Vacational training at hindustan copper limited

MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

HINDUSTAN COPPER LIMITED

MALANJKHAND

VACATIONAL TRAINING IN MINERAL PROCESSING FIELD

Training Incharge-: By:-

Mr.Sree Kumar RAHUL SINGH (2012JE1320)

AGM (Mines) DEEPAK KUMAR (2012JE1347)

GOVIND KUMAR (2012JE1346)

ANIKET SINGH (2011JE1073)

LOKESH KU. MEENA (2010JE0008)

ASHISH TUNDELKAR (2011JE0551)

SHASHANT KUMAR (2011JE1099)

FUEL AND MINERAL ENGINEERING DEPARTMENT

INDIAN SCHOOL OF MINES

DHANBAD


INDIAN SCHOOL OF MINES, DHANBAD

ACKNOWLEDGEMENT

I wish to acknowledge the Hindustan copper limited for giving the opportunity to conduct this Vacational training. I am grateful to the support of Hindustan copper limited for the training. I wish to acknowledge the support of Mr.Sree Kumar (AGM,Mines) for this training. I wish to acknowledge the support of Mr.P.K Singh I wish to acknowledge S.S.Patil (DGM,Conc.) for his special support to complete this training. I wish to acknowledge the support of S.R.Gaur (AGM, Conc.)to complete this training. I wish to acknowledge the support of Sh.Ajay Giri (CM, Conc.) and Sh.Kumarswamy (CM, Conc.) I wish to acknowledge the support of Kunal ku. Rajak , Sumit Sinha, Ranvijay Singh, Vishal ku.Mishra I wish to give special thanks to Shubharaj ( Junior Manager ) I acknowledge the wonderful support of individuals numerous to mention by name-they allowed us uninhibited access to their database for the success of the this training.

1



SUMMARY

This Vacational training report mainly deals with the -

experience gain during the training period in malanjkahand

copper project. Hindustan copper limited has location operating

units –one in Rajasthan(Khetri copper complex),one in Madhya

Pradesh (Malanjkhand copper project ) ,one in Jharkhand

(Indian copper complex).Malanjkhand copper project has

capacity of 2 million ton per annum with a grade % of 0.9 – 1.

This report deals with the production of plant ,equipment used

to extract ore ,its type ,grade of ore, primary crusher and its

reduction ratio ,secondary and tertiary crusher and their

reduction ratio .Main process unit consist of milling of ore

,flotation ,cleaner ,recleaner ,thickner ,filter .In Hindustan

copper project only mining and benefication has been done ,the

final product is transported to ,INDIAN COPPER COMPLEX

,Ghatsla (Jharkhand) for smelting ,refining precious metal

recovery.

2



CONTENTS

1.0 CHAPTER ONE

1.1 About Hindustan copper limited.

1.2 About Malanjkhand copper project.

1.3 Process description.

2.0 CHAPTER TWO- PRIMARY UNIT

2.1 Primary Crusher

2.2 Capacity ,Reduction ratio

2.3 Conveyor System

2.4 Motor and Gearbox specification

2.5Apron Feeder

2.6 Lubrication System

2.7 Safety devices and Gamma ray indicator

3.0 CHAPTER THREE –SECONARY UNIT

3.1 Secondary crusher

3.2 Tertiary crusher

3.3 Capacity ,Reduction ratio

3.4 Conveyor system.

3.5 Screen and surge bins

3.6 Lubrication system

3.7 Overall view of secondary unit.

3



4 CHAPTER FOUR- MAIN PROCESS UNIT

4.1 Fine ore bin ,Capacity ,Reduction ratio

4.2 Ball mill and its specification

4.3 Addition of reagent

4.4 Flotation cells

4.5 Cleaner and recleaner

4.6 Thickner and filter

5.0 CONCLUSION

6.0 REFERENCE

4



1.0 CHAPTER ONE -

1.1 ABOUT HINDUSTAN COPPER LIMITED

Hindustan copper limited (HCL) enterprise under the administrative

control of the Ministry of Mines, was incorporated on 9th November

1967 under the Companies Act ,1956. It was established as a Govt. of

India enterprises to take over all plant, projects, schemes and

studies pertaining to the exploration and exploitation of copper

deposits ,including smelting and refining from National Mineral

Development Corporation Ltd. It is the only company in India

engaged in mining of copper ore and owns all the operating mining

lease of copper ore and also the only integrated producer of refined

copper (vertically integrated company ). Major activites of HCL

includes mining, ore beneficiation, smelting, refining and casting of

refined copper metal into downstream products. HCL is a listed

company on BSE and NSE, with 94.01% equity owned by Govn. of

India .HCL has multi-location operating units

Following are locations-:

PLANT LOCATION FACILITIES Khetri Copper Complex Khetrinagar,

Rajasthan Mining ,Ore beneficiation ,Smelting(not in use), Refining (not in use)

Indian Copper Complex Ghatsila, Jharkhand

Mining ,Ore beneficiation ,Smelting ,Refining, Precious metal recovery

Malanjkhand Copper Project

Malanjkhand, Madhya Pradesh

Mining ,Ore beneficiation

Taloja Copper Project Taloja, Maharashtra

Continuous cast Copper rod plant



Present Capacities of HCL’s Mines and Smelter are given below:

1 )Mines

Mines Location Ore capacity (lakh tonnes per annum)

Khetri Copper Complex

Rajasthan 14.00

Malanjkhand Copper Project

Madhya Pradesh 20.00

Indian Copper Complex

,Jharkhand 4.00

Total- 38.00 lakh tonnes per annum

2)Smelter

Plant Location Metal capacity (tonnes per annum)

Khetri Copper Complex

Rajasthan 31,000

Indian Copper Complex

Jharkand 20,500

Total - 51,500 tonnes per annum



3)Wire Rod Plant

Location of plant Location Capacity(tonnes per annum )

Taloja Copper Project Maharashtra 60,000

4) Geological Reserves:

Malanjkhand Copper Project : 331.59 million MT @ 1.05 % Cu

Khetri Copper Complex : 94.87 million MT @1.30%Cu

Indian Copper Complex : 196.85 million MT @1.06%Cu

Total :623.31 million MT@ 1.05% Cu

On Going Project-:

No Mine Location Capacity

Current After Expansion

1 Malanjkhand Mines-Development of Underground mine under existing open cast

Malanjkhand ,M.P

2.0 5.2

(Underground)

2 Khetri Mines Expansion of existing Underground mine

Khetri, Rajasthan

0.5 1.0



3 Kolihan Mine- Expansion of existing underground mine

Khetri, Rajasthan

0.5 1.5

4 Surda Mine – Expansion of existing Underground Mine

Ghatsila, Jharkand

0.4 0.9

5 Rakha Mines –Re-opening of closed Underground Mine

Ghatsila, Jharkand

Nil 1.5

6 Kendadh Mine- Re-opening of Underground Mine

Ghatsila, Jharkand

Nil 0.21

7 Banwas Mine –Development of new underground mine

Khetri, Rajasthan

Nil 0.6

8 Chapri-Sideshwar-Development of new underground mine

Ghatsila, Jharkand

Nil 1.5

Total 3.4 12.41



1.2 MALANJKHAND COPPER PROJECT

Malanjkhand Copper Project was established in 1982. The Ore of Malanjkhand open pit mines have -

1)90% Chalcopyrites 2) 10% (Oxides and Sulphide ores)

The life of Open pit mine is 32 years . It has 250(Approx) million tones copper ore deposits. 52 (Approx.) million tones of the ore has been extracted till

now. 198(Approx.) million ton is still remaining . Overall plant capacity is 2.0 million tonnes per annum.

Sulphide ore are of three types depending on the percentage of Copper present in it , they are

0.95%-above—high grade ore , 0.45-0.9%-- low grade ore 0.2-0.44%--lean grade ore

1.3 PROCESS DESCRIPTION

Run of mine ore of size (-) 1200 mm is crushed in three stage to (-)

12 mm. The crushing complex consists of one primary gyratory

crusher (1350x1900 mm), one secondary cone crusher (2200 mm)

7’ standard head, three tertiary cone crusher (2200 mm) short head

and four Nos. vibrating screen and associated conveyor network,

apron feeders and belt feeders.

1.2 Primary crushed ore passes through a double deck vibrating

screen (8ft. x 20 ft.) before its entry to secondary crusher. For

tertiary crushing three nos. vibrating screens (8ft. x 20 ft.) are used

in closed circuit along with three tertiary crushers.

1.3 The under size from screen which is the feed for grinding mills

is transported by conveyors and stored in the parabolic fine ore bin



of capacity 10,000 MT. Ore is withdrawn from this bin with the

help of belt feeders and fed to the ball mills.

Single stage wet grinding is done with the help of four nos. ball

mills each of size 3810x5791 mm, operating in close circuit with

660 mm hydro cyclones. Mills are over flow type and lined with

replaceable rubber liners. CI grinding media of 80 mm dia is

charged inside the mills for grinding of ore.

1.5 Hydro cyclone over flow (35-40% -200 mesh) is subjected to

four stage flotation in rougher, scavenger, cleaner and recleaner

(all 300 cft. Cells). The recleaner concentrate (final concentrate)is

pumped to 25 meter dia thickener and the scavenger tails (final

tail) gravitates into tailing pulp tank.

1.6 Thickened concentrate from the thickener is pumped to two

nos. of disc filters 2.7 meter dia. The dewatered filter cake from

disc filter having 10 to 12% moisture is conveyed into the

concentrate storage yard. Water from the thickener over flow is

recycled back in the process circuit.

Final tails is pumped through rubber lined pipes to tailing disposal

area about 2.4 Kms away from the plant.Hydro cyclones are used

for embankment build up along the periphery of the tailing dam.

Tailing dam having capacity to 88 million tonnes of solids is at the

end of final stage of operation. The settled water at the tailing dam

is recycled back to the plant for use in process



M.C.P CONCENTRATE PLANT (6000 TPD )



2.0 CHAPTER TWO-PRIMARY UNIT

2.1 PRIMARY CRUSHER

Primary Gyratory crusher are designed for first stage crushing of ferrous and non-ferrous ores. They are generally installed in the first stage of technological crushing scheme.

Gyratory type crusher. Model No-: PGC 1350 (HEC- Heavy Engg. Corporation ,Ranchi) Width of feed opening -:1350 mm Width of discharge opening-:165mm Capacity- :870 MTPH at 150mm setting Oscillation of Crusher head -: 2-4 rpm on no load Motor drive-360kw Motor speed – 591 rpm V- Belt – (E-9093)

Before starting the crusher, check the following and make sure that they are in satisfactory condition.

Check the oil level in the settler ;it should not be below 1.2 Check the tension of V belts; all the belts should be tight. Check the crushers crushing chamber; there should be no

material in it. Check the grease lubricating system for its proper functioning. Start any one of the oil pump and observe the delivery line oil

pressure to be not less than 1.0kg/cm2 and not more than 2.0kg/cm2 .

Wait for 5-10 min, so that oil circulation stabilishes. Check the drain pipe oil temp. ,it should be below 600 C. Check the drain pipe oil temp. from counter shaft , it should be

below 600 C.



Check the oil pressure before and after the filter; the difference should not be more than 0.3kg/cm2 .

If the oil temp. is more than 60-650 C pass the oil through the heat exchanger and observe that , water inlet pressure is less by 0.3kg/cm2 to the oil outlet pressure.

Start the crusher main drive . Observe for any knocking or abnormal sound from the crusher

,there should be no such abnormal sound . Count the number of rotation of the crusher with the ore

Fig 1. OPEN SECTION OF GYRATORY CRUSHER SHOWING CRUSHER HEAD



2.2 CAPACITY, REDUCTION RATIO

Capacity-870 TPH Feed size-1200mm (max.) Product size-140mm (max.) Reduction Ratio = 8.52(approx..)

FLOW CHART

-1200mm -140 mm

FLOW DIAGRAM SHOWING EACH LEVEL OF PRIMARY UNIT

TOP LEVEL

4TH FLOOR

3RD FLOOR

2ND FLOOR

1ST FLOOR

GROUND LEVEL

PRIMARY CRUSHER (870 TPH)

GYRATORY CRUSHER

GYRATORY CRUSHER

FEEDING LEVEL

INTERMEDIATE LEVEL

(CRUSHING ZONE)

DICHARGE LEVEL

HOPPER ( GAMMA RAY INDIACTOR )

LUBRICATION SYSTEM

APROON FEEDER

CONVEYOR SYSTEM



2.3 CONVEYOR SYSTEM

Used for transportation of feed (secondary ) from apron feeder discharge to coarse ore store(COS) for convience to carry it to secondary unit.

Following are the important section of conveyor system -:

Idlers Belt Pulley Arrangement Pull cord

2.3.1>IDLERS

Pictorial view of carrying Idlers



Used to support the belt. To protect the belt. Used in carrying the belt.

.1 TYPES OF IDLERS

a) Carrying Idlers – Carry the belt b) Return Idlers – Help in returning the belt c) Impact Idlers- Protect belt from wear and tear d) Adjustment Idlers e) Self Alignment Idlers f) Side Idlers.

.2 IDLER SPECIAFICATION Number of Carrying Idlers-(199-10%)*3=540 Number of Return Idlers-(199/2)=100 Gab b/w two carrying idlers = 1000mm Gab b/w two Return idlers =2000mm

2.3.2>BELT

Length of belt -398m Commonly named as primary belt Width of belt -1400mm Nylon is used to give strength and flexibility Thickness of belt is 24mm Notation –M24

NYLON PLY

RUBBER PLY

RUBBER PLY



SYSTEMATIC VIEW SHOWING DIFFERENT SECTION OF BELT

2.3.3>PULLEY ARRANGEMENT

Total no. of pulley in primary conveyor-12

SYSTEMATIC PULLEY ARRANGEMENT OF

PRIMARY CONVEYOR

8

(2 )HEAD PULLLEY

HEAD SCUP PULLEY (3)

4

5

7

6

HEAD BEND PULLEY (9)

TAIL PULLEY (1)

TAIL SCUP

PULLEY (12)

TAKE UP PULLEY

(10)

TAIL BEND

PULLEY (11)

8



2.3.4> PULL CORD

Used to stop conveyor belt in Emergency Condition such as over loading,breakdown of belt etc.

2.4 MOTOR AND GEAR BOX

MOTOR

There are basically two motor attached to pulley No. 6 and 8

M1- PULLEY 6 M2-PULLEY 8

150 hp 150 hp 1485 rpm 1485rpm 188A 186A V-415V V-415V Frequency- 50 Hz Frequency- 50 Hz

Mgf. By- SIEMENS (GERMANY)

GEAR BOX

ELECON Mgf. SERIAL NO-WHG33992LH TYPE-SCN-355 SPEEED RATIO- 45:1

ELECON ENGINEERING CO. LTD



FLUID COUPLING Used to reduce Energy To safe motor during the condition of high load Act as best energy saver

2.5 APROON FEEDER

Crushed product from the primary crusher and coarse ore stock pile are received by apron feeders with whole speed drive through hoppers and then transferred to conveyor.

SPECIFICATION-:

APROON FEEDER AT PGC APROON FEEDER AT COS Size-:1219*9000mm 1219*9000mm Capacity-:200-1000 MTPH 200-530 MTPH Motor-:37 kw 22.5 kw

MOTOR

M1

FLUID

COUPLING C1

GEAR BOX G1 PULLEY 6

MOTOR

M2

FLUID

COUPLING C2

GEAR BOX G2

PULLEY 8



Before starting the Apron Feeder, check the following and make sure that they are in satisfactory condition.

Check all the bolts and nuts of all units and see that they are all tight.

Lubricate where it is necessary. Check for the pressure of any big boulder being jammed in the

hopper or on the apron feeder, Remove it . Tighten screw take on just enough to ensure a smooth

transition of pan line on the first return roller . Check bearings temperature , it should be within 35-550 C, After

making sure about the above points, see that the conveyor to which the apron feeder is feeding is running .

Now, start the apron chain drive ,and feed.

SYSTEMATIC VIEW OF APRON FEEDER ARRANGEMENTS

TRACK ROLLER

TRACK CHAIN

MOTION

RECEIEVING CHUTE

TRETURN ROLLER PRODUCT TAILING



2.6 LUBRICATION SYSTEM

For Eccentric Motion , shaft counter ,Bend gear . Servo-system 526 of IDC 125 lt/min ( circulation volume)

For crusher head suspension and mantle Servo Gem-2 of IOC (grease) Once in 16 hrs

NAME OF THE UNIT

NO. OF UNIT

NO. OF POINT PER UNIT

TYPE OF SYSTEM

RECOMMENDED GRADE OF LUBRICANT

VOLUME OF LUBRICANT

INTERVAL OF LUBRICANT

ECCENTRIC 1 1 Circulating

Servo- System 526 0F IDC

125 l/min.

Continous

BEND GEAR TRANSMISS

1 1 Circulating


125 l/min

Continous

COUNTER SHAFT BUSHING

Circulating


125 l/min

Continous

TOP SUSPENSION OF CRUSHING HEAD AND MANTLE

1 1 Centralised Grease

ServoGem-2 of IOC

1000 cc

Once in 16 hrs

DUST SEAL RING


ServoGem-2 of IOC

Once in 16 hrs

ANTIFRICTION BRG. OF DRIVE


ServoGem-2 of IOC

2.5cc Once in 08 hrs



2.7 SAFETY DEVICE AND GAMMA RAY INDICATOR

2.7.1 SAFETY DEVICE

For crusher safety Electromagnet Metal detector

ELECTROMAGNET

It is used to attract the metallic material which show magnetic property to avoid choking, damaging the inner shell of secondary crusher .

METAL DETECTOR It is used to detect those material / metal which donot show metallic property to avoid choking, damaging the inner shell of secondary crusher .



For Emergency safety issue Pull cord

2.7.2 GAMMMA RAY INDICATOR

When the product from discharge level from crusher increased in hopper and the level where gamma ray indicator installed crosses, then hopper level increased above it, the receiver installed at the other end does not receive the beam from the indicator at that time ,then alarm startas

Used to avoid choking of hopper . Used to avoid breakage of oil pump. Safe crusher from wear and tear.

FEED

SYSTEMATIC VIEW OF HOPPER SHOWING GAMMA RAY INDICATOR

GAMMA RAY

INICATOR

RECIEVER



3.0 CHAPTER 3- SECONDARY UNIT

3.1 SECONDARY CRUSHER

Secondary cone crusher are designed for second stage crushing

of ferrous and non-ferrous ores. They are generally installed in the

second stage of technological crushing scheme

Type of crusher:-Cone crusher (Standard head)

Width of feed opening- 350mm

Recommended max. Feed size- 300mm

Closed side setting- 30 to 60 mm

Capacity at minimum recommended setting- 550 TPH

Direct coupled with motor with coupling pad- Hydraulic setting

arrangement.

Lubricant used - Servo system 121

Motor- 250 KW/65.5A/493RPM/3.3kv

-140mm -40mm

Belt 1

Secondary crusher

Secondary crusher

BELT 5

SECONDARY CONE

CRUSHER(Standard

head)



Before starting the crusher, check the following and make sure

that they are in satisfactory condition

Check the oil level in settler Tank- it should be more than 2/3 cm.

above the suction pipe.

Start the oil pump.

Check the oil filter inlet and outlet pressure. The difference

between the two should be u8nder 0.3Kg/cm2. If it is more than

that, rotate the filter. If there is no improvement then the filter

has to be cleaned.

Check the temp. of oil inside the tank. It should be below 50 0C.

If it is more than that, the heat exchanger to be taken into circuit.

Heat exchanger water pressure to be left preferably below the oil

pressure to avoid mixing of water into oil through any leakages.

Oil pressure should be 0.4 to 2 Kg/cm2.

Temp. of oil leaving the crusher should be below 60 0C.

Check the coupling pad & bolts.

Start crusher motor.

Check the crushing head RPM it should be below 10.

Check if there is any abnormal sound or vibration.

Open hydraulic seal water until the clear water comes out from

the outlet. Quantity of Hydraulic seal water should be within 36 to

45 Lit/Min.

Start feeding.



3.2 TERTIAY CRUSHER

Tertiary cone crusher are designed for third stage crushing of

ferrous and non-ferrous ores. They are generally installed in the third

stage of technological crushing scheme.

Type of crusher- Cone crusher (Short head)

Size: 7’

Capacity: 400 MTPH

Motor: 262.5KW/61.5A/985RPM/3.3KV/Induction

V-belt driver: V-belt size-E8470; E-330

Hydraulic setting arrangement.

Lubricant used- Servo system SP 17

Water flow rate through heat Exchanger (cooler) automatically

controlled.

-40mm -12mm

Before starting the crusher, check the following and make sure


Check oil level in the settler tank. It should be at the intermediate

position in between low & high makings.

Start the oil pump.

Check the differential pressure gauge. It should show less than 25

PSI. Higher differential pressure indicate clogging of filter.

TERTIARY CONE

CRUSHER



Check the oil temp. Entering cooler. It should be above 60 0F.

Check the oil temp. Leaving cooler. It must be less than 115 0F.

Open the inspection cover of the settling tank & check the oil

drain line from the crusher. Inside the tank to ensure that the is

circulating. Normally oil flowing out of the drain line should be of

sufficient as to half fill the pipe.

Oil pressure after cooler should be within the range of 5-15 PSI.

Oil temp leaving the crusher should be less than 120 0F.

Stop the crusher if the temp of oil leaving the crusher reaches 130 0F.

Temp difference in between the oil entering the crusher & leaving

the crusher should in between 1 &3 0F. if the temp difference is

more than 5 0F crusher should be check for any fault.

Check the V-belt tension of the crusher.

Start the crusher motor.

Check the RPM of crushing head & motor current.

Check if there is any abnormal sound or vibrations.

Open the Hydraulic seal water & wait till the clear water comes

out from the out-let.

Start feeding.



3.3 CAPACITY, REDUCTION RATIO

Capacity

Secondary crusher-584TPH

Tertiary crusher-360 TPH

Reduction Ratio

Secondary crusher-3.5

Tertiary crusher-3.33

3.4 CONVEYOR SYSTEM

Used for transportation of feed (secondary ) from apron feeder at

coarse ore store(COS) for convience to carry to secondary unit

3.4.1 BELT AND THEIR NOTATION

BELT NO.

LENTH (m) WIDTH(m) THICKNESS(m)

1 380 1200 24 2 265 1400 24 3 32 1400 24 4 280 1400 24 5 270 1200 24 6 140 1200 24



BELT 1

Used to carry feed from COS to secondary crusher

BELT 2

Used to carry Crushed product from secondary

and tertiary crusher to conveyor belt 3

SECONDARY

CRUSHER

BELT 3



BELT 3

Used in transferring belt 2 product to belt 4

BELT 4

Carry (-40mm) feed from belt 3 to surge bin S1,S2,S3

S1 S2 S3



BELT 5

Carry the -12mm product from screening to FOB

(fine ore bin)

3.5 SCREEN AND SURGE BIN

3.5.1 SCREEN

Double Deck Screen- 8ft X 20ft

Panel size(mm):-

Upper Deck: 40 x 40 – 10 nos.

Lower Deck: - 12 x 20 – 6 nos.

Single Deck Screen- 8ft X 20ft

Panel size(mm):- 12 x 20 – 6 nos. 15 x 20 – 4 nos.

3.5.2 SURGE BIN

There are three surge bin named as S1, S2, S3.



3.6 LUBRICATION SYSTEM

Servo system SP17

Heat Exchanger

T1-Serial no-11070, 2.4 kg/cm2 (0-6)

T2- pressure (1-2) kg/cm2 (0-4)

LUBRICATION CONSISTS OF 4 MOTOR SYSTEM

M1 and M2 are working

M3 –Stand by

M4- Purifier

3.7 MOTOR SPECIAFICATION

EQUIPMENT TYPE

NOTATION

KW/HP PHASE

VOLT(V)

TYPE RPM

TERTIARY CRUSHER

MT1 250 3 3300 TEEPAK

492

TERTIARY CRUSHER

MT2 375 3 3300 SYMONS

993

TERTIARY CRUSHER

MT3 250 3 3300 HEC 492

LUBRICANT PUMP

ML1 5.5 - 415+-10%

- 1440

PURIPIER PUMP

MP1 5.5 - 415+-10%

- 1430



4.0 CHAPTER FOUR-MAIN PROCESS UNIT

4.1 FOB(FINE ORE BIN ) CAPACITY ,REDUCTION

RATIO

FOB acts like store in which feed materials (-12mm) of mill

are store from where it is fed into mill through different

conveyors arrangements.

Capacity -10,000MT

Reduction Ratio-

4.2 BALL MILL

Ball mill receive the crushed fine ore ( - 12mm ) and grind it wet to

the mesh-of-grind i.e. ,60% -200 mesh. Fine ore and water are fed at one

end and the milled product is discharged at the other end. Steel balls are

use as grinding media

Ball Mill Size - 5791 x 3810 mm

Drive Motor - 1200 KW

Speed of the mill - 15.1 RPM

Type of mill - overflow

Feed rate - 1515 TPD / 60 TPH

Pulp density in the mill - 75% solids by weight



Before the starting the ball mill check the following and make sure


Check the oil level of the main bearings, Check the oil wipers, light

contact with the bearing.

Check the temp. & grease of pinion & drive shaft pillow blocks. It

should not be very hot.

Check the oil spray system to the girth gear. Be sure that it

operate properly and check that there is lubricant in the

container. Air pressure require for spray is 6 Kg/cm2.

Open the water cooling valves and adjust it to satisfactory flow

rate (20 Gal. / Min.)

Start the reducer box oil pump and make sure that oil is

circulating.

Start the Hydraulic lift, at the trunnion bearings, observe the

pressure gauge. The pressure increases and then drops a little.

Inform the ground-ore pump area operator and start the main-

drive of the mill.

Observe that the mill starts smoothly.

Check the oil distribution in the trunnion bearing.

Start feeding the fine ore and water. Adjust these two to required

values.



PROCESS FLOW CIRCUIT OF GRINDING UNIT-

4.3 FLOATATION CELL

Flotation cells are used to separate out the copper sulphide particles

as a forth containing these minerals, leaving the pulp depleted of it.

There are several stages of flotation operation

SCHEMATIC REPRESENTATION OF FLOTATION CELL



ROUGHER & SCAVENGER

The aim of this stage is to float all the copper sulphide particles and

leaving a trailing which contains as less copper as is possible

Copper % in Rougher cell – 7 %

Copper % in scavenger cell – 15%

DETAILS

Cell Type & Size - 300 CFT double-overflow flotation cells.

No. of cells - 4 rows of 12 cells each, the first 7 are

rougher

& second 5 are scavenger

Drive Motor - 30 HP, 1000 RPM

V-belt used - C – 168 fenner.

Forth paddle drive - ¾ H.P. 28 RPM

Addition of Xanthate in Mill feed to increase conditioning time.

Diversion of Concentrate of first Scavenger Cell as Rougher

Concentrate to avoid recirculation.

Removal of old and inefficient recleaner cell (Fagergren cell) of

60 ft3 by efficient and bigger 300 ft 3 cell (Denver D-R cell).

Diversion of highly floatable minerals (high kinetic minerals)

from the first rougher cell concentrate directly to the thickener.

This procedure is adhered when the head grade that is being

treated is more than 1.0%Cu.



4.4 ADDITION OF REAGENT

LIME: - Is added in the mill feed in order to maintain the

desired pH (8.5-9.5)

PINE OIL: - Is added in the flotation cells and it helps in

better froth formation

SODIUM ISOPROPYL XANTHATE:-Is added in the flotation

cells and it acts as a collector for copper ore minerals.

4.5 CLEANER AND RECLEANER

This stage aims at producing a concentrate of definite copper content.

Copper % in cleaner cell – 17 %

Copper % in recliner cell – 20 %

DETAILS

No. of cells - 4 rows contain 1 cleaning cell each, and 1

for Recliner

Drive motor - 15 KW 1470 RPM

V-belt used - B-120



Froth paddle drive - 0.75KW 35 RPM

4.7 THICKNER AND FILTER

4.6.1 THICKNER

MAKERS : THE EI CO-K.C.P LTD MADRAS

SIZE OF THE UNIT : 83’0” SWD

TYPE : ‘C’ with C 54 DRIVE, CLDT0 C 54 LIFT having

2shaft and long arms

Direction of rotation: clockwise

RPM 0.1

Drive unit: moter 1 no, HP-3, RPM-1440

Lifting device: 610mm lift,motor 1 no., HP-1.5

Purpose of the thickener mechanism: 17500kgs.

To thickener the dilute concentratc product before

sending to ceramic filter



4.0 CONCLUSION

Malanjkhand copper project is a growing

project which is to be expanded in few year . The copper grade is

still not good ,it is about 0 .95% which is very costly ,but recently

many changes has to done in MCP such as changing of filter

,earlier it was Disc filter but changed to ceramic vaccum fliter

(China filter).One other hand thickner is also going to be

changed to High rate thickner ,by doing such changes time

reduce .Their is work going on in planning of underground mine

in MCP hence the project will be expanded to large extent.

We are very thankful to Research and Development department

of MCP as they guided us pretty well.

Earlier we were having theoritical knowledge of crushers and

other equipments used in metal processing but now undergoing

training in prestigious company help us enhancing our concepts

theoretically as well as practically .To a student this plant is a

good place to gain expirence in industry .



5.0 REFERENCE

Research and development department of MCP.

Ajay Giri (CM,Conc.)

Kunal ku. Rajak, Sumit Sinha, Ranvijay Singh .

Shubharaj ( Ju.Manager)



Figure 3: Illustration of the flow chart used in the Web application to generate the global estimation error

(GEE).



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5.0 FUNDAMENTAL SAMPLING ERROR MODEL

Fundamental sampling error depends on the number of critical particles in the

sample .For solides, powders and particulate materials, especially at low

concentration of critical particles the fundamental error can be very large

5.1 Application of Gy;s fundamental sampling error Eqn for designing

sample preparation procedures:

If the material to be sampled contain particle of different shape and size, it is

difficult to estimate the number of critical particles in the samples.

Gy’s formula for relative variance of the fundamental sampling error -

( Relative standard deviation of the fundamental sampling error (FSE) Where = absolute standard deviation (in concentration units) ; =average concentration of the lot; d=characteristic particle size = 95% limit of the size distribution; MS=sample size; ML=lot size; and C is the sampling constant that depends on the properties of the material sampled. C is the product of four parameters:

where f is the shape factor (fig 4)



Shape factor-:Shape factor is the ratio of the volume of the sampled particles having the characteristic dimension d to the volume of the cube having the same dimension

13

Fig. 4. Estimation of particle shape factor and liberation factor for unliberated and liberated critical particles. L is the particle size of the critical particles.

g= size distribution factor

- g=0.25 ,wide –size distribution

-g=1, uniform particle size

c is the constitution factor and can be estimated by using Eq.

Here

aL= av. Concentration of lot

= concentration of the analyte in the critical particle



= critical particle density

= diluent particle density

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6.0 ACCURACY OF GY’S FORMULA FOR THE FUNDAMENTAL

SAMPLING ERROR

-: Gy ‘s TOS consists of the prediction ,estimation or minimization of the

variance of the “fundamental sampling error” denoted by Var (FSE).

-: Var (FSE0 is regarded as the relative variance of the sampling error that is

obtained under through mixing of the population .

-: Var(FSE0 is Gy’s TOS is considered to be minimum possible variance for

incomplete or partial mixing .

-: When population is not thorpoughly mixed ,Gy;s TOS prescribes that an

additional relative variance components

Var (GSE)( variance in grouping and segregation error ) must be added

besides Var (FSE) to get the variance of the total sampling error (TSE)

Var (TSE)=Var(FSE)+ Var(GSE) + additional variance component .

Fundamental sampling error eq.

(FSE Eq.)

V= the sampling variance



f= bruntan shape factor

g= size factor

l=liberation factor

c=mineralogical composition factor

D=Nominal size

Msample =Mass of sample

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6.1 Most common error in applying Gy’s formula in the theory

of mineral sampling and the history of the liberation factor.

a)Error in calculation of liberation factor-:

Taking an example of gold mines ,since the gold inthis case is

almost pulverized down to a nominal size of 40 microns to nominal

size of 1.5 cm

liberation factor (l)=( 0.004/1.5)0.5=0.052

this value is input for formula

Table 1.showng error in calculation .



Fig.5 Sampling nomograms 16

While investigating problem ,a author discovered exact source of

thses formula difficulties ,(FRANCOIS-BONGARCON ,1991-1998)

SFSE = Sampling relative variance

MS=Sampling Mass

ML=lot mass

f = 0.5 (approx.)

g= 0.25(approx.)

c=mineralogical factor

d=nominal size

l= liberation factor

when ML>>MS , formula becomes

SFSE2= fgcld3/MS

-:Gy’s proposed experimental model of variation of l with dl and d

l=(dl/d)0.5



-:Another model for the liberation factor

l=(dl/d)b ,b= additional parameter; gold (b=1.5)

6.2 CONSEQUENCE OF AN ERRONEOUS MODEL FOR l

EXAMPLE 1- CALCULTION OF A MINIMUN SAMLE MASS

SOLUTION- Given that dl=1.27cm, a grade of I ppm Au (10-6)

density =19.3 g/cm3, f=0.5 ,g=0.25

d=10 microns for gold,SFSE2=0.01 (10%)

SFSE2= fgcld3/MS

= 0.5*0.25*c*(dl/d)0.5d3/MS

=0.5*0.25*c*dl0.5d2.5/MS

=0.5*0.25*19.3/10-0.6*(10-3)0.5*(1.27)2.5/MS

MS=13.9 *106 grams/13.9 tonnes 17

Which is not possible ,the gold is very fine and it is well known by experiment

that sample of few k are all it takes to get an acceptable reproducibility.

EXAMPLE 2-; CALCULATION OF GOLD LIBERATION SIZE.

SOLUTION -: 10% standard deviation ,

MS=15 kg , SFSE=0.10,d=1.27 ,density=19.3 g/cm3

f=0.5 liberation factor =0.25

SFSE2=fgcld3/MS

l=(dl/d)0.5, l= SFSE2*MS/fgcd3

dl= 3.9 *10-9= 0.39 A0, which is absurd result.

Hence from experimental evidence ,it is proved that Gy’s formula is inaccurate



18

7.0 CONCLUSION

From the report it is cleared that Gy’s sampling theory still not

adopted as accurate one .As we saw that the formula given by Gy’s

totally consists of assumption and factor used did not give better

result and also from the experimental data shown ,it is cleared that

the formula for calculating fundamental sampling error is inaccurate

.Number of process control, product uality control for consumer

safety and environmental control are being carried out with the

help of sampling theory developed by Pierre Gy. Examining and

designing sampling procedures normally decreases the probability

of error in sampling, sampling equipment should be correct,

sampling procedures should be examined by trained person in

regular interval .Hence at last it is concluded that sampling is



important issue in industries and more work on sampling is

required to least the error in sampling.

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8.0 REFERENCE:

1) Practical applications of sampling theory by Pentti Minkkinen ,Department of Chemical Technology, Lappeenranta University of Technology, Lappeenranta, Finland Received 1 August 2003; received in revised form 1 January 2004; accepted 12 March 2004 Available online 28 July 2004

2) Sampling-Helper: un outil internet pour qualifier la Représentativité de stratégies d’échantillonnage enréseaux d’assainissement et milieux récepteurs Rossi L, Rumley L, Ort C*, Minkkinen P** , Barry DA, Chèvre N***

3) Sampling Errors and Control of Assay Data Quality in Exploration and Mining Geology Marat Abzalov 37 Belmont Avenue, Belmont, WA6104 Australia

4) Part 1: Understanding the components of the fundamental sampling error: a key to good sampling practice by R.C.A. Minnitt*, P.M. Rice† and C. Spangenberg§

5) A Critique of Gy’s Sampling Theory Dihalu, D.S. Geelhoed, B.



6)The most common error in applying ‘Gy’s Formula’ in the theory of mineral sampling, and the history of the liberation factor by D. François-Bongarçon* and P. Gy†

1

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