TRAINING REPORT

MALANJKHAND COPPER PROJECT

M/S HINDUSTAN COPPER PROJECT
(A GOVERNMENT OF INDIA ENTERPRISES)
LOCATION : MALANJKHAND, BALAGHAT DIST. (MP)
DURATION : FROM 14.12.2019 TO 27.12.2019
SUBMITTED TO
Mr. S. K. GOUR , DGM (Conc.) -HRD
SUBMITTED BY
1. Mr. JITESH KUMAR SHARMA
2 Mr. PRANAY KHINVASARA

DEPARTMENT OF MINERAL PROCESSING

IIT(ISM), DHANBAD
PIN:-826004
Jharkhand State, India
 2019

Acknowledgement
I wish acknowledge the hindustan copper limited for giving the opportunity to
conduct this vocational training, I am highly indebted my thanks to Mr. S.K.
GOUR DGM(Conc.), MCP, Malanjkhand.

CONTENTS

Introduction

❖ Indian copper deposits

❖ About Hindustan copper limited.
❖ About Malanjkhand copper project.
❖ process description

Chapter 1: Brief Description about area

1.1. Geology and Mineralogy

1.2. Mineralization

1.3. Mode of occurrence

Chapter 2: Beneficiation studies:

2.1. Primary unit:

⮚ Primary crusher
 ⮚ Capacity, reduction ratio
⮚ Conveyor system
⮚ Motor and gear box specification
⮚ Apron feeder
⮚ Lubrication system
⮚ Safety devices and gamma ray indicator

2.2. Secondary unit:

⮚ Secondary crusher
⮚ Tertiary crusher
⮚ Capacity, reduction ratio
⮚ Screen and surge bins
⮚ Lubrication system
⮚ Overall view of secondary unit

2.3 Main process unit

⮚ Fine ore bin

⮚ Ball mill section
⮚ Cyclone
⮚ Flotation
⮚ Thickening
⮚ Filtration

Chapter 3: Tailing dam

Chapter 4: Chemical analysis (R & D)

INTRUDUCTION:

Malanjkhand is the biggest base metal (copper) open pit mine in

India located at a distance of 90 KM north-east of Balaghat district
Madhya Pradesh at an altitude of 575 MRL.

Of all the copper deposits so for discovered in India the one of the
Malanjkhand stands out as unique by virtue of its large size and
amenability to open pit mining.

The mine at full production capacity will excavate 11.5 million

tonnes of over burden and waste rock, to recover 2 million tonnes of
chalcopyrite ore average grade 0.8 - 1.04% Cu per annum. The ore of
Malanjkhand open pit mine as 95% chalcopyrite and 5% constituting
oxides and other sulphides ore. The life of the open pit mine is 32 years
and it as 250 million tonnes copper ore deposits. 50 million tonnes of
ore have been extracted till now and 200 million tonnes were
remaining, sulphide ore are of the three types depending on the % of
copper present in it they are

0.95% - above - high grade ore

0.45% - 0.9% - low grade ore

0.2% - 0.4% - lean ore

Malanjkhand concentrater plant was started on 12th November

1982. The capacity of the plant is 2 million tonnes per annum. It
processes 6000-7000 MT per day ore and produces 240-300 MT per day
Cu concentrate.

Concentrate plant receives the ore from open cast mining feed size
maximum of 1200mm, the same is being crushed in three stage
crushing – primary, secondary & tertiary crushers having the
reduction ratio of 8,3:7 & 3:8 respectively the product size of crushing
plant is 80% passing – 12mm.

The crushed -12mm material is stored is 9000 tonnes fine ore storage
bin, the fine ore is fed to 4 numbers of ball mill (size12.5x20 feet long).

The ball mill discharge is subjected to 26 inch hydrocyclone (closed

circuit). The overflow of cyclone having 35-40% -200# and 42-45%
solids by weight is fed to a battery of 300 cft flotation cells consisting
of six rougher cells, six scavengers and a cleaner cell in a row for each
mill.

The cyclone overflow along with scavenger concentrate, cleaner and

re-cleaner tails are being fed to rougher cell (closed circuit). Rougher
concentrate is pumped to cleaner cell. The cleaner concentrate is fed
to the recleaner for further enrichment. The recleaner concentrate
containing around 25-26 % copper is the final product of the
concentrator. The same is being sent to 25m dia thickener. Thickener,
thickener underflow containing 60-65% copper, 10-12% moisture and
stored. Further concentrate is being dispatched for conversion of metal
at KCC and ICC smelters.

COPPER DEPOSITES IN INDIA:

Hindustan copper limited (HCL) is presently the sole indigenous

producer of primary copper in the country. The all India recoverable
reserves of copper ore are placed at 431.046 million tonnes equivalent
to about 4.557 million tonnes of metal content. The prospective
resources are placed at 769.90 million tonnes of copper ore.

Copper concentrated states in India are, Andhra Pradesh, Jharkhand,

Gujarat, Karnataka, Madhya Pradesh, Maharashtra, Meghalaya,
Odessa, Rajasthan, Uttar Pradesh & west Bengal. Recently in
Jharkhand, copper mining as been stopped mining because
uneconomic due to higher production cost.

Boreholes drilled in chitar sectors in pali & ajmer districts in rajasthan

intersected ore zones, varying in width from 0.55-9.8m. The zone
contains grade ranging between 0.5% & 1 Cu and 1-2% Zn.

Drilling investigation in Dariba (Akola) copper prospect, Rajasthan

has indicated about 2 million tonnes of copper ore. The test drilling by
GSI at saran Bhawavat in Udaipur district of Rajasthan has shown
copper mineralization varying between 0.4-1% copper in the borehole.

In Purnapani area, west Bengal, significant copper ,mineralization

in association with the quartz vein intruding the mica schist come to
light during the course of tungsten exploration by GSI, during Geo-
chemical appraisal of Dobri-Pinglapani area in chamois district, Uttar
Pradesh, two silicified zones were noted in Trini-koteshwara area,
analysing 0.55-0.72% Cu. Recoverable reserve of 0.987 million tonnes
having 11.65 thousand tonnes of metal as been estimated from the
district of Pithoragargh in UP/Uttaranchal.

In Maharashtra copper has been reported from the district of Nagpur

where the reserves of recoverable ore is set to be 0.142 million tonnes
having 1.908thousand tonnes of metal in it.

In Odessa the district of Mayurbhanj & Samabalpur have been

reported to have a total of 1.65 million tonnes of recoverable reserve
of copper ore with 1820 thousand tonnes of metal content in it.

Madhya Pradesh was the leading producer of copper ore

contributing 39.7% to the Indian production followed by
Rajasthan (33.7%), Jharkhand (24.7%) & Karnataka (1.8%).
Nominal production was also reported from Odessa& Sikkim.
 Jharkhand has the reserve of 93.06 lack tonnes, which is about
25.94% of total India deposites. Copper deposits extend in a linear belt
of 130 KM length, 17 KM width. This belt exists from Chakradharpur
to Singri (Bahragora) through kharswan, Saraikela and Dhalbhum.

GSI (Geological survey of India) has tentatively estimated 1.59

million tonnes of copper ore, containing 2.36% Cu, in the Dhobani area.
A recoverable reserve of 0.35 million tonnes Cu ore, which might yield
575 thousand tonnes of metal, has been estimated from the district
Hazaribag.

2.1. GEOLOGY & MINERALOGY:

Geology:

The Malanjkhand deposits is made up of two divisions if the

Achaean, each with distinctive characters, separated by hiatus.

Based on the reconnaissance mapping the geological accession of the

area can be summarized as,

Literate

A Chilpi Quartz veins

R Ghat Arkosic griy and Quartzite,

C Series With politic intercalations;

H Conglomerate

A Unconformity

A Basement Meta-dolerite

N Complex Apatite

Quartz reef

Genetic rocks
 The Malanjkhand area is made up of several hillocks forming arcute.
The arcute chaine of hillock is about 2.6 KM long having eastward
convexity.

The major part of the area about Malanjkhand is occupied by granitic

rocks which consists mainly of biotitic granite you quartz diorite
through intermediate adamellite, tonalite & granodiorite.

The colour ranges frame light gray to medium gray with occasional
buff to pink shades, they are generally hard, compact and massive.

Mineralogy:

In all samples the variable elements present are Copper,

molybdenum & gold. While lead & zinc are present in trace about only.

All samples have general similar gangue mineralogy mainly quartz

with minor other silicates (not of all which are present in every
samples including potash feldspars, plagioclase feldspar and
siderite).They are significant difference in the copper mineralogy,
mainly related with degree of supergene enrichment and oxidation.

In the primary & typical ore chalcopyrite is the dominant copper

sulphide (accounting for > 90% of the Cu) but minor chalcosite,
covellite and bornite. [Note: the term Chalcosite includes various
secondary copper sulphides such as Anilite (Cu1.75S), Azurite (Cu+S) &
Chalcocite (Cu2S) ].

In the secondary ore Chalcocite , Covellite is much more abundant

(Accounting for up to 60% Cu)

In the oxide ore Chalcocite ore & Malachite predominant (accounting

for up to 90% of the Cu in approximately equal proportion) with minor
chalcopyrite, Bornite, Cuprite, native copper & azurite.

CHEMICAL % COLORAND SP. HAR

ORE FORMULA Cu & GR. NESS
MINERAL APPEARANCE
Primary Chalcopyrite CuFeS2 34.5 Golden 4.2 4.0
Sulphide Yellow

Secondary Chalcocite Cu2S 79.5 Black 5.7 3.0

Sulphide Covellite CuS 66.4 Pinkish 4.6 2.0
Bornite Cu5FeS4 63.3 Peacock 5.0 3.0
Oxide Ore Malachite CuCO3.Cu(OH)2 57.3 Green 4.0 4.0
Azurite 2CuCO3.Cu(OH)2 55.1 Deep Blue 3.8 4.0
Cuprite Cu2O 88.8 Black Browny 6.0 4.0
Tenonite CuO 79.8 Flaky Ore 6.2 4.0
Below tables contain properties of copper ores:

2.1. Mineralization:

The Malanjkhand copper deposits represents the bottom segment

near route zone rich mineralized body. A great deal of ore thus
possibly lost wing to erosion & pronounced oxidation. The zone of
oxidation goes down to depths of 40-100 meters from the top of the
ridge, primary sulphide mineralization starts abruptly below this and
zone of secondary enrichment negligible.

Surface shows of copper mineralization are noticed in the form of

sporadic encrustations of Malachite and scarcely of Azurite within the
intensely sheared, fractured & brecciaed vein.

HOST ROCK:

Vein quartz is the main host rock of the sulphide mineralization of

which more than 90% is confined to this rock. Some mineralization

Is also present in the granitic portion near its contacts within the
quartz rest. Away from the main rest, the mineralization in the
granitic diminishes in intensity. Thin bands of meta-dolerites are often
feebly mineralized but the Metadolerite bands which range in
thickness from 10 to 40 meter are divided of any mineralization.

ZONE OF OXIDATION:

The zone of oxidation extend over the entire strike length of 2.6KM,
the depth of oxidation varies from 40 to 100 KM from the hill profit.
The upper part of the zone is leached capping containing poor copper
values. Typical gossans are not developed limonite shins and box work
derived from oxidation of the sulphide are very commonly observed.
The lower part of the zone of oxidation contains at places rich copper
values.

ZONE OF SECONDARY ENRICHMENT:

The zone of oxidation is undertaking by a fairly continuous zone of

secondary enrichment specially in the central and southern part of the
deposit.

The frequently occurring secondary copper minerals are Chalcocite,

Covellite, Bornite in association with varying proportions of
chalcopyrite, pyrite and other primary sulphides.

The granitic country around Malanjkhand is traversed by a set of

NNW-SSE trending basic dykes. These are seen frequently with in
2KM wide zone extending from Jagtatola to Sarsdol. The width of
dykes varies from two meters to as much as 150 meters.

2.2. MODE OF OCCURANCE:

The rock is dirty yellowish green in colour. In hand specimen it is

fine grained and gives the appearance of highly altered rocks.

They occur as intrusive bodies cutting through the granite as well as

the mineralised quartz reef. They are devoid of any occurring thin
bands ramified by quartz vein lets.

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

1.MINES:
 MINES LOCATION ORE CAPACITY
(lak 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 lak tonnes per annum

2.SMELTER:

METAL CAPACITY
PLANT LOCATION (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

5. ON GOING PROJECT:

NO: MINE LOCATION CURRENT AFTER

CAPACITY EXPANSION

1. Malanjkhand
Mines:
Development of Malanjkhand 2.0 5.2
Underground MP (Underground)
Mine under
existing Open
Cast
2. Khetri Mines:
Expansion of
existing Khetri 0.5 1.0
underground Rajasthan
mine
 3. Kolihan Mine:
Expansion of
existing Khetri 0.5 1.5
underground Rajasthan
mine
4. Surda Mine:
Expansion of
existing Ghatsila 0.4 0.9
underground Jharkhand
mine
5. Rakha Mines:
Reopening of
closed Ghatsila Nil 1.5
underground Jharkhand
mine

6. Kendadh Mine:
Reopening of
underground Ghatsila Nil 0.21
mine Jharkhand

7. Banwas Mine:
Development of
new underground Khetri Nil 0.6
mine Rajasthan

8. Chapri-
Sideshwar
Development of Ghatsila Nil 1.5
new underground Jharkhand
mine

Total 3.4 12.41

MALANJKHAND COPPER PROJECT:

⮚ Malanjkhand copper project was established in 1982

⮚ The ore Malanjkhand open pit mines have
 1. 95% Chalcopyrite
2. 5% Oxides & Sulphides ores
⮚ The life of open pit mine is 32 years
⮚ It has 250 (approximately) million tonnes copper ore deposits.
⮚ Approximately 68 million tonnes of the ore has been extracted
till now.
⮚ Approximately 182 million ton is still remaining.
⮚ Overall plant capacity is 2.0 million tonnes per annum.

Sulphide ores are three types depending on the % of copper present in

it. They are

● 0.95% - Above -High grade ore

● 0.45% - 0.9% - Low grade ore
● 0.22% - 0.44% - Lean grade ore

1.3. PROCESS DESCRIPTION:

❖ Run of mine ore of size 1200mm is crushed in three stage to

12mm. the crushing complex consisting of one primary gyratory
crusher (1350x1900mm), one secondary cone crusher (2200mm)
7’ standard head, three tertiary cone crusher (2200mm) short
head & Four numbers. Vibrating screen associated conveyor
network, apron feeders & belt feeders.
❖ Secondary crushed ore passes through a double deck vibrating
screen, top screen size 40x40mm & below screen 12x20mm size
❖ Tertiary screen having single deck screen size 12x20mm
❖ The undersize from screen which is the feed for grinding mills is
transported by conveyors, & stored in the parabolic fine ore bin
of capacity 10,000MT. Ore is withdrawn from this bin with the
help of belly feeders & fed to the ball mills.
❖ Single stage wet grinding is done with the help four ball mills.
Each of size 3810x5791mm, operating in closed circuit with
660mm hydro-cyclones. Mills are overflow type and lined with
 replaceable rubber liners. High chrome grinding media of 80mm
diameter is charged inside the mill for grinding of ore.
❖ Hydro-cyclone overflow (35-40% - 200#) is subjected to four stage
flotation in rougher, scavenger, cleaner & re-cleaner (all 300cft.
Cells).
❖ The re-cleaner concentrate (final concentrate) is pumped to 25
meter diameter thickener& the scavenger tails (final tail)
gravitates into tailing pulp tank.
❖ Thickened concentrate from the thickener is pumped two
numbers of disc filters 2.7m diameter. The dewatered filter cake
from disc filter having 10-12% moisture is conveyed into the
concentrate storage yard. Water from the thickener overflow is
recycled back to the process.
❖ Final tails is pumped to rubber lined pipes to tailing disposal
area about 2.4KM away from the plant. Hydro-cyclones are used
for embankment build-up along the periphery of the tailing dam.
It 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
re-cycled back to the plant for process using.

CHAPTER 3 :- PRIMARY UNIT

Primay Crusher:

Primary gyratory crusher is designed for first stage crushing of

ferrous and non-ferrous ore. They are generally installed in the first
stage of technological crushing scheme

⮚ Gyratory type crusher

⮚ Model number PGC 1350 (HEC– Heavy Egg. Corporation,
Ranchi)
⮚ Width of feed opening 1350mm.
⮚ Width of discharge opening 165mm.
⮚ Capacity 870 MTPH at 150mm setting
⮚ Oscillations of crusher head 2 – 4 RPM on no load.
⮚ Motor Drive – 360 KW
⮚ 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 crusher crushing chamber, there should be no
material in it.
▪ Check the Greece 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 1.0 kg/cm2 and not more than 2.0
kg/cm2.
▪ Wait for 5-10 min, so that oil circulation stabilises.
▪ Check the drain pipe line temperature; it should be below 60o C.
▪ Check the drain pipe oil temperature from counter shaft; it
should be below 60o C.
▪ Check the oil pressure before and after the filter; the difference
should not be more than 0.3 kg/cm2.
▪ If the oil temperature is more than 60 – 65o C pass the oil through
the heat exchanger and observe that, water inlet pressure is less
by 0.3 kg/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.

SCHEMATIC DIAGRAM OF GYRATORY CRUSHER

GYRATORY CRUSHER LINERS:

1. Top shell contains 20 liners.

2. Intermediate shell contains 16 liners.
3. Bottom shell contains 16 liners.
.

CAPACITY & REDUCTION RATIO:

❖ Capacity – 870 TPH

❖ Feed size – 1200mm (maximum).
❖ Product size – 140mm (maximum).
❖ Reduction ratio – 8.52 (approximately),

FLOWCHART:

-1200mm Primary Crusher (870 TPH) Gyratory crusher -140mm

FLOW DIAGRAM SHOWING EACH LEVEL OF PRIMARY

UNIT:-

Gyratory crusher Top Level

 Feeding Level

Intermediate Level 4th Floor

(Crushing Zone)

Discharge Level 3rd Floor

Hopper (Gamma Ray Indicator) 2nd Floor

Lubricating System

Apron Feeder 1st Floor

Conveyor System Ground Level

CONVEYOR SYSTEM:

Used for transportation of feed from apron feeder

discharge to coarse ore storage (COS) for convince to carry it to
secondary unit.

Following are the important section of conveyor system:

● Idlers
● Belt
● Pulley arrangement
● Pulley card

IDLERS:

▪ Used to support the belt.

▪ To protect the belt.
▪ Used in carrying the belt.
TYPES OF IDLER:

a. Carrying Idlers – carry the belt.

b. Return Idlers – help to returning the belt.
c. Impact Idlers – protect belt from wear and tear.
d. Adjusting Idlers.
e. Self-alignment Idlers.
f. Side Idlers.

IDLER SPECIFICATION:

⮚ Number of carrying Idlers – (199 – 10%) x3=540.

⮚ Number of returning Idlers – (199/2) = 100.
⮚ Gap between two carrying Idlers = 1,000 mm.
⮚ Gap between two returning Idlers = 2,000 mm.

BELT:

❖ Length of belt – 398 m.

❖ Commonly named as Primary Belt.
❖ Width of Belt – 1400 mm.
❖ Nylon is used to give strength and flexibility.
❖ Thickness of Belt is 24 mm.
❖ Notation – M24.

SYSTEMATIC VIEW SHOWING DIFFERENT SECTION OF

BELT

PULLEY ARRANGEMENT:
 ● Total number of pulley in primary conveyor – 12.

(2)Head pulley

Head pulley (9)

Head scup pulley(3) Tail pulley (1)

5
Tail bend
6 8 12
Pulley(11)

Take up pulley (10)

PULL CORD:

● Used to stop conveyor belt in emergency condition such as

loading, breakdown of belt etc;

MOTOR & GEAR BOX:

Motor:

▪ There are basically two motor attached to pulley number 6 & 8.

M1 – PULLEY 6 M2 – PULLEY 8

150 HP 150 HP

1485 RPM 1485 RPM

188A 186A

V – 415V V – 415V

Frequency – 50 Hz Frequencies – 50 Hz

Manufactured By – SIEMENS (Germany)

⮚ Gear Box
⮚ ELECON Mgf.
⮚ Serial number – WH33992LH.
⮚ Type – SCN – 355.
⮚ Speed Ratio – 45:1.

FLUID COUPLING

❖ Used to reduce energy.

❖ To safe motor during the condition of high load.
❖ Act as best energy saver.

APRON FEEDER:

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

SPECIFICATION OF APRON FEEDER:

APRON FEEDER AT PGC APRON FEEDER AT COS

Size – 1219x9000 mm 1219x9000 mm

 Capacity – 200 – 530 MTPH 200 – 530 MTPH

Motor – 37 KW 22.5 KW

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 – 55o C, after
making sure about points, see that the conveyor to which the
apron feeder is feeding is running.
● Now, start the Apron chain Drive & feed the material.

Motion Track Roller

Tailing Track chain

Return Roller product

LUBRICATION SYSTEM:
Receiving chute
❖ For eccentric motion, shaft counter, bend gear.
❖ Servo system 526 of IDC.
❖ 125 lt/min (circulation volume)
 ❖ For crusher head suspension & mantle.
❖ Servo Gem – 2 of IOC (Greece).
❖ Once in 16 hours.

Name Of No: of No: Type of Recommended Volume Interval

The Unit Unit of System Grade of Of Of
Poin Lubricant Lubricant Lubricant
t per
Unit
Eccentric Circulating Servo – 125 Continuous
1 1 System let/min
526 OF IDC
Bend gear Circulating Servo – 125 Continuous
transmissi System let/min
on 1 1 526 OF IDC
Counter Circulating Servo – 125 Continuous
shaft System let/min
bushing 526 OF IDC
Top Centralise Servo Gem 2 1000 cc Once in 16
suspension d grease of IOC hours
of crushing 1 1
head &
mantle
Dust seal Centralise Servo Gem 2 Once in 16
ring 1 1 d grease of IOC hours

Antifriction Centralise Servo Gem 2 2.5 cc Once in 08

BRG of 1 4 d grease of IOC hours
drive

SAFETY DEVICE AND GAMMA INDICATOR:

Safety Device:

⮚ For crusher safety

 ● Electromagnet.
● Metal detector.

ELECTROMAGNET:

It is used to attract the metallic material, which shows magnetic

property to avoid choking damaging the inner shell of secondary
crusher.

METAL DETECTOR:

It is used to detect those material/metal which don’t show metallic

property to avoid choking, damaging the inner shell of secondary
crusher.

For emergency safety issue:

Pull Card

GAMMA RAY INDICATOR:

When the product from discharge level from crusher increased in

hopper & 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
start as

⮚ Used to avoid choking of hopper.

⮚ Used to avoid breakage of oil pump.
⮚ Safe crusher from wear & tear.

CHAPTER 3 – SECONDARY UNIT:

Secondary Crusher:
 ❖ Secondary cone crusher 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 – 350 mm.
❖ Recommended maximum feed size – 300 mm.
❖ Closed side sitting – 30 to 60 mm.
❖ Capacity at minimum recommended sitting – 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

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 under 0.3 kg/cm2. If it is more than that, rotate
the filter. If there is no improvement then the filter has to be
cleaned.
● Check the temperature of oil inside the tank. It should be below
50o C. 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.
● Temperature of all oil leaving the crusher should be below 60oC.
● Check the coupling pad & bolts.
● Start crusher motor.
● Check the crushing head RPM it should 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
– 45 let/min.
● Start feeding.

SCREENS:

Screens are used to sizing or classifying to separate the particles by

size usually to provide downstream unit process with the particle size
range suited to that unit operation.

Double Deck Screen.

Double deck screen is used in MCP is of the size 40x40 mm

& 12x20 mm are arranged in vertical vibration at above feeding zone
of secondary crusher.

TERTIARY CRUSHER:

Tertiary cone crushers are designed for third stage crushing of

ferrous & 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 – 262.5 KW/ 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.

-40 mm input size Tertiary Cone Crusher output size -12 mm

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

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

intermediate position in between low & high level.
▪ Start the oil pump.
▪ Check the differential pressure gauge. It should show less than
25 psi. higher differential pressure indicate clogging of filter.
▪ Check the oil pump. Entering cooler. It should above 60o F.
▪ Check the oil pump. Leaving cooler. It must be less than 115o F.
▪ Open the inspection cover of the settling tank & check the oil
drain-line from the crusher. Inside the tank to ensure that it 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 5 – 15 psi.
▪ Oil temperature leaving the crusher should be less than 120o F.
▪ Stop the crusher if the temperature of oil leaving the crusher
reaches 130o F.
▪ Temperature difference in between the oil entering the crusher
& leaving the crusher should in between 1 & 3o F. if the
temperature difference more than 5o F 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 any abnormal sound or vibrations.
 ▪ Open the hydraulic seal water & wait till the clear water comes
out from the outlet.
▪ Start feeding.

Single Deck Screen:

Single deck screen used to separate particles of one specific size.

In MCP single deck screens used at the feed of 20 mm above the
tertiary crusher with screen size of 12x20 mm. the underflow of the
screen is -12mm.

CAPACITY & REDUCTION RATIO:

Capacity:

● Secondary crusher – 584 TPH.

● Tertiary crusher – 330 TPH.

Reduction Ratio:

● Secondary crusher – 3.5.

● Tertiary crusher – 3.33.

CONVEYOR SYSTEM:
 Used for transportation of feed (Secondary) from apron feeder at coarse
ore store (COS) for convince to carry to secondary unit.

BELT & THEIR SPECIFICATION:

BELT LENGTH (m) WIDTH (m) THICKNESS(m)

NUMBER

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.

Feed From
COS

SECONDARY
CRUSHER

BELT 2: Used to carry crushed product from secondary & tertiary

crusher to conveyor belt 3.
 SECONDARY CRUSHER
T1 T2 T3

BELT 3

BELT 3: Used to transferring product of the belt 2 to belt 4.

BELT 4: Carry (-40 mm) feed from belt 3 to surge bin S1, S2 & S3.

tripper

s1 s2 s3

BELT 5: Carry the -12 mm product from screening to FOB (Fine Ore
Load
Bin).
 Double deck screen
T1 T2 T3

SURGE BIN:

They are three surge bin named as S1, S2 & S3.

LUBRICATION SYSTEM:

⮚ Servo system SP17.

⮚ Heat Exchanger.
● T1 – Serial number – 11070, 2.4 kg/cm2 (0 - 6).
● T2 – Pressure (1 – 2) kg/cm2 (0 - 4).

Lubrication consists of 4 motor systems.

❖ M1 & M2 are working.

❖ M3 – Stand By
❖ M4 Purifier.

MOTOR SPECIFICATION:
EQUIPMENT NOTATION KW/HP PHASE VOLT TYPE RPM
TYPE (V)

Tertiary MT1 250 3 3300 TEEEPK 492

Crusher

Tertiary MT2 375 3 3300 SYMONS 993

Crusher

Tertiary MT3 250 3 3300 HEC 492

Crusher

Lubricant ML1 5.5 _ 415+- _ 1440

Pump 10%

Purifier MP1 5.5 _ 415+- _ 1430

Pump 10%

Main Process Unit

 FOB

Ball Mill

Cyclone O/F

U/F

Flotation Cell

Conc.

Thickener

Ceramic Filter

Final Conc. (25-28%Cu)

(0.082 To 0.04% Cu)

Tail
Cyclone
Tailing dam

FINE ORE BIN:

 ⮚ FOB acts like a storage bin. The discharge of the single deck screen
of size is (-12mm) stored in FOB
⮚ The capacity of the FOB 10000 MT
⮚ Through conveyor arrangement -12 mm size of fine ore fed into the
Ball mill

GRINDING SECTION:

● In grinding section 4 Ball mills are used.

● They adding lime about 0.7kg per ton to the ore coming from the
FOB
● Lime is added for maintaining desired PH (9-10 pH )
● Lime is added in the grinding section because of homogeneous
mixture of pulp is produced.

SPECIFICATION OF BALL MILL:

● Ball mill size - 5791x3810mm
● Drive motor – 1200KW
● Speed of the mill – 15.1 RPM
● Type of mill – Overflow
● Feed Rate – 1515 TPD / 60 TPH
 ● Pulp Density – 75% solids by weight
● Ball Size – 80mm
Capacity of each ball mill is actually 65 TPH but they are increases up to
75-80 TPH
In grinding mill operation combined load of grinding medium, feed material
& water together it may be around 45% of total inner volume of the ball
mill. In a ball mill grinding feed material is ground due to cascading &
cataracting action. Cascading means due to abrasion, Cataracting means due
to impact that is direct falling of grinding media over the feed material

Speed of the ball mill at which mill charge centrifuge & media fixed at a
particular point in the inner periphery of the mill without taking the projector
of parabola this is called critical speed

Critical speed NC = 42.3/√𝐷 − 𝑑

D = Diameter of the mill
d = Diameter of the ball
 = 42.3/√3.84 − 0.08
= 42.3/√3.76
= 21.80
Here they are maintaining speed of mill around 65-70% of critical speed.
The total retention time of the feed material inside the mill 24-27 minutes.
The output discharge of the ball mill contains 35% of -200 # but previously
they maintained 60% of -200# Trommel is fixed at discharge end of the ball
mill. It separates the spillage (ungrounded material) from the grounded pulp
Spillage formation around 2-4% of feed rate

LINERS
It is used for ball mill to avoid ware & tare produced due to Grinding
action
In ball mill three types of liners are arranged
1. Feed head liners
2. Cell liners
3 .discharge head liners
In feed & discharge head liners contains 13 lifters & 13 plates
In cell liners, each row contains 20 bolts
4+5+5+3+3=20 (5 liners)
First, second & third liners size is 1320 mm
Fourth liner – 660 mm
Fifth liner – 1150mm
Total weight of the single liner – 89kg
Total weight of single plate – 35 kg
Lifter bar are used to lift the charge
The plates arranged in between two lifter bars
Bolt length = 150mm
Replacement of liner period is around 4-5 months

MOTORS:
The ball mill discharge pumped to cyclone through the morris pump
Each ball mill contains two Morris pumps
If one is working & another is stand by
PUMP SPECIFICATION:
Pump size – 10”x8”
Capacity - 75 Hp
RPM – 1485
V – Belt – C – 112
Lubrication – SAE-30, SAE-40 & SAE-50

CYCLONE:
Cyclone is used to separate the fine particles from the coarse particles.
Each mill contains two cyclones
If one cyclone is working another is stand by
The cyclone angle is around 20 degree
The cyclone over flow contains 45-50% solids goes to flotation.
Cyclone under flow contains 60-70% solids again fed back to the mill.

RECIRCULATING LOAD

Feed of the Ball Mill= 75 TPH

Ball Mill Discharge = 80% solids
Cyclone Feed = 70% solids
Cyclone O/F = 50% solids
Cyclone U/F = 65% solids
Solids in the Ball Mill = Solids in the Cyclone O/F
Dilution ratio of feed = 30/70 = 0.43
Dilution ratio of O/F = 55/45 = 1.22
Dilution ratio of U/F = 45/55 = 0.81
(U+75)0.43 = 0.81xU + 1.22x75
0.43U + 32.25 = 0.81U + 91.5
59.25 = 0.38U
U = 155.22
Percentage of Circulating Load = Ux100/Feed
= 155.22x100/75
Circulating Load= 206.9%
 Ore + water Collector + Pine oil
Rougher
Concentrate Tails

Cleaner Scavenger
Concentrate Tails Concentrate Tails

Re-Cleaner Final tail

Tails Concentrate

Re-cleaner tails Final Con.

FLOTATION:
Flotation cell type : sub aeration double float
Capacity : 300cft
Drive motor: 30HP
Rpm : 1000
V-belt: c-170

In flotation circuit:
4 rows of flotation cells are used; each row contains 12 cells & 1 cleaner cell For
4 cells

One junction box is fitted

In a 12 cells row 6 are rougher & 6 are scavengers.
For 4 cleaner cells 2 re-cleaner cells are provided, these cells are used for getting
good grade of concentrate
The cyclone overflows of 45-50% of solids if pulp enters to the cell
In this direct flotation technique is used
Cyclone overflow is diluted by adding little amount of water (pulp density 30-
40%)
Impeller agitates the pulp at 1000 rpm
Ph maintained in this process is about 9-10
In this ph range, increase the affinity of the collector towards the surface of the
minerals to be floated
In Flotation process xanthate used as a collector it comes under classification of
sulphydryl collectors.
They are very high powerful collector and high selectivity contains bivalent
sulphur groups
Xanthate collector’s gives good contact angle
In sulphide minerals, xanthates are used
Polar group of the xanthate reacts with chalcopyrite mineral surface and adsorbs
on it.
Resulting insoluble metal xanthate is formed
Non polar hydrocarbon chain of xanthates oriented towards air, making
chalcopyrite mineral as hydrophobic.
Longer the chain length of hydrocarbon results more powerful water repulsion
produced by it.
After conditioning, pine oil is added and it acts as a frother
Pine oil produced a reasonably stable froth for retaining mineral particles on it.
Air is supplied to the cell through four air blowers when blowers blows the air,
air bell distribute the pressurized air into all over the cell.
Air bubbles produced from the air bells

Air bubbles size depends on the hole of the air bell

These air bubbles carry the selected air bubbles particles to the surface.
Sodium silicate is added as a depressant, it mainly depress the silica and silicate
minerals
Reagents
Ph modifier: lime (Cao % >50%)
Lime consumption: 0.7kg/ton
Collector:5% sodium isopropyl xanthate
Xanthate consumption: 3-4g/ton
Frother: pine oil
Pine oil consumption: 23g/ton

Thickener
Makers: The El CO-K.C.P.LTD MADRAS
Size of the unit: 83’0”SWD
Type:’C’ with C-54 DRIVE, CLDTO C 4 LIFT HAVING
2 SHAFT AND LONG ARMS
Direction of rotation: clockwise
Rpm: 0.1
Drive unit: motor 1 no, HP-3, RPM-1440
Lifting device: 610mmlift, motor 1 no., HP-1.5
Thickener feed rate: 28.5t/h
Underflow pulp density: 60% solids
Thickener diameter: 25 meters
Weight of the thickener; 17500kg
Thickener used to separate the water or removes the water from the pulp
When flotation concentrate enters to thickener tank it settles without flocculent
Thickener discharge is diluted before feeding to the ceramic filter

FILTRATION:
Type: disc ceramic filter
Capacity: 20ton/hour
RPM: 10
Pump: vacuum pump
The diluted underflow of the thickener comes to the filter
In ceramic filter 12 discs are arranged & fixed on the middle column, inside the
column 12 pipes are available.
When one pipe is adjusted to the suction pipe, that pipe drags the water from the
cake
After suction, drier is placed; drier dries the cake by air blowers
Cake is removed from the disc using scarper
This mechanism is continue for all 12 pipes periodically
The obtained cake contains 8-12% moisture
The residual of this filtration process goes to the tailing dam
The final concentrate of filter output send to smelter of ICC.GHATSILA
TAILING DAM:

In copper processing huge amount of tail is generated daily The handling of the
tails is huge headache But in MCP they are well planned tailing dam was
constructed Tailing dam was initially occupies a basin created by the
construction of an earth fill starter dam during 1981/82 across a natural
valley Tailing dam is situated to the south of concentrator plant at a distance
of 2.4km
Tailing dam area: 2.2 sq km
Circumference area tailing dam: 6km
Pulp density of tail: 30-35%
Tailings generated daily in the concentrator plant is about 6000-6500MT per day
Tail is mainly contains 80-85% sio2
Tail generated in the plant is pumped through pipe line by 3 series of pump (each
series contains 4 pumps). 3 lines of pipe line is made for transporting the
tail, but daily 2 pipe lines are used The pipe line is adjusted to the cyclones,
cyclone overflow fed to dam & underflow is used for increases the dam
height
For each pipe line 6 cyclones are fixed
Present RL level around tailing dam bund is varied from 594-603
There are two numbers of trolley mounted pumps for reclamation of tailing dam basin
water from tailing dam to plant
From tailing dam daily 500 m3 of water we get back (tail water + seepage water)
 CHEMICAL ANALYSIS
DETERMINATION OF TOTAL COPPER IN BLAST HOLE (BH) SAMPLES

COLORIMETRY:

Transfer 1g accurately weighed samples in to 250/150 ml cap. Beakers. Digest in 20 ml aqua

regia (1:3::HNO3:HClO4) for 2 hours, initially are moderate temperature then at elevated
temperature. Continue to heat until syrupy state. Boil the content with about 20 ml distilled
water, cold. Add ammonia in excess. Blue colour will develop due to formation of tetra-
ammine copper (II) complex along with precipitation of iron as Fe(OH)3. Make up the
volume of the content to 50 ml in 50 ml cap. Measuring cylinder. Filter through whatmann
filter paper no.1. collect the filtrate in 15x150 mm test tubes. Read the absorbance of blue
colour filtrate at 610 nm wavelength in a spectrometer. Find out the equivalent % content of
copper from the calibration chart.

Calibration chart is prepared with the help of measurement of colour absorbance of a series
of standard solutions.

Note: For high grade of ore (>2%), iodometric method is employed, as described below for
feed and tails samples.

DETERMINATION OF TOTAL COPPER IN FEED & TAIL SAMPLES

IODOMETRY:

Transfer 1 g of accurately weighed sample of feed (2 gs for tail samples) to 250 ml beaker.
Digest in 20 ml. aqua regia (1:3::HNO3:HCL) for two hours on a hot plate, initially at
moderate temperature. Raise the temperature towards end of digestion. Continue to heat to
syrupy state. Add 5 ml of 1:1 H2SO4. Gradually increase the temperature to effect fuming.
Dense fumes of oxide of sulphur will evolve at high temperature and sample get finally
dehydrated completely. Cool the sample. Moisten the content with few drops of 1:1 H2SO4.
Boil with the minimum volume of distilled water to dissolve the salt, cool. Add concentrated
ammonia solution to precipitate all the iron as Fe(OH)3. Cu will form tetra ammine copper
(II) complex. Add solid ammonium bi-fluoride. Shake to dissolve the iron precipitate. Wash
the wall of beaker with minimum volume of water. This step helps to maintain the p H to the
range of 3.6 to 4. Add 5 ml of 40% solution of potassium iodide. Titrate the content with
standard solution of sodium thiosulphate (Hypo) having strength of 1 ml hypo=0.002g Cu
using starch as an indicator. Continue addition of hypo solution from burette until blue
colour vanished. Note down titre value and calculate the percentage of copper content in the
sample as follows:

Percentage Cu = Titre value in ml.x0.002x100/wt. of sample.

Note: add 5 ml of 10 % solution of potassium thio-cyanate to liberate adsorbed I2 just before

endpoint is attained.

Cu++ +2I- = CuI2

2CuI2 = Cu2I2 + I2

I2 + 2Na2S2O3 = Na2I2 + Na2s4O6

DETERMINATION OF TOTAL COPPER IN CONCENTRATE SAMPLES

IODOMETRY:

Transfer 0.5g accurately weighed samples in to 250 ml cap. Conical flask. Pour 9 ml of 1:1
mixture of nitric acid: per-chloric acid. Cover the flask with watch glass. Place the flask on
hot plate. Heat gently. Gradually increase the temperature. White fumes will start to produce
and condensed drops from watch glass. The digestion of sample will reach to it’s completion
when no further condensation appears. Remove the flask from hot plate and allow standing for
cooling. Pour 40 ml of distilled water. Boil the content of flask to dissolve the salt completely.
Remove the flask from hot plate. Allow to stand for cooling.

Add ammonia solution to above test solution till ammonia smells. This step will precipitate all
the Fe3+ into ferric hydroxide. Add ammonium hydrogen fluoride to make the solution clear.
This will help to maintain the pH of the solution above 3.2, which is necessary for avoiding the
interference during titration. Wash the wall of flask with minimum amount of distilled water.
The test solution is now ready for titration.

Add 5 ml of 40% solution of KI yellow turbidity of iodine will appear. Titrate against standard
solution of Na2S2O3 (sodium thiosulphate = hypo) having strength of 1 ml = 0.005g Cu. When
yellow colour of liberated Iodine is close to disappear, add 2 ml of 1% solution of starch as an
indicator. Deep blue colour will be appeared. Add more Hypo from burette drop wise until
blue colour disappears and a faint fleshy turbidity will be obtained. Add 10 ml of 10% solution
of KCNS or NH4CNS and shake properly. An intense blue colour will further appear due to
release of adsorbed I2 from white mass of CuI. This blue colour will require few drops of hypo
to disappear completely. Read the volume of Hypo consumed from the burette.
The number of CC of hypo consumed will be equal to the % of Cu present in the sample,

DETERMINATION OF OXIDE-COPPER IN ORE & CONCENTRATE SAMPLES

COLORIMETRY:

Transfer accurately weighed 1g sample into 250/150 ml cap. Stoppered conical flask. Add a
pinch of sodium sulphate to maintain reducing environment inside the flask. Pour 30 ml of 5%
sulphuric acid solution to the flask. Stopper the flask. Swirl the flask to mix the content. Allow
to stand the flask for an hour. Shake the flask occasionally. After one hour filter the content
through filter paper no.2. wash the content with hot water thoroughly (4-5 times). Collect the
filtrate in 250/400 ml cap.beaker. add 2-3 ml concentrated nitric acid to the solution. Boil the
solution to oxidise the ferrous into ferric. Allow to heat the beaker to reduce the volume to the
range of about 20 ml. Allow to heat the beaker to reduce the volume to the range of about 20
ml. Allow to cool.

Add 1:1 ammonia solution in excess blue colour will develop due to formation of tetra-ammine
copper (II) complex along with precipitation of iron as Fe(OH)3. Make up the volume of the
content to 50 ml in 50 ml cap. Measuring cylinder. Filter through whatman filter paper no.1.
collect the filtrate in 15x150 mm test tubes. Read the absorbance of blue colour filtrate at 610
nm wavelength in a spectrophotometer. Find out the equivalent % content of Cu from the
calibration chart.

Calibration chart is prepared with the help of measurement of colour absorbance of a series of
standard solutions.

DETERMINATION OF ACID INSOLUBLE IN CONCENTRATE SAMPLES

GRAVIMETRY:

Transfer accurately weighed sample (0.5g concentrate) in to 250ml aqua regia

(1:3::HNO3:HCL). Cover the beaker with watch glass. Digest for 1 hour on a hot plate, initially
at moderate temperature. Raise the temperature gradually. Rearrange the beaker towards low
temperature region of hot plate. Add 3-5 ml nitric :Perchloric acid mixture. Continue to heat
to allow dense fuming. Open watch glass partially. Continue to heat to dry state. Make the
content for little extra time to ensure complete dehydration. Remove the beaker from the hot
plate. Cool. Pour 20 ml HCL and boil to dissolve that salts. Add around 75 ml of distilled
water. Again heat to boil for few minutes. Filter through whatman filter paper no.42. transfer
the residue completely on to the filter paper with the help of police man. Wash the residue
thoroughly with hot boiling water to make the residue free salt and acid. Transfer residue along
with filter paper into the silica crucible. Heat the crucible to char the paper. Introduce it into
muffle furnace and ignite at 900oC for 1 hour. Remove the crucible from furnace. Allow to
stand to cool to room temperature in a desiccators. Weigh the ignited mass in an analytical
balance. Calculate the % of acid insoluble in the sample.

Note: alternatively the complete dehydration can by achieved by digestion with 15-20 ml of
nitric:perchloric acid mixture up to dense fuming at high temperature. Then boil with around
20 ml HCL and continue as described above.