CONTENTS

1. ACKNOWLEDGEMENT

2. INTRODUCTION.

3. GEOLOGY.

4. SURVEY SECTION.

5. WORKING.

6. DRILLING AND BLASTING

7. VENTILATION.

8. SAFETY AND SUPPORT.

9. TRANSPORTATION.

10. PUMPING ARRANGEMENT.

11. CONCENTRATION & BACK FILLING.

12. ELECTRICITY SUPPLY.

13. MACHINERIES.

14. ANALYSIS & CONCLUSION.

 INTRODUCTION
LOCATION OF THE MINE :
The Surda Mine is located around 200km west of Kolkata (Calcutta), in Ghatsila Subdivisional
area within the Singhbhum mobile belt of the state of Jharkhand. Surda mine is served by a good
rail network, the main Kolkata-Mumbai (Bombay) National Highway going within 10km of the
mine.The mine is also connected to Mosaboni Concentrator Plant by road. Singhbhum belt
comprises a 200 km long,east-west trending arcuate belt of folded supracrustal rocks.
HISTORY OF THE MINE :
Surda Mine is a part of Indian Copper Complex, a group of six mines, owned by Hindustan
Copper Limited, that operated between 1928 and 2003. Surda mine was started in 1930 at a very
small scale and it was fully developed in 1956. The mine was developed upto an extension of 2.2
Km. in the strike direction(N20°SE). Hindustan Copper Limited (HCL), India’s only integrated
producer of refined copper including mining, production of concentrate, smelting and refining.
Hindustan Copper Ltd (HCL) was set up in 1967 for production of primary copper in the public
sector. Presently HCL is the sole producer of copper in India and has following four units :

1.Indian Copper Complex, Ghatsila, has the following operations such as Ore mining,
Beneficiation, Smelting, Electrolytic refining and has a precious metal recovery plant (Gold,
Silver, Selenium etc).

2.Khetri Copper Complex,Rajasthan, has the same operations as ICCGhatsila.

3.Malanjkhand Copper Project, M.P. has operations of ore mining and beneficiation. The
concentrate is sent for further processing to KCC and ICC and excess quantity is sent abroad for
toll smelting;

4.Taloja Copper Project, Maharastra has C.C. rod facility.

Indian Copper Corporation Ltd was established by a British company in 1930 at Ghatsila
consisting of a cluster of underground copper mines, concentrator plants and smelter. On 25.09.72
the Govt. of India nationalized the company under provisions of the Indian Copper Corporation
(Acquisition of Undertaking Act) and merged the same with HCL. Today it falls under the state
of Jharkhand, under the jurisdiction of east Singbhum district.

Existing Infrastructure

» Established in 1930
» Operating Mine: Surda~17.4 MT @ 1.17% Cu
» Process plants to produce 19,000 TPA of refined copper Ore
Reserves including resources:

Additional mining reserves (old mines):

Rakha mine 47.19 million tonnes @ 0.97% copper Kendadih
Mine 12.85 million tonnes @1.73% copper Chapri Block
63.50 million tonnes @1.14% Copper.

Surda Copper mine was in continuous production from 1956 to 2003.in this time, Surda
has produced a total of 8,986,348 tonnes at 0.95% cu and presents the 2nd largest copper
producer from the six mines making Indian Copper Complex. The mines operations
started in 1956 and mining was ceased in January,2003. In 2007 India Resources Ltd
(IRL), a subsidiary of western Australia-based mining major Monarch Gold Mining Ltd,

restarted mining operations at Hindustan Copper Ltd's (HCL) closed Surda mine.
GENERAL INFORMATION:
Surda Mine operated between 1930 to 3rd January, 2003. The mine is 2200m in strike in north-
south direction and is serviced by 3 openings ,No.3 Shaft is vertical to level 5, from where a
Sub Inclined shaft goes down upto the deepest level, Level 13 at 474m below surface. At the
southern end of the mine, commonly known as South Surda the No.4 shaft is inclined from
surface to 9th level.The other opening is No..5 adit, near No.3 shaft,which has a horizontal
length of 115.8 m.

DETAILS :-

Shaft Inclination Dimension Depth From level To level

No.3 Vertical 4.5 * 2.5m 160.0m Surface 5th
No.4 40° 4.40 * 2.6m 576m(INCLINE) Surface 10th
Sub-Incline 32° 4.40* 1.7m 674m (INCLINE) 4th 13th

WINZES
1. 1060 S winze 5 level to 8 level incline depth- 162m(3*1.6)m
2. 1200 s winze 8 level to12level incline depth-380(3*1.6)m
3. 25m s winze 10 level to 13 level incline depth-380m(3*1.6)m

The mine is running approximately at 1300 tonnes per day, designed to produce 1400
tonnes per day and is to be upgraded to the capacity of 1700 tonnes per day. The
difference between the two consecutive levels is 37.5 m. There are two ventilation fans,
north fan and south fan are for the ventilation of the mine. The geological ore reserve is
26.04 MT of Cu and additional drilled ore reserve of 11.20 MT of Cu is defined in Surda.
The total ore reserve of Surda comes 37.24.

For the last six years prior to it closure in 2003, the Surda mine produced 1,473,000 tonnes at
an average grade of 0.9% copper. The cut off grade is 0.50%Cu and pay limit is 0.80%Cu for
wider zone and 1.00%Cu for narrow zone.

The average width of the lode is 5.08m. In this mine three type of lodes are found hangwall
lode, intermediate lode and footwall lode. Presently HCL is the sole public sector producer
of copper in India including ore mining, benefication, smelting, electrolytic refining etc. The
first copper smelter was set up at Ghatsila in 1928. An electrolytic refinery for cathodes and
wire bar plant was commissioned at Ghatsila in 1965.

Flash smelter based on Outokumpu Flash smelting technology was set up in 1971. The first
continuous cast rod unit was established in the country during 1984. Hindustan Copper Ltd
(HCL) was set up in 1967 for production of primary copper in the public sector. And Currently
Operated under Indian Resources Limited it had initial production target 450,000 tpa of ore at
average 1% Cu and has potential to double to 900,000tpa.Besides copper as many as 16
byproducts eg. gold, silver, silenium, sulphuric acid , SO2 are extracted
 GEOLOGY OF THE MINE
Indian Copper Complex (ICC) at Ghatsila, Jharkhand Singhbhum Copper Belt comprises of a
Proterozoic volcano-sedimentary rock that creates a shear zone known as Singhbhum shear zone.
Copper mineralization in SCB is localized along this shear zone. Prominent deposits of the belt
are Surda,Chapri, Rakha, Kendadih, Pathargora and Dhobani. Other deposits are: Turamdih,
Ramchandrapahar, Nandup, Bayanbil and Dhadkidih (Singhbhum, Jharkhand). Surda is one of a
number of mines of the Singhbum Copper Belt which wrap around the margin of the Singhbum
Granite. The mines are hosted in shear zones which thrust Proterozoic metamorphic rocks to the
west. Rock types are quite varied from quartzites through quartz-biotite schists to chloritic,
sericitic, micaceous and even talcose schists. Indicators of proximity to mineralisation are quartz,
chlorite and K feldspar. The ore is hosted in a mylonite schist.

Riedel shear band (indicated by red line) showing thrust movement in mylonite at Surda

Mineralisation is in the form of disseminated and stringer veins of chalcopyrite, as well as minor
quartz-chalcopyrite veins. Pyrite is also common. Two and sometimes three main lodes have
been interpreted on cross and long sections. Detailed drill sections, however, often show
many more “lodes” than the 3 interpreted. There is a high degree of continuity over 50-100m, but
lodes bifurcate, pinch, swell, end and get going again. This is generally not picked up on
sections. Nevertheless, at least one of the lodes on each section appears to be continuous over
several levels (100m+). On the sections viewed, the deepest holes appeared to show lower grade,
but in general, mineralization is probably continuous to depth, and will continue to exhibit
variability and a lack of continuity in detail. Mosaboni mine to the southeast was worked from
1924-1998, reaching a depth of 1280m, producing 2,000tpd. Lode widths vary between about 1m
to 8m. In a stope accessed from the 9 level (No. 4 shaft) the 16m apparent width “Hanging Wall
Lode” was separated from the 12m apparent width “Footwall Lode” by a waste pillar of about
6m apparent width. Calculating for the fairly constant 30° dip, these true widths are 8, 6 and 3m.
The mineralization has been regarded as a VMS type – there are metabasite (ex-volcanic) rocks
in close proximity. However, in the absence of significant zinc, any evidence of metal zonation,
or a footwall stringer zone, this interpretation is highly questionable.

A.

Oblique view (from southeast) of Surda mine drive samples coloured by Cu grade.

Preliminary work on compiling the assay and geological data from the mine instead suggests a
structurally controlled, shear zone hosted model may be more appropriate. Several high grade
zones have been identified in underground sample data.
The data is from mine grade control channel samples, taken at each face. The underground
drives were constructed as openings in the ore and were then mined between levels. The ore
appears to dip at a fairly constant 35 degrees to the northeast.

There are 12,334 samples shown in the diagram, taken from 10 of the 13 levels over a strike
length of 2kms. The samples are coloured by copper grade and the diagram shows higher
grade within linear zones, bolstering a structural interpretation of copper distribution. From
a statistical point of view, the mean value of the 12,334 drive samples is 1.42% Cu and the
median is 1.29% Cu.

One possible explanation is that these linear zones represent minor corrugations in
the mainly tabular shear zone. These corrugations could
have focused fluid flow during mineralisation. They appear to mimic a kinkband style of
deformation. In any case the correspondence of higher copper
grade with kinks in the shear zone precludes a simple primary control on metal
distribution.

Work is continuing with the capture of geological and assay data from hard copy
material provided by HCL. A new mine survey, which captures all the current mine
openings in a modern 3D software package, will provide an accurate base for this
compilation.

Further new technology being introduced is a NITON portable XRF machine, which
allows instantaneous reliable assays (30 seconds) at the working face. This will allow real-
time grade control and help to minimize dilution.
All development headings are geologically mapped and the face marked up as “Ore” or
“Waste”. In stopes, ore and waste are fired separately with different blast hole spacings
allowing a better separation of same. Channel samples are taken to define ore blocks in
rooms and panels. All data is entered into a computer and viewed in 3D via Surpac
software. Survey is carried out electronically with a Leica Total Station and can be viewed
in 3D. These tools allow effective mine planning.
 SURVEY SECTION
In earlier times, Surveying was used to be done by “conventional method” – Traversed
using optical theodolite, chain and “back station”. Level plans and cross sections were hand
drawn at various scales. But now days, Leica TCRA1200 series (Leica TCRA 1205) Total
Station and “Wall station” methods are being used for underground survey traversing.
Surpac Mine planning software is being used extensively. Surveying methods and standards
as accepted in the metalliferous mining industry

In underground station are fixed on the hangwall, footwall or on the pillar which are not
extracted for mining hence not altered for further resection and on the surface the traverse
stations are chosen which are to be permanently staying there. After that the data feeded in
the memory card are pulled out and synchronized with the National Grid with the Surpac.

This provides very easily 2D and 3D view of the mine including plan, Vertical section, and
oblique view which makes it very handy for planning and designing of the mine. It makes it
simple to understand the Stope and Block under production.

3D View of a BLOCK
In picture Cupric color shows the part of the mine extracted copper ore, drives, cross cuts, raise/winze.
 WORKING
DEVELOPMENT OF STOPE:
The process of mining from discovery of an ore body through extraction of minerals and
finally to returning the land to its natural state consists of several distinct steps.

The first is discovery of the ore body, which is carried out through prospecting or exploration to find
and then define the extent, location and value of the ore body. This leads to a mathematical resource
estimation to estimate the size and grade of the deposit. This estimation is used to conduct a pre-
feasibility study to determine the theoretical economics of the ore deposit. This identifies, early on,
whether further investment in estimation and engineering studies is warranted and identifies key
risks and areas for further work.

The next step is to conduct a feasibility study to evaluate the financial viability, technical and
financial risks and robustness of the project. This is when the mining company makes the
decision to develop the mine. This includes mine planning to evaluate the economically
recoverable portion of the deposit, the metallurgy and ore recoverability, marketability and
playability of the ore concentrates, engineering concerns, milling and infrastructure costs,
finance and equity requirements and an analysis of the proposed mine from the initial
excavation all the way through to reclamation.

Once the analysis determines a given ore body is worth recovering, development begins to create
access to the ore body. The mine buildings and processing plants are
built and any necessary equipment is obtained. The operation of the mine to recover the ore
begins and continues as long as the company operating the mine finds it economical to do
so. Shaft sinking is done, plates are installed.
And development of a stope begins which leads to development of drive, cross-cut,
raise/winze, ore-pass, finger raise for the purpose of ore transfer, pillar, rib pillar, sill pillar,
crown pillar etc.

At least three raises are developed between two levels and they are through from lower level to
upper level. Two for ventilation and one for ore pass. Drilling is done and blasted in the lode (which
contains more than 0.5% of MIC) and face is formed. As per the width of lode appropriate stoping
methods are practiced.

SPECIFICATIONS:
DRIVE 2.4m x 2.4m (Height x Width) RAISE 1.5m x 2.2m (Height x Width) ORE PASS 1.5m
(Diameter).
GRADE LINE- (Inclination of water flow in mines) 0.5%, i.e. 0.01 m depression for 2.0 m
horizontal distance.

MINE STOPING METHODS:

DECIDING FACTORS:
Depth of lode
Width of lode
Nature of adjoining strata
Availability of Technology
Geological disturbances
Strength of lode
Strength of hanging and foot wall
Being all conditions almost same for the mine width of lode is the main factor here
to decide.

METHOD OF WORKING ARE:

-Room and pillar method

(for width 1.6m to 4m)

-Horizontal cut and fill method

(for 4m to 6m)

-Post pillar method

(for width > 6m)
Distance between two pillars in strike direction is 13m and in dip direction is 9m.

METHOD OF STOPING:

The width of the ore body in Surda deposit varies from 1.5 m to over 20 m and the average dip is 350
to 400. Depending upon the geometry and geology of the ore body following mining method are
most suitable.

ROOM AND PILLAR STOPING METHOD

The method is used where the orebody width is between 1.5 m to 4.0 m. A pilot raise is put along the
H/W contact from lower level to upper level. A wooden chute is installed at the lower level, together
with an electric scraper engine. A pillar of 5 m above the lower level and a crown pillar of 4 m
below the upper level are left as support.

In this method both faces of central raise are advanced to a span of 10-15 m, with systematic bolting
of the roof at a spacing of 1.2 m. 1.5 m long 20 mm dia. Top-steel grouted rock bolt are used as
conventional support in place of timbers. 1.8/2.4 long bolt are also occasionally used for roof support
in geological disturbed area. A 3-4 m wide rib pillar is left between the two stopes. Floor stripping is
undertaken where width of ore body exceeds from 2.5 m. once the mining is completed to the
extremities of the stope,back filling of the excavated area is done and adjoin block are mined.

HORIZONTAL CUT AND FILL METHOD:

Where the width of the ore body is 4-6 m HCF method is used. The stoping is started by driving a
sill level of 8 m above the driving and the full width of the pre body is exposed for a maximum
vertical height of 4.8 m. The hanging wall is supported by rock bolt systematically at 1.5m pattern.
A FW haulage is driven on the FW side of ore drive and ore-passes are excavated there from in
waste rock to hole into the stope at interval of 60 m along strike. 1.5m dia. Ore pass rings made out
of 10mmthick steel plates are welded inside the stope to serve as manway and ore-pass through the
back fill. Cavo 310 or 0.76 cum electric LHDs are used to load and haul broken ore into the
operations. Three panels are generally prepared one for production, one for the filling and other for
filling operation. Back stripping are carried out in panels with 2.5 m vertical cut at a time.
POST PILLAR STOPING METHOD:

This method is generally adopted in ore bodies exceeding 8 m wide and a minimum strike length of
80 m . Basically, it is identical to HCF mining except for formation of 4m x 4m insitu vertical posts
to give additional stability to the roof by breaking long spans excavated. In addition to the rock
bolting of the bolt, the back of each cut in ore is also rock bolted using 1.5m long grouted type rock
bolts on 1.5m x1.5m pattern. The post pillars are spaced at an interval of 13m along strike and 9m
across it. Generally, 2.2m high cut are taken by drilling 2.23 long upper at 70m to horizontal using
two boom stope wagons/ stope air longs. Maximum height of the excavation is limited to 4.8m
above the backfill. 0.76 /1.5 cum electric LHDs transfer the broken ore into the ore passes from
where it is hauled in larger mine cars by locomotives on to the grizzly
 DRILLING AND BLASTING

DRILLING:

Drilling is a prime operation in the excavation technology without which exploration,

development, exploitation and liquidation of the mineral deposit could not succeed. In Surda
mine percussive, rotary and rotary-percussive drilling methods are used. As drilling techniques
Diamond drill bits and cemented tungsten carbide integrated drill steels are used. Drilling is used
for various purposes in the mine:

1. For exploration: Diamond core drilling process is applied. Commonly NX-size core drill is
used, representing a hole diameter of 76mm(3”) and core diameter of 54mm(2 1/8”).

2. For development and stoping: In Surda mine pneumatic tungsten carbide drill bit, rotary-
percussive drilling is used. For development and stoping drilling is done to insert explosives for
blasting.there are generally 36 holes in case of driving and 30 holes in case of raising.

DRILL MACHINE

Jackhammer is common appearance for drilling. The model used is Silver 3 Model and
manufactured by Holman Climax Company. It is compressed air operated with size of 2ft.
Drilling rod used are of three sizes.viz 4 ft,5ft & 6 ft of 32mm diameter. Having tungsten carbide
drill heads. There are 48 jack hammer drill operating in no. 3 shaft and 29 jack hammer drill
operating in no. 4 shaft. For blasting reammer hole bit dia. is 57mm.

EXPLOSIVE

In surda mines Powergel 901 is used as explosive manufactured by INDIAN EXPLOSIVE

LIMITED,GOMIA It comes in size of 200mm length and 25mm diameter weighing 125gm.
Explosives are emulsion type,non permitted and high explosives. Each box contains 200
cartridges .
BLASTING:

Blasting is the only mean for development and stoping in Surda Mine. For development i.e.
sinking, drives, cross cut, raise/winze and stoping at face is operated by blasting. Burn cut
pattern is practiced here. For blasting rimmer hole bit is drilled in the centre of drilling pattern
are of dia. 57mm for providing free space and the other holes of dia. 32mm are drilled for
inserting explosive cartridges of dia. 25mm.

For blasting the exploder used are of condenser as well as generator type.
Electric detonator (ED)and non electric detonators(NED) are used.
Detonating of Cordtex are used which has burning rate of 6500m/s, 250m length and core
load is 10gm/s/m.
Fuse wires are of length 3m and with special permission they can be of 5m length.
Indirect method is used for blasting.
For stemming solid mixture of clay and sand is used. The ratio of filling of cartridges and
stemming material is 3:1.Series or parallel connection may be used for blasting.
For blasting the blaster uses the master key of the exploder to trigger the detonator and takes
two zig-zag turns (Z shape) before blasting.
CYCLE OF OPERATION:
The time taken to drill per hole on an average is around 6-7 minutes.Therefore total drilling time
is around 3 and half hours. Charging time is around 30 to 45 minutes.The total cycle of operation
takes four and half hours.

POWDER FACTOR:
The dimension of gallery is around 2.2m x 2.4m and the rate of advance is 1.4m.The specific
gravity of ore is 2.88. Therefore total tonnage of ore produced would be (2.2x2.4x1.4x2.88)
which is equal to 21 .3 tonnes. Total no. of catridges per hole required is 4 each weighing
125gm and total no. of holes is 36. Therefore total amount of explosive consumed is around (4 x
125 x 34)g which is equal to 17kg.
Therefore powder factor = 21.3/17= 1.25 tons per kg.
 VENTILATION
VENTILATION:
Ventilation is the most important part in the planning, development and extraction ore in the
mine, as it is the only source of fresh air in the mine for respiration and to keep the temperature
of the stope adequate. The mine having three intake (shaft #3, Shaft #4 and Adit 5) and two
exhaust/outlet (North fan and South fan) it has sufficient ventilation while both the fans working
properly. Total intake air to mines is 160m3/sec. But it is necessary the regular inspection of
intake and return air way, ventilation door, fans fixing of brattice, auxiliary fan and sealing of old
workings, etc to maintain the required quantity of air in the stope.

DETAILS:
2
AREA (m ) VELOCITY QUANTITY FAN H.P
3
(m/min.) CAPACITY(m /min.)
3
(m /min.)

NORTH FAN 17.5 306 3967 4500 160

SOUTH FAN 19.5 283 4902 6000 160

AIM:

•Blasting fumes should be cleared from stope and drive within 30 minutes of blasting.

•Every stope should have intake air of at least 15m3/sec.

INSTRUMENTS:

We have sophisticated instrument to measure the mine gases, air quality and
quantity during ventilation survey.

Multi gas detector

 Digital anemometer

Digital hygrometer.
VENTILATION INTAKE:

1.NO. 2 SHAFT ------ 457.20 m3/min

2.NO.3 SHAFT-------- 33153.36m3/min

3.NO.4 SHAFT-------- 3034020m3/min

4.NO.5 ADIT----------- 1497.60m3/min

RETURN:
SOUTH FAN--------5820.60m3/min. 75mm W.G
NORTH FAN--------3747.60 m3/min. 55mm W.G

SAFETY AND SUPPORT SYSTEM

SAFETY:
Safety is the most important part in mining. In the mine (a).Safe working procedure and
(b)Safety equipments, are main concern of the above mentioned as motto is Safety First. Hence
for safety of men and machinery it is strictly followed and practiced the MMR(metalliferous
mine regulation1952) and the DGMS(Director General of Mine Safety) regulations.

SAFE WORKING PROCEDURE

*MINING PROCEDURE:
1. Drilling Procedure
2. LHD and Loco operation
3. Re-entry after blasting
4. install and Grout capsulated bolt in U/G.

*MAINTENANCE PROCEDURE:
1. Tyre changing
2. cage inspection
3. Heavy material lifting.

SAFETY EQUIPMENTS
1. Personal Safety Equipments
2. Safety signals for winding & hoisting
3. Safety Signalling System for Tub tipping at surface and Dumper Loading.

Besides above Mentioned , A Planned Task Observation and Emergency Response

System is there in the mine.

PLANNED TASK OBSERVATION:

1.Production Drilling
2.Loose Dressing
3.LHD operation
4.LOCO operation
5.Mechanical schedule maintenance
6.Rock Bolt Drilling and Grouting
7.Geological Sampling etc.

EMERGENCY RESPONSE SYSTEM:

1.First Aid
2.Emergency Telephone No.
3.Fire Fighting Arrangements
4.Mine Rescue.
Safety Signals:
1. At derailment
2. Block stopper.
And it is mendatery for every minerto be equiped with safety helmet, gumboots , eye
glasses, dust mask, ear-plugs, gloves are provided, Cap Lamp
provided by the Mine Authority.

SUPPORT SYSTEM:
For support system an SSR (systemetic support rule) is guideline which is employed
in the mine.

SSR is an approved support plan to secure the roof or back, hanging wall,footwall,
and sides. As per the guidelines of SSR

SSR for Drive and Cross Cuts:

•To be supported by rows of rock bolt.
•Length of bolt 1.5 metre long.
•Maximum spacing of 1.5 metres.
•Maximum distance of support from the face is 3.0 metres.
(Recommended for 1m)

SSR for Raises and Winzes

•To be supported by rows of rock bolt.
•Length of bolt 1.5 metre long.
•Maximum spacing of 1.2 metres.
•Maximum distance of support from the face is 3.5 metres.
(Recommended for 1m)

SSR for Room & Pillar Stope

•To be supported by rows of rock bolt.
•Length of bolt 1.5 metre long.
23
•Maximum spacing of 1.2 metres.
•Staggered pattern.
Maximum distance of support from the face is 2.5 metres.
(Recommended for 1m)

SPECIFICATIONS:

•Roof Bolt
–Material : Tor-steel
–Diameter : 20-22mm (25 mm at Surda)
Length – 1.5 m

•Bearing Plate
–MS
–150mm sq size (permission for Surda -100mm)
–6mm thick

Testing of Roof Bolt

•10% of rock bolts to be tested.
•About 90% of above to be tested at designed capacity remaining 10% to be tested
for destructive testing.
(In this mine prop or timber support is rarely used.)

LAMP ROOM:
There is a lamp room for charging, alloting, distributing and for maintenance of Cap
Lamps. The cap lamps are regularly inspected, repaired and maintained as they are the
only companion to provide light in the mine.
 TRANSPORTATION
In Surda Mine, by the mean of transportation, the ore from the face to the surface is hoisted
systematically. After blasting, dressing and roof bolting the ore is loaded by LHD/Cavo
Loader and dumped into the Ore Pass, in the bottom of the ore pass it has a special type of
opening Ore Chute in the level, through which it is loaded on Loco (a 80V battery operated
locomotive engine and attached to 8-10 tubs) and transported to OT (ore transfer), called
tramming and dumped which is collected at Ore Bin which is loaded on the Tub/Skip and
hoisted to the surface. Finally transported to the concentration plant on dumpers or trucks.

PUMPING ARRANGEMENTS
The pumping arrangement of the mine is divided into two parts.viz 3# shaft and 4# shaft
pumping arrangement.
In 3# shaft pumping system there are two sumps at level 10th and 5th .Water is collected at sump
of 10th level from where it is pumped to sump of 5th level.From 5th level water is finally pumped
to the surface.
In 4# shaft pumping system there are two sumps at level 8th and 5th .Water is collected at sump of
8th level from where it is pumped to sump of 5th level.From 5th level water is finally pumped to
the surface.

The ph value of water is 1.3 and hence is acidic in nature.Therefore high density polythene
pipe is used.

DEWATERING:
Dewatering is done by hydraulic, pneumatic and electrical centrifugal pumps. All the
waters from stopes, seepage and tailings are firstly collected at sump and finally
dewatered to the surface and again recycled for diluting the tailings.

PUMP FOR DEWATERING. TAILING PIPE

CONCENTRATION AND BACKFILLING
CONCENTRATION:
The extracted ore from the mine is transported to Mosaboni concentration plant by dumpers and
truck directly, by the the roadway which is nearly 7Km. Away. The ore is firstly finely crushed
and is concentrated. The concentration, known as MIC (METAL IN CONCENTRATE) is
supplied to HCL/ICC copper plant which contains 20-25% copper. The tailings after
concentration are used for back-filling.

BACK-FILLING:
Backfilling is done by 4inchΦ tailing pipes capacity @ 1060 tons/day at Surda Project. Ore
passes have been refurbished, with rings being redesigned for better performance. The focus has
primarily been on preparation work in conjunction with improvements in water handling. A total
of five bunkers are available currently.

1.Shaft #4 Bunker (200tpd)

2.NS Bunker (250tpd)

3.Central Bunker (600tpd)

4.Magazine Bunker (250tpd), &

5.NV Bunker

These pumps will efficiently transfer high density slimes or classified tailings from the
processing plant to underground mining stopes. Present backfilling capacity is 41000t per
month taking all constraints (water, pipe-jam). Crushed mill tailings from conentration
plant are used as backfilling material.

It is believed and practiced that through better back-filling the company can achieve
potential benefits in terms of reduced subsidence, improved support for mining
excavations, increased underground extraction, reduced tailings on the surface and
reduced rock burst leading to enhance worker safety.

TAILING RATE : 40 cubic metre / hr.

MAIN TAILING TANK CAPACITY : 200 cubic metre
MIXING TANK CAPACITY : 40 cubic metre
TAILING PIPE DIAMETER IN MINES: 4inch
MIXING RATIO(WATER TO TAILING): 3: 2
 ELECTRICAL INSTALLATION
At Surda mines electricity is supplied by JSEB(Jharkhand state electricity board). JSEB supplies
132KV to Mosaboni substation, where it is stepped down by step down transformer to 33KV
where its supplied to Banalopa IRL substation, where it is further stepped down to 11KV and
supplied to DG Set Surda mine. At Surda Mine there are two substations at #3 shaft; one on the
surface steps down 11KV to 3.3KV and 440V, another on level 5 which is supplied 3.3KV and it
steps down to 440V. The winder of shaft #3 is operated at 440V, S.I. shaft at 3.3KV and #4shaft
is operated at 6.6KV.

At D.G sub-station
Power is received at 33kV from J.S.E.B. Components used are :

 10 MVA transformer 33/11 kV

 Captive power plant

 3.5 MVA diesel generator Engine-5000 h.p. ,1000 r.p.m

 For starting engine battery of 220 V is used.

Sub-station 3#shaft
Power is received at 11kV from D.G sub-station.

 1 transformer of 1750 kVA 11/3.3 kV

 2 transformer of 690 kVA 11kV/440V

 1 transformer at north fan of 250 kVA 11kV/440V

 Current is supplied to compressors & at 10th level at 3.3Kv from here. At 10th
level(3 # shaft)
 1 transformer of 315 kVA 3.3kV/440 V

Power is supplied to surface winder at 440 V.

At 4th level 3# shaft 2 transformers(1-315 kVA ,other of 250 kVA) are used.
Power is supplied to sub-incline winder at 3.3 kV.

Sub –station 4 # shaft

Power is received at 11 kV from D.G. sub-station.
4 transformer is used.
1.750 kVA -2 transformer 11/6.6 kV used for winder at 4 # shaft.
2.1000 kVA -1 transformer 11kV/3.3 kV
3.400 kVA -1 transformer 11 kV/440 V

At 7th level 2 transformers (1 transformer of 500 kVA&other of 315 kVA) are used.
1 transformer of 750 kVA is used for fan@ 4# shaft.

Safety devices used are:-

1.Earth leakage relay
2.Overload relay
 MINING MACHINERIES
MACHINERIES USED IN MINE WINDER:
#3. SHAFT
MANUFACTURED BY (M.B.WILD B.CO, ENGLAND)
DEAPTH OF WIND 169M 440V 100 HP
Dia. of DRUM 2.57M
Dia. of SHEAVE WHEEL.2.57M
Dia. of ROPE -26MM
ROPE TYPE -FLATTENED STRANDED
LANGSLAY DOUBLE CLUTCH DOUBLE
DRUM
FACTOR OF SAFETY WITH MAN 14.1
FACTOR OF SAFETY WITH ORE 10.34
INCLINATION 90°
DATE OF INSTALLATION 1966

#SUB-INCLINE SHAFT
3.3KV 175HP
Dia. of DRUM 2.29M
Dia. of SHEAVE WHEEL 2.28M
Dia. of ROPE 22MM
LENGTH OF ROPE 900 M(UNGALVANISED ROPE)
DOUBLE CLUTCH DOUBLE DRUM

#4. SHAFT
MANUFACTURERD BY(KOPEX POLAND)
DATE OF INSTALLATION 1974 6.6KV 400KW
Dia. of DRUM 3.00M
Dia. of SHEAVE WHEEL 3.00M
Dia. of ROPE 30MM
SINGLE CLUTCH DOUBLE DRUM
FACTOR OF SAFTEY FOR MAN -14.1
FACTOR OF SAFETY FOR ORE-11.3

SHAFT
#3. SHAFT
Two Cages
RECTANGULAR and VERTICAL S.I. SHAFT
TWO SKIPS INCLINED 31-35°
#4. SHAFT
TWO SKIPS INCLINED 40°
LHD (LOAD HAUL DUMP)
OVERHAULED LHD : 5 Nos
NEW LHD : 3Nos
JC 100E (OLD) : 1 MT BUCKET CAPACITY = 4 Nos.
JC 220E (OLD): 2 MT BUCKET CAPACITY = 1 No.
EIMCO 811(V) NEW : 1.5 MT BUCKET CAPACITY = 2 Nos.
SANDVIK LH202E (NEW) : 3 MT BUCKET CAPACITY = 1 No.

CAVO
MODEL NO. 310
BUCKET CAPACITY: 1.75M3
RUN ON PNEUMATIC POWER
MOTER USED: AIR MOTOR
AIR PRESSUR 6Kg/cm2
TOTAL 6 CAVO ARE IN OPERATION

ROCKER SHOVEL
COMPANY: EIMCO ELECON
MODEL: 21B & 12B
RUN ON PNEUMATIC POWER

LOCO
(TRAMMING)
80V BATTERY IS USED WHICH GENERATE 32A.
TWO D.C MOTORS ARE FITED IN LOCO
MODEL: GEM LOCO, HYDERABAD LOCO, SOUTH AFRICAN LOCO.,G.B LOCO.
OVERHAULED OLD LOCO : 4 TON CAPACITY = 6 Nos.
OVIS LOCO (NEW) : 4 TON CAPACITY = 8 Nos.

COMPRESSOR ( Electrical Power)

1000 CFM - 3 Nos
3000 CFM -1 No.
3500 CFM- 2Nos.
OPERATION VOLTAGE 3.3KV
Speed- 593rpm
CAPACITY (Each)
WORKING PRESSURE 7Kg/cm2
COOLING WATER PUMP 20HP, 1450rpm.

PUMP
1. COMPANY KIRLOSKAR
POWER-100HP OPERATE
AT 440V, 100A R.P.M:
2950
 MULTI STAGE TURBINE PUMP
SUCTION PIPE DIA. - 4”
DISCHARGE PIPE DIA. - 3”
DISCHARGE – 50 m3/hr
No. OF IMPELLERS- 6
HEAD 200m
MOTOR TYPE: 3 PHASE SQUIRREL CAGE INDUCTION MOTOR
MAKE ABB ,125HP, 2965R.P.M, 50Hz
2. COMPANY: KIRLOSKAR
POWER: 180HP
R.P.M: 2965
50 Hz, 440V SITUATED AT 4#-8L
3. COMPANY: KIRLOSKAR
POWER: 75H.P
R.P.M: 2965
50 Hz, 440V

VENTILATION FAN
2Nos.(Axial flow,Exhaust type)
North Fan
South Fan
NORTH FAN:
Make-Eswaran&Sons Engineers Ltd.,Madras.
Exhaust type,Axial flow
Rating-160 h,p @ 750 r.p.m.
Operates at 440 V,50 Hz.
Motor type – Synchronous Induction motor.,3 phase
Motor manufactured by-English Electric Company Ltd.,London.
Water gauge developed – 55 m.m
Voltage between slipring at start -871 V
Excitation – 23 V, 176 A
Insulation class – A
Star connection

ROCK BREAKER
ELECTRO HYDRAULIC - 3 Nos.
MANUFACTURER: TELEDYNE (CANADA)
ACCUMULATOR: NITROGEN
MODEL: 1. TM-16 ROTATION 100°
2. TM-16 ROTATION 180° LOCATED AT 3# (10L),4# (7L & 9L)

HEADGEAR DRILLING MACHINE (JACKHAMMER)

TYPE: SILVER-3(HOLEMAN CLIMAX )
NO. OF JACKHAMMER: 3#-48, 4#-29

DUMPER (TATA HYVA)

FOR TRANSPORTATION ON SURFACE.
 ANALYSIS AND CONCLUSION

1. In this mine selective mining is practiced to yield better grade of ore and higher MIC.

2. Geologists provide a great view of the ore grade and plays an important role for the
maintenance of grade of ore, as the differenciate and mark waste and lode (ore)in face.

3. As the grade of the ore varies on different stopes, different faces so maintenance of average
grade is emphasized.

4. And most important observation is the working culture and professional ethic which is
always an upper hand for the mine.