Our approach is maximum results with minimum damage to the environment
Preparation plant LLC Central Preparation Plant Krasnokamenskaya was opened two years ago and since then has been producing high quality coal concentrate for further use for industrial purposes at various enterprises in the region, in the country and abroad.
The efficiency of a modern plant starts with a competent design
Despite the fact that our plant is quite young, from the very first days we showed a huge potential for development and stable, effective work: thanks to the high professionalism of the team and culture of production the commissioning process with achieving of the standard operating mode of the enterprise took only 5 days. Just within one month after startup we reached the design hourly load of 500 t/h and marketable products of premium quality.
It became possible not only thanks to us. We should also mention the work of the designers: the construction of Krasnokamenskaya preparation plant was carried out under the project of Prokopyevsk Mining and Design Institute. Thanks to their work the plant is not only equipped with highly effective state-of-the-art equipment made in Russia and abroad but has also become a site for introducing technical solutions that have no equivalents in our country and the CIS region. In particular, in the design of preliminary classification in the sorting building, the technical specialists of the design institute and the plant's preparation engineers did a lot of work with the engineers of the German Liwell screen to simulate the operation of the future equipment. They selected certain angles of inclination and tension of screen panels, which allows us to work with the capacity of 500 t/h with the screening efficiency of 98.5%.
Our way is to improve and enhance the equipment
The plant operates in the territory of the coal mining company JSC «Polyany». Raw coal is delivered to us for processing by motor transport. However, there is a well-developed railway infrastructure with five receiving and departure dead-end tracks near our site, so in the near future we will start deliveries of raw coal for processing by railway transport to the unloading track.
The main preparation method is the gravity-based separation of size fraction 3-150 mm in a dense-medium drum separator WEMCO 15x17 with the use of iron ore concentrate for dense medium creation. Its design was also upgraded as part of commissioning activities by engineers of Prokopyevsk Mining and Design Institute in cooperation with processing engineers of the plant and service engineers of the equipment supplier. All these improvements allowed us to increase the capacity of the unit. At the same time, thanks to the expanded area used to separate washed products, we receive the concentrate of premium quality and its cross-contamination with middlings or rock is excluded. This unit has no equivalents in Russia – it is unique in terms of its ability to process raw coal of size fraction 3-300 mm.
The automation of production and technological process and equipment of the plant is based on processors and provides for three-level control. Thanks to this, the process at the plant is most effectively controlled from the operator's board, allowing stable and trouble-free operation in a fully automatic mode.
Designers are not the only ones we rely on - initiative from our employees is also welcomed. If any employee brings a suggestion to improve the equipment, we are always open to the dialogue and happy to support worthwhile ideas. For example, this year we have implemented project on installation of cyclone block CMD-150/GT-B/2. It allowed us to increase the yield of marketable product by 3.1% due to extraction of valuable component from the water-slurry circuit of the plant. Sampling from all processes and product streams is fully automated, carried out by samplers and sample preparation machines and excludes human factor as an error.
Caring of the environment
Environmental safety is one of the priority tasks of the plant. The Governor of Kemerovo region Sergey Tsivilev has clearly defined the vector of actions of coal mining companies: «Clean Coal - Green Kuzbass». We fully share this idea and try to organize our work in such a way as to preserve the nature in our home region as much as possible.
In order to get engaged in this activity as efficiently as possible, our experts analyzed the experience of leading global and Russian companies and based on this, implemented a number of efficient environmental protection measures aimed first of all at reducing the negative impact on the environment. Two mobile dust suppression units manufactured by JSC «Borey» were purchased and put into operation, which enabled us to reduce coal dust emissions during operations at coal stockyards.
In addition to mobile units, four stationary dust suppression units manufactured by SCADO were also purchased and commissioned: they are fully automated, and pumping, compressor and electrical equipment are located in warm, heated block boxes designed for low temperatures peculiar for Siberian conditions with the ability to work at temperatures down to -42 ℃. All dust suppression cannons can be controlled from the automated workplace through specially developed Smart Snow program. It is also possible to change the direction of the unit operation in vertical and horizontal planes, rotate cannons by 360 degrees, change automatic pendulum rotation sector, change productivity and water flow rate, switch on snow generation and water fog modes, as well as monitor the environmental and unit operation parameters: air and water temperature, flow rate and water pressure in the system, wind force and direction, parameters of the power supply system.
The useful efficiency of these units in the horizontal plane extends to 80 m and taking into account the fact that the units are lifted to a height of 8-15 meters, the useful area increases several times and with the combined application of all units covers the entire area of the stockyard.
These automated dust suppression complexes with a single control board are the first in Kuzbass. From one operator board it is possible to control 12 systems simultaneously in real time, which leads to increased efficiency of individual units and, therefore, more effective dust suppression by the whole complex over a larger area.
The issue of environmental protection relates not only to the processing itself: the line of product unloading of size fraction of 0-3 mm is also equipped with innovative equipment - a telescopic loading unit manufactured by JSC SPACE-MOTOR. Its installation has reduced coal dust emissions from unloading of coal preparation products by 98%. The unit operation ensures dust-free unloading of coal preparation products in the outdoor stockyard. This technology allows to unload fine-graded material through a sleeve, which protects the coal dust from being carried away by the wind when screen products move from the conveyor belt to the stockpile cone, and the stockpile height is significantly reduced, which in turn minimizes dust-emission.
The unloader is equipped with a dust-proof steel bell with a dust protection skirt, which is in constant contact with the material to be unloaded. All dust is contained inside the unloader thus preventing dust leakage into the environment. This unit operates in automatic mode.
This activity will remain one of our top priorities. Now we can say that the first two years were successful for LLC Central Preparation Plant Krasnokamenskaya: we proved that efficient processing with minimal damage to the environment is not a dream, but a reality. Undoubtedly, there is a lot of modernization and technical re-equipment work ahead of us, but thanks to the proficiency of our team and the results achieved we look to the future with confidence.
