production of raw materials for the ferrous metallurgy. GOK provides more than a third of Russian exports of raw materials for steel production. The plant is part of the company Metalloinvest».
Agree, such an enterprise, and even in your hometown, you need to “know by sight”. Let's learn more about GOK and the technological process at the enterprise ...
Here we are on the territory of the GOK, everything is neat and tidy:
The history of the enterprise dates back to the adoption in 1967 of a decision to build a mining and processing plant in Gubkin, Belgorod Region, on the basis of the Lebedinsky iron ore deposit of the Kursk Magnetic Anomaly.
On August 11, 1967, the Decree of the Council of Ministers of the USSR on the construction of the first stage of the Lebedinsky GOK was adopted, and from that date the plant has been keeping a record of its history, its successes and achievements.
In the same 1967, at the then operating Lebedinsky quarry of rich ores of the KMAruda plant, mining and capital work began on the construction of a quarry for the extraction of ferruginous quartzites, and in the following year, 1968, they began construction of facilities for enrichment and pelletizing production.
Photo 3. 
In 1971, the Lebedinsky quarry for the extraction of ferruginous quartzites was put into operation, and in 1972 the first sub-stage of the concentrating plant was put into operation, at which the first iron ore concentrate with a high iron content was obtained on November 24 of the same year.
In August 1975, the first stage of the pelletizing plant for the production of pellets for blast furnaces was put into operation and the first batch of high-quality raw materials, which are in great demand among metallurgists, was received. At the end of 1976, the construction of the first stage of the plant for the processing of 30 million tons of ferruginous quartzite per year was completed, and a decision was made to build the second stage, bringing the enterprise's ore capacity to 45.5 million tons. in year.
Do you see the so-called shale tongue in the middle of the quarry? These are poor breeds. I also expected that the quarry would be in the shape of a cone, going deep down at the top. And in general, according to all the rules, it should not have been. It’s just that in the Soviet years, when developing a quarry, they tried to give out a plan and chose only “rich breed”. And now we still have to develop this language, too. it already significantly interferes with work in a career:
At the end of the 70s, the first-born of blast-furnace metallurgy in Russia, the Oskol Electrometallurgical Plant, was built on the raw material base of Lebedinsky GOK in the late 70s, and in June 1982, a factory for the re-enrichment of iron ore concentrate was put into operation at Lebedinsky GOK.
In the socialist period of development, the high-quality products of the Lebedinsky GOK were left in the country, not giving it access to the world market. About 20 metallurgical enterprises of the Soviet Union were consumers of the plant's products. Only in 1989, Lebedinsky GOK began to establish trade relations with foreign companies, entered the European market with its products, and in 1994 became the leading exporter of iron ore in Russia.
We go down by bus to the quarry. The views from the window are more and more reminiscent of aliens.
Nature has created unique wealth in the center of Russia - it is no coincidence that Lebedinsky GOK is called the “Pearl of the KMA”. "Swans" - this is how the plant is lovingly called by thousands of selflessly devoted miners, enrichers, metallurgists, railway workers, motorists, electricians, repairmen, workers of auxiliary shops, builders and assemblers - all who happened to build Lebedinsky GOK, develop its capacities, work at the All-Union shock Komsomol building. These people are worthy of deep respect, it is their work, the work of Soviet and Bulgarian builders, that a giant plant was built in a short time, which gave a new impetus to the development of the cities of Gubkin and Stary Oskol, the entire Belgorod region. We even have a monument to the Bulgarian-Soviet friendship in our city.
The plant, named by Russian President Boris Yeltsin the national pride of Russia, is the largest enterprise in the Belgorod Region and its main taxpayer.
LGOK today is one of the leading Russian manufacturers ZhRS, the only manufacturer of hot briquetted iron (HBI) in Russia and the largest producer of commercial HBI in the world. The main products of the enterprise are iron ore concentrate, pellets and hot briquetted iron.
And here we are almost at the bottom of the career. Around us, like in Avatar, huge trucks are passing by. The only thing missing is arrows in the wheels, remember that scene from the movie?
Lebedinsky GOK is part of Metalloinvest. It is a leading producer and supplier of iron ore products and HBI in the global market, one of the regional steel producers. The company has the world's second largest explored iron ore reserves - about 14.4 billion tons according to the international classification JORC (IMC Montan), which guarantees about 150 years of operating period at the current level of production. Metalloinvest combines the assets of high-tech and efficient enterprises of the mining and metallurgical industry in Russia: OJSC Lebedinsky GOK, OJSC Mikhailovsky GOK, OJSC Oskol Electrometallurgical Plant, OJSC Ural Steel. It is the largest iron ore company in Russia and the CIS.
A few years ago, a Hitachi excavator with a bucket capacity of 23 cubic meters was purchased. (before this time, the maximum bucket capacity of mining excavators is 12 cubic meters). By the way, the excavator is “powered”, as you probably already noticed, via electric cables:
Today, LGOK continues to increase production volumes, improve product quality, and progressively improve the technological process.
In 2013, Lebedinsky GOK launched the Metalloinvest Mining and Transport Complex Development Program. To date, the drilling and blasting department of the LGOK has received two new drilling rigs SBSh-250, the mining department - one domestic-made excavator with a bucket volume of 15 and 20 m3, three ECGs with a bucket volume of 10 m3 and a high-performance excavator from the Japanese company Hitachi with a bucket volume of 23 m3 .
You can find different information about the depth of the quarry on the Internet, from 300 meters to 600. In fact, the workers of the plant told us that the depth of the quarry is approximately 440 meters.
Two dump trucks of the BelAZ brand with a carrying capacity of 220 tons, five large Caterpillar trucks with a carrying capacity of 180 tons were purchased for the autotractor management of the Lebedinsky GOK. Prior to this, Caterpillar heavy trucks with a maximum carrying capacity of 136 tons and BelAza - 130 tons were used in the plant's quarry. In parallel, five T-35 heavy-duty caterpillar bulldozers manufactured by the Chetra plant in Cheboksary began work. Ten modern traction units of the Novocherkassk Electric Locomotive Plant of the latest generation and one shunting diesel locomotive have come to the disposal of the railway workers at LGOK.
From 2013 to July 2015, Metalloinvest invested about 4 billion rubles in the development of the mining and transport complex of the Lebedinsky GOK.
Next year, the modernization of the mining and transport complex of LGOK will continue. About 1.3 billion rubles have been allocated for these purposes. In 2016, it is planned to purchase another excavator from the Japanese company Hitachi with a bucket capacity of 23 m3, a domestic-made EKG excavator with a bucket capacity of 15 m3, three Caterpillar heavy-duty dump trucks with a load capacity of 180 tons and two drilling rigs.
The key direction of the investment program is the construction of the third shop for hot briquetting iron, the production capacity of which will be 1.8 million tons. The implementation of this project will create an additional 500 jobs in the Gubkinsky urban district, and the growth in production volume and increase in work efficiency will contribute to an increase in income, and, accordingly, an increase in tax revenues to the federal and regional budgets.
Unfortunately, it was not possible to ride on these giants ...
Today's economic conditions in the industry also affect the work of Metalloinvest and Lebedinsky GOK. Therefore, the implementation of the HBI-3 project is of fundamental importance. The Company's development strategy provides for the intensification of the implementation of this project, and at present, work is being carried out ahead of schedule.
Photo 12. 
Lebedinsky GOK has a gold medal of the Laureate of the international exhibition Metal-Expo for the development and implementation of a set of works to master the production of new types of iron ore products - iron ore concentrate with a mass fraction of iron of more than 69.5%, fluxed pellets, iron ore briquettes (HBI).
Lebedinsky GOK Laureate of the competition for participants in foreign economic activity in the Best Exporter nomination. The competition is organized by the Federal Customs Service of Russia. The winners of the competition are participants in foreign economic activity and organizations working in the field of customs who have achieved the greatest success in international trade, the introduction of advanced customs technologies, and ensuring the transparency of customs procedures.
Lebedinsky GOK is a repeated winner and prize-winner of the All-Russian competition "Russian organization of high social efficiency", the industry competition "Enterprise of the mining and metallurgical complex of high social efficiency".
Here bloggers are photographed for comparison - exactly half of the wheel. Unforgettable experience from this whopper of course. True, for me, as a local resident, this is not entirely news - we periodically meet them on the roads outside the city.
Lebedinsky GOK is the winner of the review competition for the best organization of work on labor protection and production culture among enterprises of the mining and metallurgical complex of the Belgorod Region, which is held by the regional committee of the GMPR and the Department of Labor and Employment of the Belgorod Region.
Lebedinsky GOK makes a significant contribution to the development of the city and the region, being the largest taxpayer in the Belgorod Region. At the end of 2014, Metalloinvest's contributions to the consolidated budget of the Belgorod Region exceeded 6 billion rubles. The total amount of deductions for the last four years amounted to more than 40 billion rubles.
Metalloinvest makes a significant contribution to the development of the regions where it operates under the Social and Economic Partnership Agreement. In 2015, the Company's total investment in the development of the region will exceed RUB 2.2 billion. Over the previous four years of cooperation, Metalloinvest allocated RUB 2.8 billion to social projects and programs in the Belgorod Region.
Why buy Caterpillar? Foreign equipment is under repair and maintenance (with continuous use) 4 hours a month, and Belaz - a week. But of course it is much more expensive.
The Metalloinvest company is actually the head of numerous kindergartens, schools and sports facilities in the city. The social obligations of the company are visible to the residents of the city without an armed glance.
Photo 15. 
I would like to see how the rock is blown up at the plant. This happens several times a month. Drilling machines drill wells, explosives are laid there. All equipment and people are removed from the quarry and produce an explosion. the collapsed rock is taken by dump trucks to the plant.
Photo 16. 
By the way, when I lived in the Southwestern part of the city, close to the quarry, our 9-storey building swayed decently after the explosion.
Local TV company Channel 9 interviews a blogger ZAVODFOTO. They also took it from me, but I still don’t know whether it was shown on TV or not. It would be interesting to look at yourself from the side :-)
It would also be interesting to look at the repair of these giants, their maintenance. What kind of nuts and wrenches are there for example :-)
Photo 18. 
Removing overburden, the plant simultaneously receives sand, chalk and clay, which is then used by other industries, such as the Stary Oskol cement plant located nearby. Chalk even goes to Gosznak to make money. So you probably carry a piece of Lebedinsky GOK rock in your pocket
Photo 19. 
Here is a sand extraction site on one of the cuts in the quarry. From the black world of ore and metal we find ourselves in the white-yellow world of water and sand. A very strange and interesting contrast.
Photo 20. 
Water flows through these pipes to create a pulp with sand, which is transported to the place of loading into the machines.
Photo 21. 
This is how the sand is washed out with a water gun and the pulp is formed and pumped out.
Delivery of sand in this way is much more profitable than trucking. They showed how a quarry wall was brought down with a cannon. Spectacular.
Photo 22.
Before we go from the quarry to the plant itself, see a brief production flow diagram:
We go to the enrichment factory. The huge building is almost a kilometer long.
Photo 23. 
Consider mills and crushers. In them, self-grinding of ore (without grinding bodies) up to 300 mm and sorting takes place.
Photo 25. 
The chain goes beyond the horizon.
The noise is deafening. They didn’t go down to the workshop itself - it’s a whole city.
Photo 26. 
Here is the control panel. This is where monitoring and control of the process takes place.
Photo 27. 
By the way, I have a friend who works here in the automation department. In general, this is my specialty too :-)
Photo 28. 
Photo 29. 
The crushed ore is processed and roasted in furnaces to turn into metallized pellets.
Here is the video of the process:
Photo 31. 
Photo 32. 
Photo 33. 
Here they are.
Photo 34. 
Here it is - the wealth of the Kursk Magnetic Anomaly.
Photo 35. 
Photo 36. 
However, modern metallurgy involves a gradual transition from open-hearth and blast-furnace processes to the production of pure steel grades through the increasing use of electric arc furnaces. Steelmakers prefer to deal with metallized pellets, but pellets have one significant drawback: they do not like wet weather and long storage - they quickly oxidize and become unsuitable for steel production. But metallized briquettes do not have this drawback. They are preferable for steelmakers, although more expensive.
Plus, fluxed iron ore pellets have a mass fraction of iron of about 66.5%, but iron ore briquettes (hot briquetted iron) already have a mass fraction of iron iron of more than 90%.
Here they are delivered from the GBM plant for loading.
Photo 38. 
Photo 37. 
In general, these huge machines are very impressive. When next to you is an aggregate the height of a house, and very close to you a wheel is spinning two of your height and something is rowing in - atas!
Photo 39. 
Photo 40. 
Photo 41. 
Photo 42. 
The final stage of our tour was the site for the construction of the HBI-3 plant
Photo 43. 
Commissioning of the CGBZH-3 is scheduled for December 2016. This will strengthen the Company's position in the global high value-added iron ore market.
HBI has a metallization degree of over 93 percent and a density above 5.0 g/cm3, making it an ideal raw material for steel production in both electric arc furnaces and converters. HBI produced from the ores of the Lebedinsky deposit contains practically no foreign impurities, which determines the high quality of the steel produced from it. Due to the low content of fines, briquettes are well suited for transportation by rail and sea. The energy efficiency of HBI production is 2 times higher than in the production of pig iron, which gives hot briquetted iron significant competitive advantages. At the same time, HBI is a more environmentally friendly product: during its production, greenhouse gas emissions are almost half as compared to classical blast-furnace production.
Photo 44. 
P.S. Sorry for the quality of the photo, there were technical problems with the standard camera, I had to shoot on a Chinese phone for 5 thousand rubles :-)
The visit to this enterprise and the organization of this most interesting excursion became possible thanks to the company Metalloinvest
For more on the topic, you can see the post about The original article is on the website InfoGlaz.rf Link to the article from which this copy is made -
Company
LGOK is the only Russian manufacturer of hot briquetted iron, which is used as a high-quality raw material in steel production. The main difference between HBI and its counterpart - ferrous scrap - is the absence of impurities.
The production of HBI at the plant began in 2001 with the launch of a shop for the production of hot briquetted iron with a capacity of 1 million tons per year. In 2007, the construction of the second HBI production unit was completed, using the MIDREX technology. Its capacity is 1.4 million tons per year. Thus, today LGOK can produce up to 2.4 million tons of HBI per year.
The resource base of LGOK is iron ore reserves, estimated by JORC standards at 4.2 billion tons.
The plant accounts for 20% of the Russian output of sinter ore and iron ore concentrate.
In 2010, LGOK's output amounted to:
- 19.8 million tons per year of iron ore concentrate;
- 8.8 million tons per year of pellets.
An important factor in the successful operation of Lebedinsky GOK was the introduction of an information management system. It allows you to monitor and control the technological process in real time - from loading rock mass in a quarry to receiving and shipping finished products. The system provides specialists with information on the iron content in the ore, makes it possible to assess the condition and operation of concentration equipment, roasting machines, HBI shop and other equipment. All data necessary for analysis and decision-making are archived by the system and are available at any time. The introduction of the system made it possible to adjust the equipment to the most efficient modes of use and led to significant savings in energy resources.
Products
- ordinary iron ore concentrate
The mass fraction of iron is about 68%.
Non-toxic, non-flammable, non-explosive, low in sulfur, phosphorus and titanium oxide;
- reenriched iron ore concentrate
Mass fraction of iron - about 70%;
Produced by additional enrichment of ordinary concentrate;
- dried iron ore concentrate
Mass fraction of iron - about 68;
Due to the low moisture content, this concentrate does not freeze at low temperatures, and therefore is suitable for the production of sinter in winter;
- iron ore unfluxed pellets
Mass fraction of iron - 66%;
- fluxed pellets
Mass fraction of iron - 66.5%;
They are used in the production of HBI and metallized pellets;
Mass fraction of iron - about 90%;
The degree of metallization is about 93.7%;
- screening of iron ore pellets and fines of hot-briquetted iron
By-products of LGOK used in the production of sinter.
The volume of output of the main types of products at LGOK, thousand tons
| Product types | 2008 | 2009 | 2010 | 1 sq. 2011 | 2 sq. 2011 |
| Primary iron ore | 47559 | 38614 | 47362 | 10581 | 12760 |
| Ordinary iron ore concentrate | 19732 | 16040 | 19829 | 4400 | 5400 |
| Reenriched iron ore concentrate | 7076 | 6522 | 6812 | 1712 | 1840 |
| Dried iron ore concentrate | 105 | 394 | 381 | 200 | 219 |
| Unfluxed pellets | 4477 | 4265 | 5298 | 1240 | 1352 |
| Fluxed pellets | 3501 | 3267 | 3485 | 866 | 898 |
| HBI | 2144 | 2165 | 2271 | 578 | 618 |
| Screening of iron ore pellets and HBI fines | 517 | 419 | 427 | 103 | 118 |
Production
Mining
JSC "Lebedinsky GOK" carries out a complex of works on extraction and processing of ferruginous quartzites of the Lebedinsky and Stoilo-Lebedinsky deposits.
Ore mining is carried out by open pit mining, excavation and transportation of rock mass by road and rail. Along the way, non-metallic mineral raw materials are mined - sand, chalk, crystalline schists, quartzite sandstone, which is shipped to consumers using internal rail transport.
The mining of the rock mass is preceded by explosive preparation, carried out in order to loosen the rock mass. Drilling of blast holes is carried out by SBSh drilling rigs. Blasting is carried out by borehole charges.
The development of ferruginous quartzites and rocky overburden is carried out by excavators of the "mechanical shovel" type EKG-10, EKG-8I, EKG-8US and EKG-6.3US, followed by loading onto railway and road transport. The rock mass worked out for road transport is subject to subsequent reloading into rail transport at transshipment points in the quarry. Rocky rock mass is reloaded by EKG-10 excavators. Loose overburden is worked out by excavators EKG-6.3US. In addition, dragline excavators ESH-10/60 and ESH-10/70A are used on loose overburden.
Transportation of rocky and loose overburden to dumps is carried out by rail. Stacking of transported rocks on dumps is carried out by excavators. In addition to excavation mining of loose overburden, a method of mining by means of hydromechanization with transportation of overburden to a hydraulic dump is used.
Production of iron ore concentrate
Production of iron ore concentrate with a mass fraction of iron less than 69.5%
Ferruginous quartzites are transported by rail to the processing plant, where they are subjected to coarse crushing. Crushed ore enters the processing plant through conveyor paths and is placed in silo-type bins, from where it is fed to grinding with the help of apron feeders.
The technological feature of the processing complex of the plant is the method of complete self-grinding of ferruginous quartzites, which excludes the traditional stages of medium and fine crushing from the ore preparation process, which ensures a significant reduction in capital and operating costs throughout the processing process. This method, which provides the most complete disclosure of mineral grains, allows the production of a concentrate of the highest quality. Magnetic enrichment and desliming technologies are also used to produce the concentrate.
The finished concentrate is delivered through pipeline systems to the filtration section, from where, after the dehydration operation, it is transported along conveyor paths to warehouses for shipment to consumers or to a pelletizing plant. The concentration plant produces a concentrate with a mass fraction of iron less than 69.5%.
Production of iron ore concentrate with a mass fraction of iron of more than 69.5%
Part of the concentrate obtained at the beneficiation plant is sent for refining to the re-enrichment shop, which produces concentrate with a mass fraction of iron of more than 69.5% and a silicon dioxide content of up to 3%. The production of re-enriched concentrate is carried out using the technology of ball regrinding and magnetic re-enrichment of ordinary concentrate.
The concentrate obtained at the re-enrichment plant is supplied through pipeline systems to the Oskol Electrometallurgical Plant and to the filtration section, from where, after dehydration, it is fed to the pelletizing plant for the production of fluxed pellets for metallization.
Pellet production
The pelletizing plant consists of a batch preparation shop, pelletizing sections, four OK-306 conveyor-type roasting machines, a screening (sorting) section, a storage and transportation system for finished products, auxiliary systems and gas cleaning systems.
Unfluxed pellets
From concentrate with a mass fraction of iron less than 69.5%, the pelletizing plant produces unfluxed iron ore pellets for blast-furnace metallurgy, which are sent to external consumers.
The technological cycle for the production of non-fluxed pellets includes the processes of charge preparation, pelletizing and screening of raw pellets with their subsequent roasting and sorting.
Fluxed pellets
Fluxed pellets with an iron content of 66.5% are produced from concentrate with a mass fraction of iron of more than 69.5% at the pelletizing plant, which are raw materials for the production of hot briquetted iron. Fluxed pellets are transferred via a tubular conveyor to HBI workshops No. 1 and 2.
A distinctive feature of the technology for the production of fluxed pellets is the addition of flux-hardening components to the charge, which ensures stable operation of the hot-briquetted iron shop.
Production of hot briquetted iron (HBI)
The basis of the production of metallized briquettes is the process of direct reduction of iron, which consists in the interaction of streams of reformed natural gas and iron ore pellets, occurring at a temperature of about 900°C. The feedstock for the production of HBI is fluxed pellets with a mass fraction of iron of more than 66.5%, produced from a re-enriched concentrate.
In terms of its quality characteristics, HBI is superior to cast iron and is used in many steel-smelting enterprises of the world along with scrap. However, unlike scrap metal, which is currently used as the main raw material for steel production in electric arc furnaces, briquettes are original raw materials that do not contain impurities of plastics and non-ferrous metals, which significantly degrade the quality of steel.
Hot Briquetted Iron Shop No. 1 produces iron ore briquettes using HYL-III technology and consists of a shaft reduction furnace, a reformed gas production plant, process gas circuits, a raw material loading system into the furnace, a briquetting system, a finished product transportation and shipment system, auxiliary and gas cleaning systems. Hot briquetted iron workshop No. 2 produces iron ore briquettes using the MIDREX technology. Its structure is similar to HBI shop No. 1. Both workshops produce iron ore briquettes with an iron content of at least 90%. The total annual capacity of the two workshops is 2400 thousand tons of briquettes. Briquettes are sent to external consumers by rail.
Shareholders
Holding Metalloinvest. Its main shareholders are Usmanov (50%, through Gallagher), Vasily Anisimov (20%) and Andrey Skoch (30%).
Insurance
Year 2011
In connection with equipment breakdown and stoppage of production at the enterprise, JSC "Lebedinsky Mining and Processing Plant" filed a claim for the recovery of 857.612 million rubles from JSC "AlfaStrakhovanie".
AlfaStrakhovanie OJSC requested that the plaintiff obtain documents confirming the reasons for the damage to the equipment.
On March 21, 2011, the Moscow City Arbitration Court approved a settlement agreement between OJSC Lebedinsky Mining and Processing Plant and OJSC AlfaStrakhovanie in a claim for 857.612 million rubles. The terms of the settlement agreement were not announced at the meeting. Lebedinsky Mining and Processing Plant and AlfaStrakhovanie signed a settlement for $30 million.
In September 2011, OJSC Lebedinsky GOK filed a lawsuit with the Arbitration Court of the city of Moscow demanding to recover 332 million rubles from OJSC AlfaStrakhovanie. debt.
The case (А40-101809/2011) will be handled by Judge Galina Larina.
Year 2009
AlfaStrakhovanie will provide insurance coverage for four regional plants - OAO Oskol Electrometallurgical Plant, OAO Lebedinsky GOK, OAO Mikhailovsky GOK and OAO Ural Steel. The term of insurance is 1 year. According to the terms of the contracts, the company accepts for insurance property, buildings and premises, equipment of the holding enterprises, risks associated with interruption in production as a result of an insured event. The total sum insured under the contracts exceeded $18.5 billion.
year 2013
The Belgorod branch of the SOGAZ insurance group concluded compulsory insurance contracts with OAO Lebedinsky GOK and subsidiaries operating hazardous facilities.SOGAZ provided OAO Lebedinsky GOK and its subsidiaries with liability insurance services for the operation of 40 hazardous facilities located in the Belgorod Region. The total sum insured amounted to 1.055 billion rubles. The agreements will be valid throughout 2013.
- . Rental and leasing construction machines and equipment
- . Activities for the provision of telephone services
- . Rental and leasing of devices, devices and other equipment used for medical purposes
- . Manufacture of other products from base metals, not included in other groups
- . Other retail trade in non-specialized stores
- . Distribution of gaseous fuel through gas distribution networks
- . Transportation of goods by specialized vehicles
- . Renting and management of own or leased non-residential real estate
- . Restaurant activities and food delivery services
- . Distribution of water for drinking and industrial needs
- . Activities in the field of television broadcasting
- . Steam distribution and hot water(thermal energy)
- . Repair of shoes and other leather goods
- . Activities of hotels and other places for temporary accommodation
- . Investments in securities
- . Rental and leasing of commercial equipment
- . Rental and leasing of other land vehicles and equipment
- . Activities related to engineering and technical design, construction project management, construction control and architectural supervision
- . Training of highly qualified personnel
- . Storage of nuclear materials and radioactive substances
- . Development of projects for industrial processes and industries related to electrical engineering, electronic engineering, mining, chemical technology, mechanical engineering, as well as in the field of industrial construction, systems engineering and safety engineering
- . Railway transport activities: freight transport
- . Operation of restaurants and cafes with a full restaurant service, cafeterias, fast food restaurants and self-service restaurants
- . Preparing to sell your own non-residential real estate
- . Transfer of steam and hot water (thermal energy)
- . Other accommodation activities
- . Storage and warehousing of oil and products of its processing
- . Transportation through pipelines of other types of cargo
- . Additional professional education
- . Activities of catering establishments for other types of catering
- . Preparing to sell your own residential real estate
- . Operational activities highways and motorways
- . Mining and primary processing of limestone and gypsum stone
- . Ensuring the operability of heating networks
- . Security activities in emergency situations other
- . Production, transmission and distribution of steam and hot water; air conditioning
- . Activities of health resort organizations
- . Production of products of direct reduction of iron ore and sponge iron
- . Production of steam and hot water (thermal energy) by boiler houses
- . Other entertainment and entertainment activities, not included in other groups
- . Production of electricity from renewable energy sources, including that generated by solar, wind, geothermal power plants, including activities to ensure their performance
- . Clay and kaolin mining
- . Shale mining and primary processing
- . Production of industrial gases
- . Activities in the field of radio broadcasting
- . Electricity distribution
- . Electricity transmission and technological connection to distribution networks
- . Provision of services by hairdressers and beauty salons
- . Rental and leasing of agricultural machinery and equipment
- . Wholesale non-specialized trade
- . Activities of sports facilities
- . Ensuring the operability of boiler rooms
- . The activities of restaurants and bars to provide food in railway cars, restaurants and on ships
- . Activity of bus transport on regular intracity and suburban passenger transportation
- . Power generation
- . Development of gravel and sand pits, extraction of clay and kaolin
- . Rental and leasing of computers and equipment
- . Activity advertising agencies
- . Rental and leasing of office machines and equipment
- . Production of explosives
- . Vocational training
- . Water intake and treatment for drinking and industrial needs
- . Buying and selling your own residential real estate
How to understand: will the kitten be fluffy?
What kind of light alcohol can be drunk for pregnant women: the consequences of drinking
Why do the legs swell in the ankles and ankles of the feet in pregnant women: causes and methods of treatment
The wedding of Prince Harry and Meghan Markle: scandalous and secret details of the marriage (photo) The future marriage of Prince Harry year NTV
How to close white plums for the winter