SUBMITTED BY: SUBMITTED TO:

CHIRAG SHARMA MR. UDAY KUMAR

(NITK Surathkal) (CHIEF MILL SUPRITENDENT)

 CONTENTS

~Basic introduction of uranium.

~History of UCIL.

~Overview of mill section.

~Primary crushing and fine crushing.

~Grinding.

~Neutral thickening.

~Neutralization and acid filtration.

~Acidic leaching.

~Ion exchange.

~Product (Filtration drying and packing).

~Reagent preparation section(pyrolusite and lime).

~ Tailing neutralisation.

~ Burst lime slacking.

~ sand preparation and tailing disposal.

~ ETP(water retreatment plant).
Basic introduction of uranium
• Uranium, atomic number 92 is a radioactive element that is transformed
into stable state lead via intermediate state involving emmision of alpha
and beta radiation

• Natural uranium consists of three isotopes whose concentrations in

different resources are usually the same, even to the fourth decimal:
238U, 99.2762 at%; 235U, 0.7182 at%; 234U, 0.0056 at%. However,
uranium from one deposit in Gabon (the Oklo mine) is exceptional [8],
the proportion of 235U being lower :

• Expected 235U’content 0.711 %

• Measured 235U’ content (July 7, 1972) 0.7078%
• Absolute discrepancy 0.0032%
• Relative discrepancy 0.45%
• Accuracy ofmeasurement ± 0.0001%

• Uranium was discovered in 1789 by MA'RTIN HEINRICH KLAPROTH, who

extracted it from pitchblende. He precipitated the yellow uranate and
reduced this with charcoal.

• In 1841, E. M.PELIGOT reported that he had obtained uranium metal by

tpermal reduction of anhydrous uranium tetra oxide with potassium in a
platinum crucible.

• The discovery of radioactivity by A. H.BECQUEREL on March 1, 1896,

resulted from experiments with uranium. The fluorescence and
phosphorescence of uranium compounds had been studied from about
the mid-1800s.

• World War II and U.S. decision to have a nuclear weapon led to intense
activity in uranium research and nuclear development. Uranium
enrichment plant based' o~ the electromagnetic process was started in
1943 in Oak Ridge, Tennesse
 History of UCIL
Uranium Corporation of India Limited was established as a government of India
enterprise in 1967. UCIL fulfils the requirement of uranium for the nuclear reactors.
UCIL consists of six underground mines namely Jaduguda mine, Turamdih mine,
Mohuldih mine, Bhatin mine, Narwapahar mine, and Bagjata mine. Bagjata,
Jadugoda, Bhatin, Narwapahar, Turamdih and Mohuldih are underground mines
whereas Banduhurang is open cast mine. Uranium bearing minerals occur in very
finely disseminated form.
UCIL has implemented a composite scheme for reclamation of water and effluent re-
treatment to make the final discharged effluent environmentally safe. Water from all
mines is collected, clarified and reused in the ore processing plant. The Tailings Pond
effluent is also clarified and a part of this is sent to the ore processing plant for reuse.
The remaining portion is re-treated with barium chloride and lime, clarified and the
settled precipitates are sent back to tailings pond. The harmless liquor is discharged.
Two types of wastes are generated while processing Uranium ore i.e. liquor depleted
in Uranium from ion exchange unit after Uranium recovery and filtered cake depleted
in Uranium from filtration of leached slurry. Both are neutralized with lime stone and
lime slurry to precipitate the remaining radio nuclides along with heavy metals like
manganese, iron, copper etc. The neutralized slurry is classified and the coarse
fraction is pumped back to the mines for back filling the voids. The fine particles are
pumped into the tailing pond where slime settles and clear water is decanted
through decantation wells and sent to the Effluent Treatment Plant for re-treatment.
The Tailings Pond is a well-engineered containment having an earthen dam on one
side while the other three sides are protected by hills.

Turamdih processing plant processes ore from Turamdih, Bandhuhrang and

Mohuldin mines. Turamdih uranium deposit is located about 24 km west of
Jadugoda. This mine was commissioned in 2003. The entry into the mine is through a
degree decline which provides facilities for using trackless mining equipment like
passenger carrier, jumbo drill, low-profile dump truck etc. at a depth of 70 m, the ore
body has been accessed from the decline by a cross-cut. Decline has been further
extended upto a depth of 140 m, a vertical shaft of 5 m diaupto depth of 260 m has
been completed.

The plant at Turamdih has been set up to treat the ore produced from Turamdih,
Mohuldih and Banduhurang mines.
 Overview of mill section
Processes involved in processing of Uranium ore
Ore

Crushing

Grinding
Recycle
Neutral
Water
Thickening
Filtrate O/F
U/F
Water
Neutral Filtration

Reagents Acid Leaching

Filter Cake
Flocculants Acidic Filtration

Barren Solution Bleed

Precipitated Iron Cake

Un-clarified Pregnant Liquor

Recycle Barren Liquor

Neutralisation Lime

Sand/Slime Sand for Backfilling of Mines

Clarification separation
Eluent
O/F
Tailing Thickener
Ion Exchange U/F
Sampling Point for Solid

Tailing Pond
Recycle Water

Iron Precipitation and

Reagents Separation Decant Water
Pond
Reagents
MDU Precipitation
Effluent Treatment

Recycle to Process
Product Plant Monitoring Pond

Treated Effluent to Environment

Primary crushing and fine crushing
Crushing is basically process of reduction of particle
size of ore.primary crushing is done by jaw crusher
fine crushing is done by cone crusher.

Uranium ore particles are fed to an apron feeder through a grizzly of

size -500mm and of capacity 350 tph. The over-size particles are
reduced either manually or by secondary blasting. The -500 mm
particles are then taken for screening, through a belt conveyor (BC-
1), to a screen of 100 mm. The +100mm size (over-size) particles are
then sent to the jaw crusher for size reduction. The jaw crusher is a
single toggle jaw crusher and has a capacity of 350 tph. The
discharge is of the size range 120-130mm. The -100mm particles and
the jaw crusher discharge are loaded on a belt conveyor (BC-2) which
transfers the material to a shuttle conveyor (BC-3). The shuttle
conveyor forms stockpiles at four positions (IVF-1 A, B, C, D)
sunp pulley: its main function is to increase the
contect surface area between belt and pulley.
Bend pulley : to bend the belt in a particular
direction.
Gravity takeup pulley:its function is to maintain the
tension in the belt
The ore from the stockpile is falls on to a conveyor belt (BC-4) which
takes the ore for fine crushing. Magnets are attached to a rotating
belt at the start of the conveyor belt for removal of iron ore particles,
if any. The feed from the conveyor belt is passed to a Y-chute, which
handles the direction of flow of the ore. The feed from the Y-chute
falls on screens of size 35mm, inclined at 16 degrees. The oversize
particles are fed to a secondary crusher (cone crusher). The
discharge is transferred to a belt conveyor (BC-7) through BC-6
whereas the undersize particles are transferred to BC-7 through BC-
5, 6. The feed from BC-7 is allowed to fall on screens of size 25mm.
The over-size particles are sent back for tertiary crushing through a
conveyor belt (BC-9) while the undersize particles are sent to fine ore
bins through a series of conveyor belts (BC-13,14, 15, 15-A). There
are five ore bins of which four are 750 tonnes in capacity each and
one is 1000 tonnes in capacity.

Feed input: 550 mm.

Feed output: 120 to 150mm.
Crusher motor: 3 phase a.c. induction motor.
Power: 160/214kw(hp).
RPM: 989.
Frame: TPR4000.
Volts: 6600V.
Current: 20A.
Frequency: 50hz.
Weight: 4939kg.
F/L efficiency: 92%
RV: 350.
RA: 270.
AMB: 50’C.
Heater terminal
Volts: 240V.
Apron Feeder
Material Manganese
steel
Angle of repose 38 degree
Size and Thickness 1584*222*25
Conveying speed 0.007-0.075
m/s
Conveying capacity 263 tph
Motor Rating 22 kW

Secondary (Cone) Crusher

Feed 100% passing 90 mm

Feed 80% passing 48 mm
Feed arrangement Vibrating feeder
Liner material Mn steel

Tertiary (Cone) Crusher

Feed 100% passing 25 mm

Feed 80% passing 17 mm
Feed arrangement Vibrating feeder

Vibrating Screen

Capacity 300 tph

Inclination 10 degrees
Size(W*L*H) 1200*2000*250
mm
Type unbalanced
 Crushing Circuit
Stockpile

BC-4

BC-4
Y-Chute

BC-5
 BC-7
BC-7
BC-6

The ore from the stockpile is falls on to a conveyor belt (BC-4) which takes the
ore for fine crushing. Magnets are attached to a rotating belt at the start of the
conveyor belt for removal of iron ore particles, if any. The feed from the
conveyor belt is passed to a Y-chute, which handles the direction of flow of the
ore. The feed from the Y-chute falls on screens of size 35mm, inclined at 16
degrees. The oversize particles are fed to a secondary crusher (cone crusher).
The discharge is transferred to a belt conveyor (BC-7) through BC-6 whereas
the undersize particles are transferred to BC-7 through BC-5, 6. The feed from
BC-7 is allowed to fall on screens of size 25mm. The over-size particles are sent
back for tertiary crushing through a conveyor belt (BC-9) while the undersize
particles are sent to fine ore bins through a series of conveyor belts (BC-13,14,
15, 15-A). There are five ore bins of which four are 750 tonnes in capacity each
and one is 1000 tonnes in capacity.
The grinding circuit operates in three parallel circuits. Each circuit is identical in design and
comprises of a rod mill, a ball mill, a tank, a pump and a hydrocyclone.Ore from the fine ore
bins is fed to the rod mill. The discharge of the rod mill flows to a tank. The ore in the tank is
then pumped to the hydrocyclone. The underflow of the hydrocyclone is sent as feed to the
ball mill. The discharge of the ball mill falls in the same tank after passing through a trommel
screen. The overflow of the hydrocyclone is sent for neutral thickening through a pump.
Thefeedsizeof the grinding section is -25mm and size of the product is 200 mesh (75 m).
Equipment specification
Parameter Rod Mill Ball Mill
Feed 80 % passing 20mm 1000 m
Feed 100 % passing 25mm 2000 m
3
Pulp density 1.6 g/cm 1.6 g/cm3
Mill Speed 19 rpm 18 rpm
Critical Speed
Lining type Lifter Lifter
Lining material Rubber Rubber
Shell thickness 25 mm 32 mm
Mill size(diameter x length) 2500 x 4000 3100 x 5000
Grinding media Forged steel rods Ni-Cr balls

Grinding and Thickening Circuit

O/F

H
C
Feed from Fine Ore Bin
Thickener
U/F
Rod Mill Ball
mill

To Filtration

Sump
Tank
Neutral Thickening and Filtration
Thickening is the most widely applied dewatering technique in mineral processing,
and it is a relatively cheap, high capacity process, which involves very low shear
forces, thus providing good conditions for flocculation of fine particles.
The thickener is the industrial unit in which the concentration of a suspension is
increased by sedimentation, with the formation of a clear liquid. In most cases, the
concentration of the suspension is high and hindered settling takes place. Thickeners
may operate as batch or continuous units, and consist of tanks from which the clear
liquid is taken off at the top and the thickened liquor at the bottom.
The overflow of the hydro cyclone has a pulp density of 48-52% and goes as feed to
the conventional thickener (circuit 1, 2) and high rate thickener (circuit 3). The slurry
is thickened to about 60% in these thickeners and then filtered in horizontal bed
filters. The water is recycled to the grinding section. The dewatered cake is then re-
pulped with the help of secondary drum filters filtrate and mixed with iron gypsum
cake and then sent to the tanks for leaching.
Equipment Specifications
Leaching Tank
No. 8(6 operational, 2 standby)
Capacity of tank 330,000 litres
pH 1.5-1.8
Temperature 45-55 degrees C
EMF 450-550 Mv

Bed Filters
Filter length 69.33 m
Size 70*3.33 m
Capacity 1,40,000 litres/hr.(Neutral),
50,000/hr. (Acid)
Feed pump slurry 55-60 %(w/w Solid)
Filter cake moisture 20%(w/w)
Belt speed(avg.) 22 m/min(Neutral), 12 m/min (Acid)
CHEMICAL HOUSE
 Water removing.
 Acidic leaching.
 Acidic belt filter.
 Ion exchange reaction.
 Iron precipitation.
 Drying and packing.

Leaching section

From thickener

Acid
Neutral
HBF
water Leaching
tank

Acid HBF
Re-pulper tank

Re-pulper
tank
Clarification and Ion Exchange Section
Re-pulping tank after leaching

Pre-coat
vacuum drum
Filter
Adsorptio
n column
Elution Standby
column

Storage
Tank

For MDU recovery

For acidic leaching:

The following conditions are maintained
pH: 1.5-1.8
EMF: -450 to -500 mV
Temperature: 55oC (through steam)
Following reactions occur in the leaching section
Mn+4 Mn+2
Fe+2 Fe+3
U+4 U+6

UO22+ + SO42- UO2(SO4)

UO2(SO4)+ SO42- UO2(SO4)22-
UO2(SO4)22- + SO42- UO2(SO4)34-
Acidic Filtration, Clarification, Ion Exchange
After leaching, the slurry is brought to the filter house for solid liquid separation. This
separation is done by rotary vacuum drum filters. The filtration results in two types of
products: un-clarified pregnant liquor and filter cake. Un-clarified pregnant liquor is clarified
in a vacuum drum pre coat filter. The solid content in un-clarified pregnant liquor is around
200-300 ppm while in clarified liquor it is about 2-3ppm. The filter cake is neutralised by
lime after which sand and slime are separated. The sand obtained is sent for backfilling of
mines. The tailing is sent to the tailing pond after thickening. It further goes through for
decantation and ETP (Effluent Treatment Plant).
The clarified pregnant liquor is then taken for purification and concentration in the ion
exchange column. Clarified liquor is passed through ion exchange column, where
uranylsulphate ions and ferric ions get adsorbed on the resin beds.
R+X- +UO2(SO4)34- R[UO2(SO4)34-] + X-
The adsorbed uranium is eluted with the help of acidified brine solution.
R[UO2(SO4)] +Na+Cl- Na[UO2(SO4)] + R+Cl-
The strong eluate, from the ion exchange column contains 3 gm. /litre iron. Uranium is
pumped to the precipitation section; iron and uranium are precipitated separately in two
stages. First the strong eluate is treated with lime solution and the pH is brought up to 3.72
to 3.8, at this pH, iron precipitates out and is separated in the in a precipitation tank as iron
– gypsum cake which is mixed with the slurry before acidic leaching.
Elution Step Time
Stage I II III IV
Present time Present time Present time Present time
(min) (min) (min) (min)
Stage I Flush 60 60 60 60
Stage II Early 25 25 35 25
Backwash
Stage III 25 25 25 25
Stage IV 225 225 250 250
Stage V 25 25 25 50
Stage VI 225 225 225 225
Stage VII 25 25 35 25
Stage VIII Late 60 60 60 60
Backwash
U2O2precipitationis done. This precipitate is separated out in another thickener washed,
filtered in a belt filter and dried in the spray drier and then automatically packed in drums
lined with polythene bag.
The liquor coming out of the ion exchange columns after adsorptions of U and Fe is called
barren liquor. It is sent to the tailing treatment plants, treated with lime solution to raise the
pH to 9.5-10.*
Equipment Specifications

Precoat Drum Filters

Drum Diameter 3.65 m

Drum length 4.3m
Filtration Area 49,000 square metres
Material for coating Diatomaceous earth and clay
Motor used 3.7 KW
Vacuum pressure 600 mm Hg

DRYING AND PACKING SECTION

Precipitation and MDU Recovery Section

The liquor received from Ion exchange and clarification contains about 0.3 g/l
of U3O8 along with impurities like other heavy metals. Iron precipitation is
carried out at pH of 3.5-3.8 by addition of lime. The precipitated iron slurry is
fed to thickener for settlement of iron gypsum where the overflow is clarified
through pre-coat drum filters and filtrate is sent for magnesia precipitation.
The underflow of the thickener which contains iron gypsum along with some
uranium is passed through filters for recovery of uranium. The filtrate is
recycled back to iron thickener. The overflow of thickener is subjected to
uranium precipitation with addition of magnesium oxide (MgO). The
precipitated uranium is sent to high rate thickener for settling of MDU.
Underflow is filtered, washed, and sent for spray drying. Overflow known as
barren eluate is sent to Ion Exchanger.

Drying, Packaging & Storage

The MDU cake slurry received from the MDU thickener underflow (10-25%
solid) is washed with DM water for removal of chloride and other ions and the
washed slurry is re-pulped and pumped to MDU belt filter for drying process.
Drying is done by atomiser spray drier which rotates at high rpm and spray tiny
droplets, moisture is evaporated by blowing air and dry flakes of MDU is
obtained. The filtration, drying and packaging is carried out in a glass enclosed
compartment to facilitate spillage and dust control. Bag filters are installed to
suppress dust. When feed is charged for drying it contains approx. 65-70 %
moisture and product leaves with 2% moisture. Temperature is at approx.
150oC.
Tailing neutralisation

Tailing Neutralisation, Sand Slime Separation & Disposal:

While processing uranium ore two types of wastes are generated

1: Liquor depleted in uranium from Ion-Exchange unit after uranium recovery

2: Filtered cake depleted in uranium during filtration of leached slurry.

The rejected cake from the leach pulp belt filter is pulped again with barren
liquor from ion exchanger and fed to neutralization reaction tanks. Both the
slurry are neutralized partially by addition of limestone slurry and finally by
lime solution to 10.5 pH to precipitate radionuclide’s along with heavy metals
like manganese, iron ,copper etc..
The neutralized slurry is fed to battery hydro-cyclones to separate the coarse
and slime. The coarser part is sent to mines for backfilling and slime fraction is
sent to slime thickener. The thickener underflow is sent to tailing ponds for
separation of solid and liquid by allowing settling of solid under gravity and
clear water is recycled back to process to overcome the requirement of fresh
raw water. The effluent received from tailing pond is sent to effluent
treatment plant.

The tailings pond is a well- engineered containment having an earthen dam on

one side while the other three sides are protected by hills.

Brunt lime slaking

CaO+H2O======= Ca(OH)2

Reagent Preparation Section:

Lime slurry preparation section:

Limestone particles of size -50 mmare received in bags through trucks and are conveyed to a
cutter through belt conveyor where bags are cut and separated using revolving screen and
limestone lumps goes to hammer mill for size reduction. Limestone is reduced to -6 mm to
>5 micron. The reduced limestone is passed through bag house where bag filters traps
particle of >5micron and are conveyed to two limestone bin having capacity of 500 TPH
each. Reduced limestone is then sent to slaker where limestone gets reacted with water and
form lime slurry and unreacted particles are released. In slaker, 20% solid and 80% water is
used. Large particles of unreacted or grits are separated through rake classifier and pumped
to limestone slurry storage tank where it is mechanically agitated to make lime in slurry
form. The rejected material or grits are disposed by trucks.

Pyrolusite preparation Section:

Pyrolusite lumps of size of 150 mm are fed to crusher by means of vibratory feeder. These
lumps are then reduced by jaw crusher to 50 mm (80% passing), which is further reduced by
roll crusher to 15 mm. Dust is suppressed while transferring reduced to bin. From surge bin,
it is fed to ball mill and water is added. The ground slurry is discharged to sump tank, from
where it is pumped to hydro-cyclones. Hydrocyclone underflow is taken back to ball mill and
overflow is taken to thickener and thickened slurry is collected in storage tank from whe
reiis sent to leaching section.

precautions
 Health and Physic unit is established in UCIL considering the
environment and health aspects of the employees in view. Uranium
mining and processing involves radiation effects and environmental
hazards.
 The norms of radiations are controlled according to the Atomic Energy

Regulatory Board (AERB). The amount of radiation observed is measured

in terms of ‘Dose’. ‘Dose’ may be defined as the amount of energy
observed or deposited by unit mass of tissue.
Dust hazards and drinking water norms:

Silicacauses silicosis. Its limit is 0.8 mg / m 3. Drinking water norms are as

follows: -

Ra: 300 Bq / m3; U: 60 mg / m3; Mn: 0.1 g / m3; SO42-: 150 g / m3; Cl: 250 g / m3;
Hardness: 300 g / m3; pH: 6.5 to 8.5

Measurement of radiation:

Dosimeter records dose during work period (2 to 3 per month). Measurements

are taken from EFM, groundwater, soil, plant, food, milk, SPM, etc. The
elements to be analysed (monthly analysis) are: Ra, Th, U, Mn, SO 4, Cl, and
Hardness.
 ACKNOWLEDGEMENT

I would like to express my sincere gratitude to Mr. Uday kumar sir, C.S. (mill) UCIL,
Turamdih for extending support for the completion of my training.

I am also thankful to Mr. Anil Kr. Topno, Mr. S.K. Burman, Mr. J.D. Kannan, and Mr.
S.N. Prasad, Mr. Ashwini Dubey, Mr. Vivek for their guidance and help during the
training.

Shri Uday kumar

C.S. (Mill) Chirag sharma

(NITK Surathkal)