Download the questionnaire and submit it to us
info@torch-air.com
Made in the USA
Scan the QR code or click on it to start a chat in WhatsApp
Home / Case Studies / High-Efficiency Dust and Gas Cleaning for Pyrite Dust at Copper-Zinc Mines
High-Efficiency Dust and Gas Cleaning for Pyrite Dust at Copper-Zinc Mines
Client
One of the world's largest full-cycle processors of copper and zinc ore, from mining to smelting and producing marketable products.
Production Process
At the mine, the processes of extraction, crushing, transportation, and grinding take place. All processes must be equipped with wet-type dust collectors.
Problem
A wet-type dust extraction system is required for the copper ore mining facility currently under construction.
Current system component
There is no existing system.
Temperature
-20 to +20 °С
Gas/Dust
Copper-zinc ore. Operational experience of crushing sections has shown that during crushing, screening, and transportation of ore by belt conveyors, a large amount of fine dust containing pyrite sulfur is generated. The pyrite dust that forms settles and accumulates on process equipment and, under certain conditions, tends to self-ignite, which can lead to prolonged downtime of process equipment and significant costs for eliminating the consequences.
Initial Data
Client Technical Specification
The aspiration system shall be provided as a wet-type system based on a Venturi scrubber, with air recirculation and return of the resulting slurry to the existing technology of the main units.
On the upper platform of the bunkers (crushed ore storage), a dry-type aspiration unit shall be provided with periodic discharge into the crushed ore bunker.
At the material loading/unloading points from crushers and screens, and at the transfer points to/from belt conveyors, local hoods shall be installed to remove dust-laden air.
Manual vacuum cleaning of spillage on belt conveyors shall be provided.
In electrical rooms, overpressure shall be maintained to prevent dust ingress; the necessity for installation of exhaust ventilation shall be determined by the design.
The designed aspiration system shall be connected to the existing engineering networks.
Requirements:
On the upper platform of the bunkers (crushed ore storage), a dry-type aspiration unit shall be provided with periodic discharge into the crushed ore bunker.
At the material loading/unloading points from crushers and screens, and at the transfer points to/from belt conveyors, local hoods shall be installed to remove dust-laden air.
Manual vacuum cleaning of spillage on belt conveyors shall be provided.
In electrical rooms, overpressure shall be maintained to prevent dust ingress; the necessity for installation of exhaust ventilation shall be determined by the design.
The designed aspiration system shall be connected to the existing engineering networks.
Requirements:
- Air cleaning efficiency – not less than 98%;
- Automatic start of the aspiration system before the conveyor line equipment of the crushing sections is started, ensuring synchronization of scrubbers with the conveyor line operation;
- Operation of the main crushing section equipment shall be blocked if the wet scrubber is not operating;
- Ensure integration of the newly installed equipment into the existing automatic control system, in accordance with the schemes approved by the Client.
Calculations of Required Capacities:
Placement of Utilities:
- The system requires compressed air from a compressor station (to be determined by the design);
- For process water, use a connection from the existing water supply system of the main building;
- For recirculated water, use a connection from the existing recirculated water system of the main building.
- Instrument air pipelines – stainless steel;
- Water supply pipelines – polyethylene (HDPE);
- Sewage pipelines from the aspiration systems, laid to the tail sump of the main building – polyethylene (HDPE).
- Water balance to determine the demand of aspiration systems for recirculated and process water;
- Technological pipelines of aspiration units – to be coordinated with the Client.
- All measurement signals, status indicators, and alarm signals must have the technical capability and software compatibility for integration into the PROSCON process screen. Communication shall be implemented via Profibus DP;
- Communication with the PROSCON system shall be organized using standardized signals through a Siemens distributed I/O system with support for the Profibus DP protocol;
- Electric actuators with constant speed for remote control shall comply with the technical requirements;
- Pneumatic diaphragm actuators shall comply with the technical requirements;
- Starting and protective devices shall be implemented using Siemens Simocode equipment with Profibus DP protocol support and provisions for the use of safety interlocks.
Equipment Requirements and Configuration
The Venturi scrubber shall be supplied with all necessary piping, a scrubber spray pump of appropriate capacity and performance, a control cabinet, and an automation system with the following instruments:
- Pressure gauges and flow meters for water supply;
- Differential pressure gauge to monitor the air pressure drop;
- Thermometers to monitor the air temperature before the coagulator pipe, after the droplet separator, and the slurry temperature.
- Automatic control of the discharged slurry temperature to prevent freezing in cases where the cleaned air temperature drops below 0 °C;
- Alarm for droplet separator or wet scrubber overflow.
- Scrubber spray pump assembly;
- Set of differential pressure gauges;
- Set of thermometers;
- Set of level sensors for droplet separator or scrubber overflow alarm;
- Control device (logic relay, controller, etc.).
Requirements
Quality of Supplied Goods
The equipment must be new and unused, manufactured no earlier than 2020, of high-quality workmanship and materials. The supplier shall provide the client with a manufacturer’s quality certificate.
Safety of Supplied Goods
The goods must be safe for use as intended and comply with the safety regulations in force in the Republic of Kazakhstan. The supplier shall provide the client with a manufacturer’s quality certificate and a certificate of conformity.
Functional Characteristics (Performance Properties) of the Goods
Technical characteristics must be confirmed by the manufacturer’s quality certificate.
Dimensions, Packaging, Shipment of Supplied Goods, and Delivery Conditions
The equipment shall be delivered in its original factory packaging, ensuring preservation during storage and transportation, adequate protection against environmental and climatic impacts, and prevention of unauthorized opening without visible damage to the packaging integrity.
Warranty Period and/or Scope of Warranty Coverage
The warranty for the equipment is 12 months from the start of operation or 18 months from the date of delivery. In case of a warranty claim, replacement of the goods shall be carried out at the supplier’s expense. Defective goods must be replaced by the supplier within 30 days from the date the client submits a documented claim. Removal and transportation of the goods shall be carried out by the supplier.
The equipment must be new and unused, manufactured no earlier than 2020, of high-quality workmanship and materials. The supplier shall provide the client with a manufacturer’s quality certificate.
Safety of Supplied Goods
The goods must be safe for use as intended and comply with the safety regulations in force in the Republic of Kazakhstan. The supplier shall provide the client with a manufacturer’s quality certificate and a certificate of conformity.
Functional Characteristics (Performance Properties) of the Goods
Technical characteristics must be confirmed by the manufacturer’s quality certificate.
Dimensions, Packaging, Shipment of Supplied Goods, and Delivery Conditions
The equipment shall be delivered in its original factory packaging, ensuring preservation during storage and transportation, adequate protection against environmental and climatic impacts, and prevention of unauthorized opening without visible damage to the packaging integrity.
Warranty Period and/or Scope of Warranty Coverage
The warranty for the equipment is 12 months from the start of operation or 18 months from the date of delivery. In case of a warranty claim, replacement of the goods shall be carried out at the supplier’s expense. Defective goods must be replaced by the supplier within 30 days from the date the client submits a documented claim. Removal and transportation of the goods shall be carried out by the supplier.
Drawings of the Technical Solution
1 - Wet Scrubber Drawing – Capacity up to 75,000 m³/h
2 - Wet Scrubber Drawing – Capacity up to 75,000 m³/h
1- Drawing of Wet Scrubber up to 45,000 m³/h
2- Drawing of Wet Scrubber up to 45,000 m³/h
Venturi Scrubber Package for This Project
Description of the Operating Principle of the Venturi Scrubber Automation
Diagram
List of units where liquid flow is regulated. For this purpose, a flow meter and a motorized valve are installed:
For periodic spraying of the labyrinth droplet separator and the water seal, a solenoid valve is installed. Its operation is controlled by a timer for periodic irrigation, along with a flow meter that signals the operation of the spraying on the droplet separator. If there is no flow while the valve is open, an “alarm” signal is triggered.
A similar principle is applied to the water seal flushing device. It operates based on a timer and is also forced by the lower position of the level sensor. Additionally, a check valve is installed near the water seal in this system.
The level sensor has two thresholds:
Other parameters, such as temperatures and differential pressure, are monitored. If readings go beyond the measurement range, a “warning” signal is activated.
All control is performed via a controller, with output signals sent to the plant control system.
All parameters are displayed in real time on the monitor. All faults and alarms are shown with an indication of their source.
- Flow to the main nozzle.
- Spraying/wetting of the Venturi tube – after the flow meter, the pipe splits for overflow.
- Spraying/wetting of the centrifugal droplet separator walls.
For periodic spraying of the labyrinth droplet separator and the water seal, a solenoid valve is installed. Its operation is controlled by a timer for periodic irrigation, along with a flow meter that signals the operation of the spraying on the droplet separator. If there is no flow while the valve is open, an “alarm” signal is triggered.
A similar principle is applied to the water seal flushing device. It operates based on a timer and is also forced by the lower position of the level sensor. Additionally, a check valve is installed near the water seal in this system.
The level sensor has two thresholds:
- First level – triggers “alarm”.
- Second level – shuts off the water supply pump and fan.
Other parameters, such as temperatures and differential pressure, are monitored. If readings go beyond the measurement range, a “warning” signal is activated.
All control is performed via a controller, with output signals sent to the plant control system.
All parameters are displayed in real time on the monitor. All faults and alarms are shown with an indication of their source.
Excerpt from the Technical Specification for the Automation System
Requirement for the functional purpose of the automated control and monitoring system:
a) In the field of technological parameter monitoring, the system shall provide measurement and display of the following parameters:
The ability to transmit data and receive control commands using the Profibus DP protocol.
Profibus DP Control Protocol
The automated control and monitoring system operates in both “manual” (from the local control panel) and “automatic” (without operator intervention, following a predetermined algorithm) modes.
The system consists of the following levels:
Technical requirements:
Documentation included in the supply:
Pressure range: 0 to 4 kPa
Operating temperature: –20 to +40 °C
Relay output: up to 250 V, up to 2 A
Protection rating: IP65
a) In the field of technological parameter monitoring, the system shall provide measurement and display of the following parameters:
- Gas pressure differential at the scrubber inlet and outlet (measured parameter);
- Liquid level at the bottom of the wet scrubber (monitored parameter: low-level and high-level alarms);
- Position of actuators of the shut-off and control valves;
- Wet scrubber status (stop / operation / service wash / emergency).
- Visual and audible alarms when monitored parameters exceed allowable limits;
- Generation of a pre-start warning signal locally before operation;
- Indication of the root cause triggering the safety automation.
- Protection of equipment from unacceptable operating conditions;
- Technical and software means ensuring the specified sequence of operations during startup, operation, and shutdown of the scrubber.
The ability to transmit data and receive control commands using the Profibus DP protocol.
Profibus DP Control Protocol
The automated control and monitoring system operates in both “manual” (from the local control panel) and “automatic” (without operator intervention, following a predetermined algorithm) modes.
The system consists of the following levels:
- “Lower” level – sensors, actuators, and similar devices;
- “Middle” level – control block/controller, control devices, indication/alarm devices, etc.
Technical requirements:
- Controllers manufactured by Siemens;
- The supply includes specialized software and the necessary cables/adapters for loading (or restoring) the application software.
Documentation included in the supply:
- Functional automation diagram;
- Electrical schematic diagrams;
- Connection diagrams;
- General view of the control and monitoring cabinet (SHUF);
- Equipment and software specifications;
- Installation and commissioning manual;
- Operator manual.
Pressure range: 0 to 4 kPa
Operating temperature: –20 to +40 °C
Relay output: up to 250 V, up to 2 A
Protection rating: IP65
Photo of the Implemented Project
Proposed Solutions
The proposed solution for the copper ore mining facility is a wet-type Venturi scrubber, designed to handle extreme operational conditions while ensuring high-efficiency dust removal. The solution includes:
- Venturi scrubbers with modular Venturi tubes for easy maintenance and replacement of worn parts.
- Centrifugal and labyrinth-type droplet separators with modular design and self-cleaning spray systems.
- Local hoods at material transfer points, manual vacuum cleaning of spillage, and overpressure in electrical rooms.
- Integration into the existing automatic control system with Profibus DP protocol support.
- Automated control and monitoring of air and water flow, temperature, pressure, and slurry level to prevent operational failures.
Result
Since 2020, these Venturi scrubbers have been operating at the mine under extremely harsh conditions—high temperatures in summer and very low in winter. Over the years, the scrubbers have cleaned millions of cubic meters of air from thousands of tons of dust, prevented an environmental catastrophe, and continue to work for the benefit of the community. The client became a regular customer and has purchased many other dust and gas cleaning solutions from us.
Best Scrubbers for Pyrite Dust
We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
After filling out this form, you will obtain the cost of the equipment and time frame over which it will be delivered
By filling out this form, you agree to our personal data processing policy
DELIVERY AND INSTALLATION ALL OVER USA, CANADA, MEXICO
FULL ADHERENCE TO QUALITY STANDARDS
WE CUSTOMIZE INSTALLATIONS TO SUIT YOUR COMPANY
FAVORABLE PRICES FROM A US MANUFACTURER
Operating in USA, Canada, and Mexico
