Technical science
Anuar A.B.,Ormansha
Z.D.,Master Students
Abitova Gulnara,Candidate
of Technical Sciences, PhD
L.N.Gumilyov Eurasian National University, Kazakhstan
Optimization of
Control Systemfor the Technological Processes of the Rare Metals Production
Abstract. This work is devoted to the
creation of a new, modernized system of automatic control of technological
process of preparation of stock solutions for the extraction of rare metals
from chloride-sulfate solutions in lead production.
Keywords: Automation of technical processes, non-ferrous
metals, extraction processes, rare metals.
I Introduction.Different areas of the world economy demonstrate a
trend of consolidation and globalization of production. The world experience
shows that the only way to create competitive industrial structures is to
concentrate capital and production capacities and to integrate them vertically.
This integration improves production efficiency by reducing transaction costs
and indirect taxation of intermediate products.
In the late twentieth century, countries with market economies
experienced a growth in steel consumption and innovative restructuring of the
mining industry. This laid the foundation for the reduction of production
capacity in steel manufacturing and the construction of new compact plants for
processing final products with high added value (Yellishatty et al., 2011). The
impetus for this was the desire of industrialized countries to achieve cleaner
production (Baines et al., 2012). It caused a relative decline in steel
production in developed countries in the second half of the twentieth century
and contributed to the growth of its import from developing countries (Ernst
& Young, 2014).
The decrease in the share of the metallurgical industry in the national
output of developed countries led to the growth of metallurgical production in
developing countries (EUROFER, 2014). In developing countries, metallurgical
production was built mainly on a new technological basis; it had a progressive
structure of production and corresponded with global development trends.
Statistical data show that China is world leader in the production and
consumption of steel. In 1996, China produced almost 130 million tons of steel;
in 2014, this figure exceeded 700 million tons (Horvath, 2012; Li, Jian &
Jiang, 2012). The annual growth of steel production ranged from 2.1 to 26.8% on
average in 2000-2011. These growth rates of steel production in China were
caused by the launch of modern steel-producing facilities, which accounted for
about 700-730 million tons of steel per annum (‘China Iron and Steel
Association’, 2013).
This was more than Chinese companies could actually sell. However, the
Chinese government does not plan to cease the construction of new facilities.
On the contrary, in 2010, it approved the construction of a plant with a total
capacity of 10 million tons of steel per annum in the Guangdong Province, which
was built by the Baosteelcompany, and in the Guangxi Province, which was built
by the WISCO company. The Baosteel, WISCO, and Angang companies combined plan
to produce a total of 60 million tons of steel per annum in 2015-2016 (Wang,
2012; Bloomberg, 2015).
The mining and metallurgical industry (MMI) is one of the most important
industries of any country, because of its high level of capital concentration
and business integration. During the last 30 years, the volume of world mineral
production has increased by more than 1.5 times; it is expected to exceed 25
billion tenge by 2050 (Galiyev&Yusupova, 2013).
The effectiveness of the MMI is very important for Kazakhstan. At
present, Kazakhstan is the leader in terms of both mineral raw material
reserves and its production volumes. In these circumstances, ensuring
sustainable growth of the industry and its integration into the world economy
is crucial [1].
Therefore, it is necessary to analyze the current state, identify the
problems, and formulate strategic priorities for the development of the mining
and metallurgical industry of Kazakhstan.
Kazakhstan occupies a leading place in the world reserves of rare
elements and metals that has a great influence on scientific and technological
progress.
Although forecasts the global market of rare metals in the near future
are very favorable, the production and consumption of rare metals, is currently
in the country are not sufficiently developed.
In addition, the planned rise in the country's total industrial
production, accelerated development of high-tech industries and the
strengthening of the defense capability will significantly increase the
consumption of non-ferrous and rare metals, leading him to the level of
industrialized countries.
II Formulation of the
problem. The level of
automation of metallurgy, including the production of rare metals, is one of
the leading places among other industries. Metallurgical installation is
characterized by continuous processes occurring in them. In this processing of
mineral raw materials shall meet the requirements for the production of
eco-friendliness. Almost all operations and metallurgical plants, especially on
devices hydrometallurgy, and in particular, solvent extraction, mechanized and
transients which develop relatively quickly. This explains the high development
of automation in the production of rare metals hydrometallurgy [2].
Automation liquid extraction includes automatic control, remote control,
technological protection, chemical control, technological lock and alarm.
Rare Metals Production Process Control refers to a rather complex
control systems that maintain the technological regimes within the prescribed
limits, monitoring their condition requires the collection of large amounts of
information and to provide a significant number of devices, sensors, and
control mechanisms. Therefore, how to optimize the production process control
of rare metals with the development and application of the modernized control
system for the production of rare metals are actual and reasonable.
The novelty of the study is to provide a scientific basis for the production
of rare metals management system based on the synthesis of a mathematical model
of the process and the creation of systems of control and management of
production lines on the basis of a personal computer, allowing to improve,
modernize and optimize existing production technology of rare metals. Provide
with the effectiveness and comprehensiveness of their extraction, improving the
quality of output of commodity products is a relevant and important scientific and technological challenge.
The common and most rational today flowsheet producing rare metals of
melts lead production, including the deposition of the concentrate with its
subsequent sulfation and transfer metal oxide soluble form from which the rare
metal is recovered by the extraction method has a number of disadvantages
associated with a deviation in technological conditions, the need to maintain
and regulate the process parameters within specified limits, prompt and
efficient management of production technology in general.
One of the methods that meet the requirements of the complex and to
maximize the recovery of valuable components from industrial products and
tellurium metallurgical processes is an extraction method for extracting rare
metal, based on the pre-sulfation strong sulfuric acid and metal compounds into
solution [3].
Thus, analysis of existing methods for obtaining rare metal shows:
1) The main source of rare metal now in the production of lead and zinc
are the lead melts away refining of lead bullion.
2) The most common and best technology in the industry are considered
rare metals extraction processes that transform raw materials poor and provide
significant economic benefit.
3) One of the methods to ensure a comprehensive and maximum extraction
of valuable components and rare metals from industrial products metallurgical
processes is the extraction method based on pre-sulfation strong sulfuric acid
compounds and the transfer of rare metals in the solution.
4) Extraction processes for the production of rare metals are
characterized by simplicity and versatility, in connection with what they are
easier to automate and optimize, which is a prerequisite for any improvement of
the process and its intensification [4].
III Results. The paper was reviewed and investigated directly
itself a rare metal production - namely, the process of extraction of rare
metals from lead melts applied in the metallurgy production.
The process of producing a rare metal on the metallurgy production
consists of several steps, consisting in oxidizing the concentrate of
concentrated sulfuric acid in order to convert it into an oxide form in the
leaching slurry hydrochloric acid solution to form an extractable component for
conducting rare metal extraction process tributyltin phosphate, stripping it
ammonium chloride solution, cleaning solution from impurities, metal deposition
sodium sulfite and melting it to obtain the final product - a rare metal stamp
TA-1 [5].
According to the technological instructions adopted by the metallurgy
production, an operation sulfation (oxidation) of the concentrate into the
reactor a total volume of 5m3 (working volume – 5m3)
pumped 1,6m3 of concentrated sulfuric acid. The amount of acid was
measured wooden slats (6 bars or 80sm on the rail). When the stirrer was
charged to the reactor 0,4t rare earth concentrate or third party materials. To
determine the required amount of concentrate for loading concentrate in the
container is weighed before and after loading process weighbridge. Number of
loaded raw material is determined by the difference of weight measurements.
After loading concentrate into the reactor started the process of
oxidation. Initially, the oxidation proceeded without heating (closed steam
supply to the reactor jacket), since the beginning of the process splicing
(oxidation) at elevated temperature can be too violent reaction to the release
of large amounts of gases [6].
This leads to a strong release and foaming of the reaction mixture.
Therefore, steam supply is only 2-4 hours after loading concentrate into the
reactor. At a reaction temperature not lower than 1400 °C the duration of the
oxidation process is not more than 48 hours [6].
End splicing process (oxidation) should be determined by the laboratory
on the basis of the analysis of samples taken, as a result of which the
efficiency of set rare metal concentrate oxidation. In the case where the
efficiency is 95-97%, the oxidation step is complete. But in practice this
method is not widely used because of the complexity and duration of the method.
Therefore, the end of the process was determined visually by the color of the
resulting pulp, which has a pure milk-white color [6].
IV
Conclusion.Physical and chemical processes for the production of rare metals in
industrial production is well researched and tested in practice. As a result of
experimental studies on the existing production line producing rare metals,
analysis and processing of the actual process data, it is shown that:
1) The production line producing rare metals,
lead production is characterized by a large number of transients that are
maintained in the optimal mode requires a clear system of control and
regulation of technological parameters and an effective management system to
all production.
2) Preparation of a rare metal on the lead
production today is incidental production quality is to increase the level of
semiconductor purity (i.e., base substance content in the final product should
be not less than 99.99%) can only be secured mathematically Precision balance
main chemical components used in the art.
3) The solution to improve the quality of
manufactured product and the complexity of the use of raw materials is only
possible with the use of complex automation, advanced sensors and flowmeters [6].
4) Therefore, one of the main objectives of this
study is to develop, both theoretical foundations and practical ways to improve
and optimize the extraction process for producing rare metals from industrial
products of lead production based on modern high-performance methods and means
of control and development of advanced monitoring and control systems in the
production of rare metals.
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