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

49

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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