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A Report
OnIndustrial Training In
Mechanical Maintenance And
Introduction OfHindustan Zinc LimitedRajpura Dariba Mines
(1st june, 2013 to 15thJuly, 2013)
Submitted By Garvit Agrawal(11001894)
B.Tech Mechanical Engineering (2010-14)
Lovely Professional University, Punjab
Under the Guidance ofMr N.K.Devpura
Mr J.P.VermaMr R. L. SainiMr Y. S. Bhati
Hindustan Zinc Limited, Rajpura Dariba Mines
1
CERTIFICATE OF COMPLETION
This is to certify that Mr. Garvit Agrawal,fourth year student of B.Tech Mechanical Engineering from Lovely Professional University has completed the project titled “Industrial Training in Mechanical Maintenance and Introduction of Hindustan Zinc Limited, R.D.Mines” during the period from 1st
June 2013 to 15thJuly 2013 at Hindustan Zinc Limited, Rajpura Dariba Mines.
Mr N.K.Devpura(Sr. Manager, Safety & Training)
2
ACKNOWLEDGEMENT
First and foremost, I am highly indebted to the Hindustan Zinc Limited, R.D.Mines, for
providing me an opportunity to carry out the project work under their highly skilled and
experienced team. Moreover, the learning atmosphere present over here enhanced my interest
in the project.
I would like to express my special thanks of gratitude to my mentors Mr. J.P.Verma, Mr.
Ramji Lal Saini,Mr. Yogendra Singh Bhati, who were always there with me throughout
the project despite their busy schedule. They helped me with everything they had, be it their
approach towards the project, their practical knowledge and experience which made me
analyze things in a better way.
I would also like to acknowledge the assistance of the following individuals, without whose
help, successful completion of my project would not have been possible: Mr. Sunil, Mr.
Prabhu Verma, and Mr. Babu Singh Ravna.
Thanks are also extended to those who acted as a reference group, and to others who
willingly contributed.
3
TABLE OF CONTENTS
1. Objective and Methodology……………………………………….……....1
2. Introduction………………………………………………..……….…...….2
2.1 Exploration History……………………………………….…….….…....3
2.2 Regional Geology and Structure……..…………………………..……...3
2.3 Aim of an industry…………………………………………….…...…....4
2.4 Problems/interruption with an indust…………………………….……..4
2.5 Uses of Zinc…………………………………………………..….……...5
3. Mineralisation……………………………………………………….……..6
3.1 Mine Geology………………………………………….…….....….……6
3.2 Lithology……………………………………………………….….……6
3.3 Geological Discontinuous ……………..……………………….….…...7
3.4 Lodes and Mineralization…………………........……………….….…...7
3.5 Reserves………………………………………………………....…..….7
4. Mining………………………………………..………………….……........8
4.1 Access to the mine…………………………………………….…….….8
4.2 Fill Plant…………………………………………………….…….……9
4.3 Rock Mechanics Cell……………………………………….…….…….9
5. Environment Management…………………………………………...…10
6. Vocational and Safety aspects…………………………………………...10
7. Infrastructure Facility……………………………………………..….....11
7.1 About Organisation………………………………………………........12
7.2 Central Workshop……………………………………………………..12
7.3 Mining Department……………………………………………………20
7.4 Mill Mechanical Department………………………………………….30
8. Mining Process……………………………………………………………43
9. Overview of the Process…………………………………………….……45
10. Conclusion…………………………………………………………….…..46
4
OBJECTIVE & METHODOLOGY
OBJECTIVE
The objective of this training is to get practical and field knowledge of the mechanical
engineering. To get in depth knowledge and role of the different departments such as
workshop, mill, mining and to know how mining is done.
METHODOLOGY
The training started with the importance of the safety aspects and what are the safety
measures taken in the industry. Further, the equipment required and how the mining is done
and what are the parameters for designing the cement slurry that is required during mining.
The training also focused on how to refine and separate the different elements from the ore
that was taken out by the mining process.
Also involved, the different machines used at different departments such as workshop, mill,
mining.
The training included how to refine and separate the elements from the extracted minerals.
5
1. INTRODUCTION
There are many places in our country, where we get different types of
metallic substances as raw material for industries. In these substances, the metals are present
in compound form. These substances are called as minerals. Minerals are mostly present as
oxides, sulphides, carbonates, chlorides and silicates.
Those minerals from which we can get the metals conveniently and at low cost are called
ores.
Less reactive metals, as gold, silver, platinum etc. are obtained in Free State in nature.
Copper is basically obtained as copper pyrites (CuFeS2). It is obtained from mainly
the states Rajasthan, Bihar, Madhya Pradesh, Orissa, Karnataka etc.
Iron is obtained from Hametite (Fe2O3), from the states Madhya Pradesh, Andhra
Pradesh, Tamil Nadu, Karnataka, Goa, and Maharashtra.
Zinc is mainly obtained from its ore Zinc Blende (ZnS) available mainly in the states
Rajasthan and Orissa.
Rajpura Dariba Mine is located at the southern extremity of Rajpura Dariba Bethumni
metallogenic belt in Rajsamand district, Rajasthan, at a distance of 76 kms from Udaipur.
Other prominent deposits in the belt are Sindesar Khurd and Bamnia Kalan. Rajpura Dariba
has been under production since 1983 whereas Sindesar Khurd is currently under mine
development stage.
Extensively mining both by opencast and underground methods was carried out by ancient
miners for many centuries. Carbon dating of wooden implements recovered from the
ancient working has these operation are as old as 2500 years.
Surface manifestation of mineralization is by the way of an extremely well developed
Gossan (declared as an National Gossan Monument by GSI).The zone of oxidation extends
to depth of 40-50m from surface. The presence of ancient workings, heaps of mine debris
and slag serve as guides to Sulphide Mineralization.
6
1.1.1 EXPLORATION HISTORY
Though worked extensively in the past, well-developed gossan / ferruginous breccia and
slagheaps were first reported by B.C. Gupta of Geological Survey of India (GSI) in the
year of 1934. However, systematic exploration was initiated by GSI in 1962 at the southern
end of belt.
Drilling in Rajpura Dariba, Bethumni and few other locations were completed by 1970.
This was followed by detailed delineation, feasibility study and commencement of mining at
Rajpura Dariba deposits by Hindustan Zinc Limited (HZL).
1.1.2 REGIONAL GEOLOGY AND STRUCTURE
Dariba, Bethumni Metallogenic belt comprises an assemblage of medium to grade
metamorphic equivalents of orthoquartzites carbonates and carbonaceous facies rocks
belonging to Bhilwara Super-Group (3.5-2.5 Ga) and extends for about 19 km in north-
south direction. This cover sequence is underlain by basement rocks (gneisses and schists) of
Mangalwar Complex.
The structure of the belt is as an isoclinal fold (GSI, 1990) having synformal closure at
Dariba in south and antiformal closure at Bethumni in the north.
The synformal closure exhibits steep plunge (55°- 60°) towards ENE and the antiformal
closure shows shallow plunge (15°- 20°) towards NE.
The regional trend of the formations veers from N-S between Dariba and Rajpura in the
south, to N15°E-S15°W between Sindesar Khurd and Sindesar Kalan in the middle and
finally to N50°E-S50°W around Bethumni in the north. The rocks generally show moderate
to sleep deep towards E\SE.
7
1.1.3 Aims of an industry
To produce goods
To have continuous production
To produce goods at low cost
To produce goods of high quality
Have long life of equipment.
1.1.4 Problems/interruption with an industry
Break Down
Power Failure
Industrial relation problem
Fire and Explosives.
8
1.1.5 Uses of Zinc
Zinc Powder
Bras Items
GI pipes
CuSO4
UdaipurDabok Airport
Mavli
Nathdwara
Vallabh Nagar
Fatehnagar
Kankroli
Dariba
Sindesar Khurd
Matrikundia Dam
Jaisamand
Bhupal Sagar
0 4 8 16 24 km8
Scale
Jaipur
UdaipurDariba
Rajasthan
240-54’
240-34’
730 -
40
’
740 -
00
’
740 -
20
’
Road River, Nalah Rail
LocationMap
Places
240-14’
Bamnia Kalan
Zawar Group
9
2.1 MINERALIZATION
Lead zinc deposits of various sizes and grades occur throughout the belt in both calc-silicate
bearingdolomite and graphite mica schist horizons.
The latter in general containing low grade disseminated Sulphides of large volumes. The
resources of the belt is around 261MT grading 3-4%Pb+Zn. However, the reserves with
higher grade constitute only 37MT with 2.2% Pb and 7.3% Zn confined to Dariba,
Sindesar Khurd and Bamnia kalan.
Ore mineralogy of the belt, particularly at the south end, is unique due to its multi-metallic
sulphosalt association.
Sphalerite and galena mineralization exhibits lithological, stratigraphic and structural
control and occurs in the form of fracture filling, veins, stringers and disseminations
forming tabular to lenticular bodies, Rhythmic banding is characteristics of mineralization in
graphite mica schist.
The nature of mineralization is synsedimentary, later remobilized and recrystallized during
subsequent polyphase deformation and metamorphism.
2.1.1 MINE GEOLOGY
Dariba mine is located at the southern extremity of the belt. The ore materials are
designated at main lode (south and north) and east lode.
Mining activities are, at present, restricted to main lode only.
2.1.2 LITHOLOGY
The mine area is constituted mainly by a sequence of meta-sedimentaries consisting of
mica schist, calcareous biotite schist and graphite mica schist (from footwall to hanging
wall).
Calc-silicate bearing dolomite occurs within the graphite mica schist horizon towards its
contact with the calcareous biotite schist. The formations, in general, strike N-S with
moderate to steep easterly dips. Cross-beds and laminations are observed in mineralized
schist and dolomite bands. The area between the South and North lodes is traversed by 2-
10m wide meta-basic dykes.
10
2.1.3 GEOLOGICAL DISCONTINUITIES
Four sets of joints developed due to deformation.
Shears are represented by narrow zones of crushing, beneficiation and gouging, mostly
0.1-2.0m wide. These are highly persistent along strike and dip and occur at the contacts and
within the ore bodies.
Faults are of reverse type with low south-easterly dipping planes striking N40°- 60°E.
2.1.4 LODES AND MINERALIZATION
The main lode extends over a strike length of 1700m and is separated by a barren stretch of
3000m into two ore bodies viz. South and North lodes.
The South lode, striking N-S and dipping 60°-70° towards east, has a strike length of
500m.
The North lode has a strike length of 900m. It strikes N-S and dips 70°-75° towards
east.
The East lode, with a length of 600m, also strikes N-S and dips easterly at 60°-70°. It
is located about 150-200m away from the hangwall side of the South lode.
The average widths of South, North and East lodes are about 24m, 18m, 18m respectively
and to decrease in depth.
Ore forming minerals are mainly sphalerite, galena, chalcopyrite and fahlore
(tetrahedrite-tennantite).
Preferred concentration of silver has taken place in fahlore and chalcopyrite.
2.1.5 RESERVES
The main lode ore resources are estimated to be about 17.76 million tonnes grading 2.0%
lead, 7.6% zinc, and 90-100gm\t of silver.
The East lode has a potential of 6 million tonnes with 1.3% lead and 6.9% zinc
11
2.2MINING
Underground exploratory mine development was started by GSI in July, 1967 through two
incline shafts, located 100m apart on the Western side of Dariba Hill, to open levels at 436
and 400mRL respectively.
Subsequently, HZL acquired mining lease of 11.42 Sq. km covering Dariba and parts of
Rajpura block in April, 1970.
Mine was re-opened by HZL on December 28, 1971 and deepening of one of the inclines
upto 300MRL was taken up for underground exploration and mine development works.
2.2.1 ACCESS TO THE MINE
Access to the mine is through a main and an auxiliary shaft.
The main shaft is 592m deep from the surface (500mRL) to (-) 92mRL. It is equipped with
tower mounted keeps winder for skip (740kw) and cage winding (236kw).
The skip winder is equipped with two counter balanced 6t capacity skips and raises ore
from underground.
On the other hand, the auxiliary shaft extends down to 0mRL and is used for material
winding only besides serving as a second outlet. It is provided with a 225kw drum
winder, which can hoist 3.5t of load at a time. 50m spaced main levels have been opened
between 400 and 0mRL, and each level is connected to both the shafts.
A computerized process control system along with an automated grinding circuit
control, In-stream analysis (ISA) and instrumentation for other parameters is in use for
improving metallurgical efficiency.
Multi-gravity separators (MGS) for removal of graphite in lead concentrate and column
flotation for controlling silica in zinc concentrate have been installed.
12
2.2.3 FILL PLANT
A fill plant is in operation fill to the mine. Classified mill tailings from a fill storage tank is
conveyed to a mixing tank where it is mixed with cement at a desired rate through RV
feeder and a conveyor belt as per demand from the mine.
The cement mixed slurry is pumped to underground through centrifugal pumps for filling
into void spaces.
The quality parameters of the fill materials like grain size, pulp density and cement
proportion are constantly monitored through proper instrumentation.
2.2.4 ROCK MECHANICS CELL
This Department works for safety of employees working in the underground mining. This
Dept. deals with:
Vibration testing: for this, vibration meter is used to measure vibration produced
due to explosion in underground mining. It is max. up to 15mm\sec. It can be
controlled by reducing the amount of explosives used to carry out explosion.
Stress testing: for this, stress meter is used to find out tensile strength of rock bolts
which are used to provide support to rocks. It can support wt. max upto 8 tonnes but
used to support only 1 tone in mining.
Measurement of flow rate: flow rate of water is measured through cement filling in
void spaces to check the strengthening of cement. It should be upto 10cm\hr. More
fine is the grain size, less the water flow. Hence grains of -400 mesh size should not
be more than 20%.
Displacement measurement: To determine displacement of rocks under given depth,
HOOK JOINT method is used.
13
Rock testing: Testing of compressive strength of sample of rock under given depth
is carried out on universal testing machine (UTM).
2.3 ENVIRONMENT MANAGEMENT
An Environment Management Plan has been prepared which covers monitoring of the
environment on regular basis and also deals with the input required to improve it.
The various parameters of environment which are constantly monitored are
Water and waste water,
Air
Noise
Soil
Dispersal of metal in vegetation
Flora and fauna.
In addition, a planned scheme has been launched for afforestation in and around the mine
area.
2.4 VOCATIONAL AND SAFETY ASPECTS
A Vocational Training Centre educates the work force on various vocational and safety
aspects related to the profession.
Periodical Refresher Courses are also conducted for the workers to apprise them of the
latest safety aspects with a view to handle the equipment with safety.
Accidents is most unwanted interruption because it involves human life and the main effects
of accidents are
Stopping of production
Human suffering
Loss of good skilled employees
14
Material loss
Demoralizing effect on employees and society
Legal proceeding
Harassment to management
Compensation
Safety Materials:
Safety Belt,Safety Shoes, Ear Muff, Face Shield, Helmet, Ear Plug, Safety Glass, Breathing
Set, Acid proof glass, Air stream helmet, Dust and gas mask.
2.5 INFRASTRUCTURE FACILITY
Rajpura Dariba Mine has all the infrastructure facilities including a Central Workshop for
any major overhauling, maintenance and fabrication job.
The power supply to the mine is received from Rajasthan State Electricity Board. Two
3.5MW DG sets have been installed at the mine as standby.
Water requirement for industrial and township usage is met from Matrikundia dam built on
Banas River about 22km away. HZL also has a few tube wells in Banas River near Bamnia
Kalan for augmenting water supplies from Matrikundia.
A Workforce of 704 Workmen is employed to support various operations of the mine. The
strength of Executives is 94.
The mine has a well-laid township having marketing, recreational and cultural facilities.
A 30 bed hospital fully furnished with modern therapeutics equipment manned by specialized
staff attends to the medical requirement of the employees and their families.
15
2.5.1 ABOUT ORGANIZATION
Sterlite Industries India Ltd. (SIIL), a part of Vedanta Group is one of major player in non-
ferrous metal industry. SIIL in turn controls Bharat Aluminium Company (BALCO) and
Hindustan Zinc Ltd. (HZL). The Indian promoters Chennai Aluminium Company (MALCO)
currently holds 7.13% in SIIL.
Vedanta is a London listed metals and mining company with its principal operation located
throughout India.
The major metals produced are Aluminium, copper, zinc and lead.
The company also manufacture aluminium cold rolled products with technical know-how
from J W aluminium, US. During 1994, it entered into the manufacture of optical fibres, the
basic raw material for optical fibre cables.
This project was promoted through Sterlite Communication (SCL), a subsidiary, in technical
collaboration with the Nokia group, Finland leaders in the telecommunication sector.
2.5.2 CENTRAL WORKSHOP
NEED:
This workshop is responsible to maintain all the mechanical equipment of the plant. Any
damaged from any department is brought to this workshop and after required repairing will
be sending back to the concerned department for further use.
16
SUB-DEPARTMENT:
17
CENTRALSTRUCTURE
GARRAGE
TRANSPOR
T
H.E.M.M
DOZER
Terex
CENTRALWORKSHOP
CIVIL
PUMPING
CONSTRUCT
ION
ELECTRICAL
DG-SET
ELECTRICAL
HEMM: Heavy Earth Moving Machine
S.N Name of Assets Description Name of Company
1. Lathe machine Model 1675
Height 200mm
Spindle bore 55mm
M\s Mysore Kirloskar Ltd., Hubli
2. Lathe machine Model LB 17
Height 170mm
Spindle bore 90mm
M\s Chamundi Machine Tools Ltd., Banglore
3. Lathe machine Model LB 20 M\s HMT
4. Lathe machine Model EP 2215
Spindle bore 90mm
M\s Mysore Kirloskar Ltd., Hubli
5. Shaper machine Model WE 0366 M\s Modgil Comp., Batala
6. Radial drill machine Model UVR-5” M\s Batiboi and co., Surat
7. Power-hacksaw machine
Model heavy duty M\s Machinery Impex, Mumbai.
8. Hydraulic press 200 tones M\s Advance Automation and Process Control Pvt. Ltd.
9. Plate-bending machine Model PINCT M\s Citizen Engg. Works, Mumbai
10. Horizontal-boring m\c Size 100mm M\s Kamala Foundary, Batala
11. Compressor Model VT 250 P.D M\s Atlas Foundary, Batala
12. Crane Model Double girder M\s Dhiraj Enterprises Ghaziabad
18
SPECIFICATION OF THE MACHINE TOOL:
1. Central Lathe LB 17
Manufacturer Hindustan machine tool
Model LB 17
Height of centre 170mm
Type of the bed Straight bed
Spindle speed 18
Range(standard) 45-1000
(slow) 23-1000rpm
Spindle nose American standard
Spindle bore 42mm
Motor(standard speed) 7.5\3000kw\rpm
(slow speed) 5.67\1500Kw\rpm
Lubricants Mobile Oil DTE Heavy or
medium Mobil Grease BRB No.1
2. Centre Lathe LB 20
19
Manufacturer Hindustan machine tool
Model LB 20
Height of centre 200mm
Type of the bed Straight bed
Spindle speed 18
Range(standard) 32 to 1600 RPM
(slow) 16 to 800 RPM
Spindle nose American Standard L1-Type
Spindle bore 42 mm
Motor(standard speed) 7.5/3000 KW/RPM
(slow speed) 5.6/1500 KW/RPM
Lubricants Mobile Oil DTE Heavy or
medium Mobil Grease BRB No.1
3. Enterprise 1675 High speed Precision Lathe
20
Manufacture Mysore Kirloskar Limited
Centre Height 200 mm
Swing over Bed 400 mm
Swing over Cross Slide 245 mm
Spindle Noise Cam lock D 1-6”or 2-6”
Spindle Bore Ø 55
Motor of Motor 7.5 HP
Speed 630 to 800 RPM
4. Enterprise 2215 High Speed Precision Lathe
Manufacture Mysore Kirloskar Limited
Centre Height 280 mm
Swing over Bed 560 mm
Swing over Cross Slide 375 mm
Spindle Noise Cam lock 11
Spindle Bore 1.5/1500 KW/RPM
Capacity of Motor 15 HP
5. Knee Type Milling Machine
Manufacture Hindustan Machine Tools Limited
21
Model FN 2
No. of Spindle Speeds 18
Speed Range 355-1800
No. of Feeds 18
Power of Main Motors 5.5/1500 KW/RPM
Feed Motors 1.5/1500 KW/RPM
Weight 3300 KG
Lubricants Mobile DTE Oil, Mobile Grease No.2
Coolant SOLVAC 1535 or Indent Cutting Oil
Swivel of Table on either side 45°
Swivel of Milling Head oneither side 45°
6. Punching, Shearing, Cropping Machine:
Manufacture Ashok Manufacturing Co. Pvt. Ltd.,
New Delhi
Model PBSCN-13
This machine serves as three machines in one, it have different units
They are:
Punching Unit
Plate 13 mm
22
Flate 125*16 sq. mm
Length of Blade 250 mm
Round Bars 41 mm
Square Bars 38 mm
Plate Shear & Bar Cropper
Plate 13 mm
Flate 125*16 sq. mm
Length of Blade 250 mm
Round Bars 41 mm
Square Bars 38 mm
Section Copper Unit
Angle Squarer 110*1000*111 cu mm
Notcher Weight square Tools
Plate 10 mm
23
Notching Width 50 mm
Notching depth on stroke 65 mm
No. of strokes/min 36 mm
Motor Power 5 HP
Net Weight of Machine 3 TPmmes
Lubricants TELLUS 29 BURMAH SHELLO,
Shell Nareta 3.
2.5.3 MINING DEPARTMENT
NEED:The need of mining is to take ore from earth by process like drilling, blasting, mucking
and crushing.
The need of a mechanical engineer is in maintenance the various machines in used in the
process that done the process of taking ore from underground.
Vision:
Fitness of machine:
24
Underground workshop
Mine Mechanical
For this regular checking of various machines is necessary which include:
a) Proper lubrication
b) Proper maintenance for regular working.
Service:In this monitoring of condition of machine is done atregular interval of time.
Repair:In this damaged parts are either replaced by new parts or repaired so that
machine works properly.
List of Major Equipment& Machineries of Mining Block
mRL: Meter Reducing Level
Level name Machines observed
250 mRL 1. CUBEX R110
2. LHD 10A
3. SIMBA M\C
300 mRL 1. TORO LH203
2. DIESEL LOCO
100 mRL 1. WAGNOR
2. CUBEX R110
3. SIMBA M\C
-35 mRL 1. Crusher
-55 mRL 1. Conveyor\Belt
50 mRL 1. LHD
25
Other levels are 200,150 and -92 mRL.
100 mRL
# Distance from North to South: 1900m
1) Wagnor machine
Machine type Loader
Weight 17 tone
Bucket capacity Approx. 5 tone
Motor capacity 100 BHP
Tyre size (Tubeless) 17.5x 25
Tyre pressure 65-70
Speed gears 03
Hydraulic tank capacity 273 litre
Pump Tandon pump
Pump flow capacity 64 GPM
Power supplied 440 volts
Hydraulic fluid Fluid-32
BOBCAT Machine
It is also a loader type machine used to displace the other machines like simba
machine, pump sets, motors etc. to the required place.
Its output power is 36.4kw.
26
It is a diesel operated loco operated by single operator.
It is also provided with a bucket to carry load.
300 mRL
1) TORO LH – 203
Company name Sandvick mining and const.
Machine type Loader
Engine power 71.5 CC
Fuel Diesel
Total wt. 8200 kg
Tyre size 12x20
Tyre pressure (front) 87
(Rear) 67
Bucket capacity 1.51 cube tone
Tank capacity 122 litre
Torque converter capacity 22.5 litre
Oil No.30
Functions: Loading
Hauling
Dumping
27
0 mRL
# North- South distance: 914m
Name of loco 1.Clayton
2.Gemco
Type Electric loader
Company name Clarke company ltd.,
England.
Power supplied 250 volts
Motor capacity 45 BHP
Wagon capacity 5 tones
No. of wagons 10
No. of motors 02
Function of loco:
Electric-operated loco are also called as “Tram”.
Tram has the function of loading the wagons from the suits where ore is received from
different levels and then carry it on the ramp.
At the dumping point, ore is dumped into the main hole; transfer the ore to -35mRL for
crushing operation.
250 mRL
SIMBA Machine:
28
It is simply a drilling machine used to make holes of 57mm diameter and 6m
depth in the roof of the level.
PVC pipe along with cable bolts are then fitted into the hole.
Cement slurry is then injected into the pipe with pressure by injector.
Cable bolts are used to support the surface of adjacent upper level.
PARTS OF SIMBA MACHINE:
Skid Ring Motor Feed beam Jack column bar
Levers to control Air and Water supply
Drilling tool having chuck and valve
Screw bar with lead screw
Water along with compressed air of 92-110 PSI is used to carry out operation.
TORO-151 Loader
Noise level(at 2300rpm) 93 DB
Total length 6970mm
Width without bucket 1420mm
Maximum width 1480mm
Height with safety canopy 1740mm
Operating weight 8700kg
Total loaded weight 12200kg
Bucket capacity 1,5mⁿ
29
Bucket motion time(raise)
(lower)
5.5sec
2.9sec
Driving speed (Ist gear)
(IInd gear)
(IIIrd gear)
5km\hr
3.3km\hr
24km\hr
Frame material Raex multisteel
No. of cylinder 06
Cooling system Air cooled
Combustion system Direct injection,4-stroke
Exhaust system Double wall exhaust pipe
Turning angle 40°
Tyre size 12x20
Fuel tank capacity 130litre
Tyre pressure (front)
(Rear)
87.1psi
50.8psi
250 mRL
CUBEX R-110
30
Function:
This is used to drill a hole of 165mm diameter and depth of 50m in the underground
mining surface so that operator can fill up explosives in it for blasting.
It has two basic parts:
1. Compressor
2. Drilling machine
CUBEX Compressor
Pressure of compressed air received from
1. Surface compressor
2. CUBEX R-110 compressor
92-110psi
300psi
Thus, function of compressor is to compress the air received from surface compressor.
PATH OF COMPRESSED AIR IN CUBEX COMPRESSOR:
Primary filter ---- Secondary filter ---- Valve Suction ---- Inlet manifold ---- Compressor ----
Discharge manifold ---- After Cooler ---- Thermostat Valve ---- Air receiver ----
Transmission
Primary filter:
It is used to remove dust particle, moisture etc. having size upto 12Ц from compressed air.
Secondary filter:
Remove dust particle, moisture having size upto 5Ц.
Valve:
It is operated automatically by joystick, to control the amount of compressed air to pass.
Suction inlet manifold:
31
It is attached with three piston-cylinder assembly to compress the air. These are operated
independently to control the magnitude of pressure of compressed air.
After Cooler:
Compressed air received is at high pressure and temp. (Boyle’s law), so to lower down the
temp it is passed through after cooler having tiny fins on surface.
Thermostat valve:
To further lower the temp. air is passed through thermostat valve having two sections: one for
compressed air and other for cold water. Water absorbs heat from air and then drained off.
Motor capacity 75 BHP
Receiver tank capacity 550psi
Price 2cr 30lks
DRILLING Machine of CUBEX R-110
Machine type Driller
Hydraulic pump capacity 71CC
Diesel pump capacity 85CC
Hydraulic fluid Fluid-32
Length of feed rod 1.5m
-35 mRL
32
CRUSHER:
Type Double Toggle Jaw Crusher
Company UTMAL
Size 1200x900m
Power supplied 160 KW
Capacity 250 TPH
Discharge size 6’’
Feed Rose Chain Feeder
The blasted ore cannot be taken as it is to the surface because lumps are large in size and
heavy to carry. So before taking it to the surface, the ore should be crushed in DTJ crusher.
Lumps of ore from each level are dumped into the main hole at 0 mRL transferring it to the
crusher where it is crushed down into lumps size of 6’’. Skip from -55mRL carry the crushed
ore on the surface for further processing.
-55 mRL
Belt\Conveyor:
Total length: 150m
Motor capacity: 20HP
Belt material: Linol
Load carried by skip: 6tone
Rock material after crushing into small lumps is passed over the vibrator, which transfer it
on the conveyor.
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Belt at it other end dump the lumps into the container having load cell and diverter. As the
wt. of ore equals to 6tonne, load cell get activated and these are dumped into the skip
which carry it on the surface.
There are two skips; skip A and B.
Diverter controls the process of loading of ore into the skip alternatively.
2.5.4 MILL MECHANICAL DEPARTMENT
NEED: The ore extracted from mine are in form of large lumps with high percentage of impurities.
Hence ore cannot be taken to smelting plant as it is. So the process of ore dressing is
carrying out at mill dept.
Mill block has been divided into following section:
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Mill Mechanical dept.
Crusher Ball mill Flotation
Filter Thickner P.D.O
1. CRUSHER
This Dept. works to fulfil the requirement of ball mill.
Lumps having size in the range of 250-150 mm are crushed down to 16mm or less.
One sec. and two tertiary crusher work to crush lumps of large size.
Following are the parts of crushers installed:
CONVEYORS:
Conveyor\belt is used to carry ore in bulk from one place to other where ore is
required.
These conveyors are installed horizontally and somewhere in inclined manner. It
moves on rollers with the help of pulleys which are driven by motors.
Snub pulley is also installed to increase the contact area of belt on pulley to prevent
slipping.
Conveyors are made of rubber plies and fasteners are used to join two conveyors.
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Crusher Assembly
Conveyor no. Width size Motor power
1085 800mm 45KW
1325
1340
1220 1200mm 110KW
1270 1000mm 70KW
Reciprocating Plate Feeder
Company SISCO
Size 1526x760mm
Capacity 20-200TPH
Power 5HP
Stroke 30-175mm
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Stroke\min 32
Weight 1840kg
Sun Iron & Steel Co.(P)Ltd.
Function:
Feeder is used to transfer heap of lumps on the conveyor by the reciprocating motion of plate
on the wheels driven by the motor and chain on sprocket.
Crusher
Type Capacity Motor Feed Discharge Crusher
No.
Feeder
No.
Standard Head Cone
Crusher
(HEC)
350TPH 160
KW
150m
m
50mm 1215 1095
Short Hand Cone
Crusher
(SYMON)
300 TPH 184
KW
50
mm
16mm 1296,
1295
1286,
1285
The ore from mining is feed to crusher where it is crushed to desired size, that crushed ore
is then subjected to screens which have very fast vibrating motion, the screened ore is
collected in the tank and remaining ore is again feed to SYMON crusher by conveyor1270.
Scalping Screen
This is also called Double Deck Screen.
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Both the screens are large metal grid of size 20’x8’ with square holes in it to allow
ore particle.
It is inclined at 20°.
The upper grid of 25mm holes to pass through for bottom screen of holes size
16mm.
The ore particles of size bigger than specified above are feed back to the crusher
through conveyor 1270.
2. Ball Mill
Need:This is required for crushing the ore of 16mm size into (-) 400 mesh size to carry out froth
flotation process.
Ball Mill Feed
Motor capacity 7.5KW
Gear box Elecon
Reduction ratio 60:1
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Balls of Ball Mill
Gear box type 7FSS
Belt material Nylon
Width 600mm
Length 51.3m
Capacity 63TPH
No. of plies 05
Pulley Drum dia x width
Head pulley 400 x 880
Snub pulley 210 x 675
BALL MILL
Company KCC, Madras
Size
(Diameter x Length)
3.3ø x 4.5m
2.7ø x 3.7m
Capacity 900 TPD
Rotational speed (rpm) 18
Bearing type Double row spherical roller
Gear box
Company Elecon
Reduction ratio 10:1
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Type SBN-500
No. of teeth on girth gear 228
No. of teeth on pinion gear 26\27
Grinding media size 2’’,3’’,4’’
There are four ball mills for crushing of ore. Three are of dia. 3.3ø and one is of 2.7ø. The
ore size of 16mm is supplied to ball mill through conveyor belt.
For proper crushing of ore, rotational speed of ball mill should always be less then critical
speed otherwise grinding media will keep on rotating along with ball mill results in
improper crushing of ore.
Power transmission to Ball Mill
Motor ---- Fluid Flywheel ---- Gear Box ---- Pinion Gear ---- Girth Gear ---- Ball Mill
These Ball Mills are cylindrical in shape having layer of manganese steel as a liner to
prevent the wear and tear of mother body during the crushing of ore.
About 12 tonnes of manganese steel balls (Grinding Media) are used in each Ball Mill to
grind the ore into fine particle of (-) 400 mesh size.
Instruments
Load Cell:
It is mounted near the end of conveyor belt to measure total feed (ore) to the ball mill. It
measures feed in tonnes. It converts the measured value into electric signals representing
the output to the operator.
To Measure Level in Sump:
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UV radiations are used to measure level of slurry in sump.
UV radiations after reflecting back from the bottom of sump is received by radiation
meter and measures time required by the radiations to travel total distance.
Motor used to pump slurry is also frequency based and adjusted according to level
of slurry in the sump.
3. FLOTATION CELL
Ore slurry from ball mill is mixed with chemicals like MIBC, Copper Sulphate in definite
proportion to extract the concentrate of Lead and Zinc from slurry.
The flotation cell is an assembly of tank and a rotor fitted in series. There are basically two
cell blocks: AS2-6, AS2-3
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Flotation Cell
Specification AS2-6 AS2-3
Volume (in mⁿ) 6 3
No. of motors 02 01
Motor capacity 11KW 11KW
Impeller diameter 400mm 400mm
Process Description
Ore slurry from Ball mill is carried to conditioner from where it is distributed equally to
four cell blocks.
Slurry is mixed with definite proportion of MIBC and CuSO4. Here, MIBC act as a
Froather and copper sulphate along with cyanide settle down zinc present in slurry.
Impeller near the bottom of tank rotates the slurry and the air from bottom blow
concentrate to top of tank called filtration.
Froths are separated and passes into lead filtration block.
Remaining slurry is mixed with ZnSO4 and froths so obtained are separated passing into
zinc filtration block.
FILTRATION
In this section water is removed from the ore using two filters:
1. Drum Filter
2. Pressure Filter
Drum Filter
In drum filter, there is a cylindrical drum which rotates so that slurry is uniform in
composition. One end of the drum is attached with vacuum pump so that moisture is
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absorbed from the slurry by applying pressure of 500 mm Hg. The outer part of drum is
made of cloth having high porosity.
Drum is 8 feet in dia. and 10 feet in length.
Pressure filter
In this filter, water is drained from slurry by applying high pressure. It is made in Germany
and controlled automatically by computer.
Process of pressing is completed in 8 minutes and about one tonne of concentrate lead\zinc
is produced.
THICKENERS
Thickener where excess water is recovered for recycling in plant and underflow is pumped to
Tailing Dam constructed 4 kms.
VASA PUMP
These pumps are suitable for:
Mining and Mineral processing
Cyclone feed
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Industrial processing
Mill discharge
Medium duty abrasive slurries
Benefits:
Robust construction designed for highly abrasive, maximum duty.
Maintenance slide base option.
Computer aided designed thick volute casing and heavy duty large diameter
impellers, carefully matched to provide high efficiency, hydraulics for even wear.
These pumps operate at or near their highest efficiency. Thereby reducing both the rate of
wear and power consumed.
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Impeller
Vasa Pump
TAILING DISPOSAL & FILL PLANT
Slurry after separation of concentrates is pumped to Fill plant where Hydro cyclone separate
slime (-) 37Ц and sand.
Slimes are pumped to Tailing Thickenerwhere excess wateris recovered for recycling in
plant and underflow is pumped to Tailing Dam constructed 4 kms. away from mine.
Three pumps are connected in series to pump underflow to tailing dam.
In the mines for filling stops, + 32 microns fraction of tailing is used as fill material. River
sand is used to supplement the fill as and when required.
Cement is added for the initial two lifts of the operations. The fill material (pulp) is pumped
at 65% solid through 10 mm dia pipelines which pass from surface to underground through
bore-holes. For this, two pumps are connected in series.
Design capacity of the supply of fill is 50 – 60 tonnes per hour through each of the three
lines.Out of total tailings 55% is used for mine back filling and balance 45% is pumped to
tailing dam. Solids are allowed to settle in Tailing Dam and water reclaimed through filter
and recycled for plant use.
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Roller Bearing
For VRM operations the Fill Plant has been modified with arrangement for automatic
handling and addition of cement in the desired quantity. Monitoring of various quality
control parameters such as particle size analysis, pulp density, cement ratio of10% and 5%
being maintained depending on filling for plug formation. The average monthly requirement
of cement in VRM back filling is approximately 700 – 1000 tonnes.
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2.6 MINING PROCESS
1. Ore Detection
First process that comes in mining is ore detection.
It is done by taking sample of ore to the laboratory where percentage of Zinc and
Lead are find out with various chemical methods.
2. Drilling
Drilling process is carried out in underground mining for:
A hole of 165mm dia. and 50m depth has to drill in under-ground mining surface so
that an operator can fill explosives in it for blasting.
A hole of 57mm dia. and 6m depth has to drill in the roof of the level. PVC pipes
along with cable bolts are then fitted into the holes so as to support surface of adjacent
upper level.
Following are the machines used to carry out operation:
CUBEX R-110
SIMBA machine
M.T.I
3. Blasting
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Ore Detection Drilling Blasting Mucking Hauling Winders
In blasting, explosives are filled in holes of 165mm dia to obtain ore rich in
percentage of Zinc and Lead.
All workers come at surface from underground during the blasting because loose can
fall after explosion causing the severe accidents.
4. Mucking
After blasting, ore so obtained is in form of large lumps. This blasted ore is taken to
the place where it is collected in huge amount and then it is subjected to hauling
machine. Thus, the process of taking ore to hauling machine is called Mucking.
This process is done with Wagner and Toro which are operated either manually or
automatically.
5. Hauling
Hauling is the process of taking ore from suits of each level and dumping it into the
main hole, subjected that ore to the crusher.
Hauling process is carried out at 0mRL using the Loco which are:
Electric Locomotive
Diesel Locomotive
6. WINDERS
It has two sections: Cage and Skip
Cage
Cage is a type of lift used to carry workers to the various levels ranging from 200mRL to (-)
92mRL. Its maximum capacity is 6 tones and can carry 40 workers at a time. Its maxspeed is
10m\sec but for safety it is operated at 3m\sec.
Skip
It is used to carry crushed ore from underground i.e. (-) 55mRL to the surface. There are two
skips; Skip A and B connecting to the winder. Both skips run simultaneously so that they
balance each other. Its max capacity is 6 tonnes. Its max speed is 10m\sec
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3.1 OVERVIEW OF THE PROCESS
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Mining
CrusherPlant
M
Screen House
M
Ball MillChemical Process
Lead Thickner
Zinc Thickner Bulk
ThicknerTailing
Thickner
3.2 RESULT
The result of the training was to get the indepth knowledge about the machines used in
industries and how to communicate and handle the workers in a team.The maintenance work
gives idea about the different parts used in machines and how to handle a machine or any
work during it’s failure.by this training I get knowledge about the mining processes ,different
machines used during mining and their maintenance .then further in mill plant I get to know
the crusher plant and ball mill process in detail and replaces the liners of the ball mill and the
crusher.
This training really help me during my job career in future and provide help to me in
developing my professional future.
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4.1 CONCLUSION
It was a wonderful learning experience at Hindustan Zinc Limited,R.D.Mines site for one and
half month.i gained a lot of insight regarding almost every aspect of site like in mining ,mill
and workshops .i was given exposure in almost all the departments at the site.The friendly
welcome from all the employees is appreciating,sharing their experience and giving their
peace of wisdom which they have gained in long journey of work.I am very much thankful
for the wonderful teaching facility from HZL.I hope this experience will surely help me in
my future and also in shaping my career.
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