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EVRAZ KGOK is one of the five largest ore mining enterprises in Russia.

Produced in 2018
58.5 million tonnes ore
3.5 million tonnes sinter
6.5 million tonnes pellets

EVRAZ KGOK is one of five key mining companies in Russia. Located in the Sverdlovsk region, 140 km from EVRAZ NTMK, EVRAZ KGOK mines titanomagnetite iron ore with vanadium content at the Gusevogorskoe deposit. The vanadium content makes it possible to produce high-strength grades of alloy steel.

Mt. Kachkanar is the only source of vanadium ore in Russia. Surveying of this deposit began in the early 1930s. In 1956, the government of the USSR decided to construct a mining and concentrating complex at Mt. Kachkanar to supply Nizhny Tagil Iron and Steel Works and, later, all steel works in the Urals region with vanadium ore. Over the years, KGOK became one of the leading mining companies in the USSR and in Europe.

EVRAZ KGOK has a capacity of about 55 million tonnes of iron ore per year. EVRAZ NTMK is a primary consumer of EVRAZ KGOK’s products.

At the moment, EVRAZ KGOK uses three open pits to produce the ore that is then processed by its crushing, processing, sintering and pelletising plants. The final product (i.e. sinter and pellets) is loaded into railway cars and shipped to consumers, including those abroad.

Today, EVRAZ KGOK:

  • is one of five key mining companies in Russia;
  • is the only producer of V-iron ore in Russia;
  • mines titanomagnetite iron ore with vanadium content at the Gusevogorskoe deposit, which is used to produce high-strength grades of steel;
  • is the only Russian company that produces high-quality materials from iron ore with low iron content (15%);
  • is the source of iron ore for another EVRAZ company, i.e. EVRAZ NTMK. The deposit of titanomagnetite iron ore is 140 km from Nizhny Tagil, which makes cooperation between the companies rather efficient.

EVRAZ KGOK has a capacity or more than 58 million tonnes of iron ore per year.

The ore is mined in four open pits: the Glavny, Zapadny, Severny and Yuzhny deposit open pits. The ore is removed from the pits by BelAZ trucks and then delivered to the crushing plant by rail. Pit machinery includes heavy-duty 130-tonne dump trucks, modern NP-1 locomotives and 12 m2 shovel excavators.

Yuzhny deposit pit

The average iron content of the ore is 15.7%, while V content is 0.13%.

EVRAZ KGOK uses the following mining process: drilling — blasting — excavation — transportation of ore and dumping of waste rock.

The Glavny open pit was established on 1 April 1959 and put into operation in 1963. The Glavny pit now produces more than 14 million tonnes.

Development of the Zapadny open pit began in 1967 and was accepted for operation by the State Committee in 1968. The scheduled yield is more than 11 mtpa. Zapadny pit ore has higher V content.

The Severny open pit produced its first ore in April 1969 and was established on 1 September 1971. Today, the Severny pit is the KGOK’s longest, with levels running up to 2 km long. The ore produced in this pit has high processing capacity but low iron content. The scheduled yield is about 25 mtpa.

The Yuzhny deposit pit has been mined as a separate pit since 2015, but it was initially a part of the Glavny pit. The ore produced in this pit has high iron content (more than 16%) but has low processing capacity.

The crushing plant crushes ore into three sizes, i.e. large, medium and fine. The crushing plant was put into operation in 1963. The plant uses 11 large crushers, 11 medium crushers and 22 fine crushers, 20 feeders, 22 screens (GIT-51) and 18 conveyors. The final product is crushed ore of 16.0 mm. In 2012, its medium and fine crushing areas had a major upgrade: Sandvik-produced (Sweden) crushers were supplemented with high-performance ThyssenKrupp crushers.

The processing plant is a set of facilities for dry magnetic separation and processing of ground ore, wet magnetic processing with pulverising and wet magnetic separation. This facility also incorporates equipment for iron and vanadium concentrate drying, storing and transporting to the pelletising plant. In total, the facility runs 29 process sections: sections 1–15 produce concentrate for sinter production, while sections 16–29 produce material for pellet production.

The plant produces 10 million tonnes of concentrate per year.

The processing stage at EVRAZ KGOK enables the processing of low-grade titaniferrous ores into concentrates for sintering and pelletising to achieve an iron weight percentage of 60% and 63%, respectively, as well as 0.55–0.6% vanadium pentoxide.

This subdivision acquires and stores discardable tailings produced during wet magnetic separation at the processing plant and clarifies return cycle water. EVRAZ KGOK’s modern tailings facility is divided into three areas: Rogalevksi, Intermediate and Visokiy. Hydrotechnical facilities include: bund walls, settling ponds, collecting channels, a syphon spillway, a slurry pumping station, slurry distribution lines and other facilities. State sanitary and epidemiological authorities have performed multiple studies of the environmental hazards associated with the slurry produced at Kachkanar and found it to be non-toxic and environmentally friendly.

Two tailings lines deliver over 45 mtpa of discardable tailings to the pond.

Finished products — pellets and sinter — are produced at the pelletising plant.

One of the Company’s main subdivisions, the sinter plant, processes burden material and produces sinter. Sinter production involves two AK 3-200 sintering machines with a sintering area of 236 square metres. The plant also operates a sinter cooling unit.

In 1977, Kachkanar GOK’s sinter was awarded a national quality seal. The plant is constantly upgrading its production facilities and incorporating new technologies. KGOK has taken steps to improve its sinter’s metallurgical properties and to ensure high basicity and low fines content.

Iron content in sinter reaches 57%, vanadium pentoxide 0.55 %, and its mechanical resistance exceeds 70%.

In recent years, KGOK has put considerable effort into decreasing specific consumption of natural gas. An elaborate set of operations has been performed to enhance the gas cleaning system. Six electrical precipitators were completely replaced, which made it possible to considerably decrease dust emissions and stabilise exhaust fan operations.

The sinter plant currently produces over 3.5 mtpa.

The pelletising plant operates four OK-228 indurating machines with auxiliary equipment, including a modernised pit cooler and a gas distribution system.

All indurating machines are equipped with a hearth temperature control system. The installed control systems ensure accurate, real-time data on pellet heating.

The current annual pellet production capacity exceeds 6.5 million tonnes.

Pellets are spherical products obtained through special concentrating processes that involve induration of fine (dust-like) ore or finely ground concentrates.

The material handling plant prepares and batches raw materials for pellet and sinter production. The plant includes a set of buildings and structures that receive and handle the raw materials. All the buildings are connected by a system of belt conveyers and a fleet of vehicles. The plant also includes a bentonite clay storage and a bentonite powder production facility.

Raw material batching is fully automated. The implementation of automated continuous batching machines made considerable improvement of batching accuracy possible. The installation of new dedusting and ventilation equipment improved air purity in the facility.

Bentonite batching machines supplied by Schenck Process, Germany, as well as conveyor scales, humidity sensors and a new batching and humidity control system have been installed in the facility to ensure high performance.

The Kachkanar power plant’s main equipment includes two high-pressure power boilers, two low-pressure power boilers, three water boilers and two turbine generators.

The power plant supplies heating and hot water to the whole residential area of Kachkanar, as well as a number of industrial facilities.