MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

HINDUSTAN COPPER LIMITED

MALANJKHAND

VACATIONAL TRAINING IN MINERAL PROCESSING FIELD

Training Incharge-: By:-

Mr.Sree Kumar RAHUL SINGH (2012JE1320)
AGM (Mines) DEEPAK KUMAR (2012JE1347)
GOVIND KUMAR (2012JE1346)
ANIKET SINGH (2011JE1073)
LOKESH KU. MEENA (2010JE0008)
ASHISH TUNDELKAR (2011JE0551)
SHASHANT KUMAR (2011JE1099)

FUEL AND MINERAL ENGINEERING DEPARTMENT

INDIAN SCHOOL OF MINES
DHANBAD
MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

ACKNOWLEDGEMENT

I wish to acknowledge the Hindustan copper limited for giving the

opportunity to conduct this Vacational training.
I am grateful to the support of Hindustan copper limited for the
training.
I wish to acknowledge the support of Mr.Sree Kumar (AGM,Mines)
for this training.
I wish to acknowledge the support of Mr.P.K Singh
I wish to acknowledge S.S.Patil (DGM,Conc.) for his special support
to complete this training.
I wish to acknowledge the support of S.R.Gaur (AGM, Conc.)to
complete this training.
I wish to acknowledge the support of Sh.Ajay Giri (CM, Conc.) and
Sh.Kumarswamy (CM, Conc.)
I wish to acknowledge the support of Kunal ku. Rajak , Sumit
Sinha, Ranvijay Singh, Vishal ku.Mishra
I wish to give special thanks to Shubharaj ( Junior Manager )
I acknowledge the wonderful support of individuals numerous to
mention by name-they allowed us uninhibited access to their
database for the success of the this training.

INDIAN SCHOOL OF MINES, DHANBAD

MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

SUMMARY

This Vacational training report mainly deals with the -

experience gain during the training period in malanjkahand
copper project. Hindustan copper limited has location operating
units –one in Rajasthan(Khetri copper complex),one in Madhya
Pradesh (Malanjkhand copper project ) ,one in Jharkhand
(Indian copper complex).Malanjkhand copper project has
capacity of 2 million ton per annum with a grade % of 0.9 – 1.
This report deals with the production of plant ,equipment used
to extract ore ,its type ,grade of ore, primary crusher and its
reduction ratio ,secondary and tertiary crusher and their
reduction ratio .Main process unit consist of milling of ore
,flotation ,cleaner ,recleaner ,thickner ,filter .In Hindustan
copper project only mining and benefication has been done ,the
final product is transported to ,INDIAN COPPER COMPLEX
,Ghatsla (Jharkhand) for smelting ,refining precious metal
recovery.

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

CONTENTS

1.0 CHAPTER ONE

1.1 About Hindustan copper limited.
1.2 About Malanjkhand copper project.
1.3 Process description.

2.0 CHAPTER TWO- PRIMARY UNIT

2.1 Primary Crusher
2.2 Capacity ,Reduction ratio
2.3 Conveyor System
2.4 Motor and Gearbox specification
2.5Apron Feeder
2.6 Lubrication System
2.7 Safety devices and Gamma ray indicator

3.0 CHAPTER THREE –SECONARY UNIT

3.1 Secondary crusher
3.2 Tertiary crusher
3.3 Capacity ,Reduction ratio
3.4 Conveyor system.
3.5 Screen and surge bins
3.6 Lubrication system
3.7 Overall view of secondary unit.

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

4 CHAPTER FOUR- MAIN PROCESS UNIT

4.1 Fine ore bin ,Capacity ,Reduction ratio
4.2 Ball mill and its specification
4.3 Addition of reagent
4.4 Flotation cells
4.5 Cleaner and recleaner
4.6 Thickner and filter

5.0 CONCLUSION
6.0 REFERENCE

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 MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

1.0 CHAPTER ONE -

1.1 ABOUT HINDUSTAN COPPER LIMITED
Hindustan copper limited (HCL) enterprise under the administrative
control of the Ministry of Mines, was incorporated on 9th November
1967 under the Companies Act ,1956. It was established as a Govt. of
India enterprises to take over all plant, projects, schemes and
studies pertaining to the exploration and exploitation of copper
deposits ,including smelting and refining from National Mineral
Development Corporation Ltd. It is the only company in India
engaged in mining of copper ore and owns all the operating mining
lease of copper ore and also the only integrated producer of refined
copper (vertically integrated company ). Major activites of HCL
includes mining, ore beneficiation, smelting, refining and casting of
refined copper metal into downstream products. HCL is a listed
company on BSE and NSE, with 94.01% equity owned by Govn. of
India .HCL has multi-location operating units
Following are locations-:
PLANT LOCATION FACILITIES
Khetri Copper Complex Khetrinagar, Mining ,Ore beneficiation
Rajasthan ,Smelting(not in use),
Refining (not in use)
Indian Copper Complex Ghatsila, Mining ,Ore beneficiation
Jharkhand ,Smelting ,Refining, Precious
metal recovery
Malanjkhand Copper Malanjkhand, Mining ,Ore beneficiation
Project Madhya
Pradesh
Taloja Copper Project Taloja, Continuous cast Copper rod
Maharashtra plant

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

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

1 )Mines

Mines Location Ore capacity

(lakh tonnes per
annum)
Khetri Copper Rajasthan 14.00
Complex
Malanjkhand Copper Madhya Pradesh 20.00
Project
Indian Copper ,Jharkhand 4.00
Complex

Total- 38.00 lakh tonnes per annum

2)Smelter
Plant Location Metal capacity
(tonnes per annum)
Khetri Copper Rajasthan 31,000
Complex
Indian Copper Jharkand 20,500
Complex

Total - 51,500 tonnes per annum

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

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

On Going Project-:

No Mine Location Capacity

Current After
Expansion
1 Malanjkhand Mines- Malanjkhand 2.0 5.2
Development of ,M.P
Underground mine (Undergro
under existing open und)
cast
2 Khetri Mines Khetri, 0.5 1.0
Expansion of existing Rajasthan
Underground mine

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

3 Kolihan Mine- Khetri, 0.5 1.5

Expansion of existing Rajasthan
underground mine
4 Surda Mine – Ghatsila, 0.4 0.9
Expansion of existing Jharkand
Underground Mine
5 Rakha Mines –Re- Ghatsila, Nil 1.5
opening of closed Jharkand
Underground Mine
6 Kendadh Mine- Re- Ghatsila, Nil 0.21
opening of Jharkand
Underground Mine
7 Banwas Mine – Khetri, Nil 0.6
Development of new Rajasthan
underground mine
8 Chapri-Sideshwar- Ghatsila, Nil 1.5
Development of new Jharkand
underground mine
Total 3.4 12.41

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

1.2 MALANJKHAND COPPER PROJECT

 Malanjkhand Copper Project was established in 1982.
 The Ore of Malanjkhand open pit mines have -
1)90% Chalcopyrites
2) 10% (Oxides and Sulphide ores)
 The life of Open pit mine is 32 years .
 It has 250(Approx) million tones copper ore deposits.
 52 (Approx.) million tones of the ore has been extracted till
now.
 198(Approx.) million ton is still remaining .
 Overall plant capacity is 2.0 million tonnes per annum.

Sulphide ore are of three types depending on the percentage of

Copper present in it , they are

 0.95%-above—high grade ore ,

 0.45-0.9%-- low grade ore
 0.2-0.44%--lean grade ore

1.3 PROCESS DESCRIPTION

 Run of mine ore of size (-) 1200 mm is crushed in three stage to (-)
12 mm. The crushing complex consists of one primary gyratory
crusher (1350x1900 mm), one secondary cone crusher (2200 mm)
7’ standard head, three tertiary cone crusher (2200 mm) short head
and four Nos. vibrating screen and associated conveyor network,
apron feeders and belt feeders.
 1.2 Primary crushed ore passes through a double deck vibrating
screen (8ft. x 20 ft.) before its entry to secondary crusher. For
tertiary crushing three nos. vibrating screens (8ft. x 20 ft.) are used
in closed circuit along with three tertiary crushers.
 1.3 The under size from screen which is the feed for grinding mills
is transported by conveyors and stored in the parabolic fine ore bin

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

of capacity 10,000 MT. Ore is withdrawn from this bin with the
help of belt feeders and fed to the ball mills.

 Single stage wet grinding is done with the help of four nos. ball
mills each of size 3810x5791 mm, operating in close circuit with
660 mm hydro cyclones. Mills are over flow type and lined with
replaceable rubber liners. CI grinding media of 80 mm dia is
charged inside the mills for grinding of ore.

 1.5 Hydro cyclone over flow (35-40% -200 mesh) is subjected to

four stage flotation in rougher, scavenger, cleaner and recleaner
(all 300 cft. Cells). The recleaner concentrate (final concentrate)is
pumped to 25 meter dia thickener and the scavenger tails (final
tail) gravitates into tailing pulp tank.

 1.6 Thickened concentrate from the thickener is pumped to two

nos. of disc filters 2.7 meter dia. The dewatered filter cake from
disc filter having 10 to 12% moisture is conveyed into the
concentrate storage yard. Water from the thickener over flow is
recycled back in the process circuit.

 Final tails is pumped through rubber lined pipes to tailing disposal

area about 2.4 Kms away from the plant.Hydro cyclones are used
for embankment build up along the periphery of the tailing dam.
Tailing dam 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 recycled back to the plant for use in process

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

M.C.P CONCENTRATE PLANT (6000 TPD )

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

2.0 CHAPTER TWO-PRIMARY UNIT

2.1 PRIMARY CRUSHER
Primary Gyratory crusher are designed for first stage crushing of
ferrous and non-ferrous ores. They are generally installed in the first
stage of technological crushing scheme.

 Gyratory type crusher.

 Model No-: PGC 1350 (HEC- Heavy Engg. Corporation ,Ranchi)
 Width of feed opening -:1350 mm
 Width of discharge opening-:165mm
 Capacity- :870 MTPH at 150mm setting
 Oscillation of Crusher head -: 2-4 rpm on no load
 Motor drive-360kw
 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 crushers crushing chamber; there should be no
material in it.
 Check the grease 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 1.0kg/cm2 and not more than
2.0kg/cm2 .
 Wait for 5-10 min, so that oil circulation stabilishes.
 Check the drain pipe oil temp. ,it should be below 600 C.
 Check the drain pipe oil temp. from counter shaft , it should be
below 600 C.

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

 Check the oil pressure before and after the filter; the difference
should not be more than 0.3kg/cm2 .
 If the oil temp. is more than 60-650 C pass the oil through the
heat exchanger and observe that , water inlet pressure is less by
0.3kg/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

Fig 1. OPEN SECTION OF GYRATORY CRUSHER SHOWING

CRUSHER HEAD

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

2.2 CAPACITY, REDUCTION RATIO

 Capacity-870 TPH
 Feed size-1200mm (max.)
 Product size-140mm (max.)
 Reduction Ratio = 8.52(approx..)

FLOW CHART
PRIMARY CRUSHER (870 TPH)
-1200mm GYRATORY CRUSHER
-140 mm

FLOW DIAGRAM SHOWING EACH LEVEL OF PRIMARY UNIT

GYRATORY CRUSHER TOP LEVEL

FEEDING LEVEL

4TH FLOOR
INTERMEDIATE LEVEL
(CRUSHING ZONE)

DICHARGE LEVEL 3RD FLOOR

2ND FLOOR
HOPPER ( GAMMA RAY INDIACTOR )
LUBRICATION SYSTEM

APROON FEEDER 1ST FLOOR

GROUND LEVEL
CONVEYOR SYSTEM
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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

2.3 CONVEYOR SYSTEM

Used for transportation of feed (secondary ) from apron feeder
discharge to coarse ore store(COS) for convience to carry it to
secondary unit.

Following are the important section of conveyor system -:

 Idlers
 Belt
 Pulley Arrangement
 Pull cord

2.3.1>IDLERS


Pictorial view of carrying Idlers

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

 Used to support the belt.

 To protect the belt.
 Used in carrying the belt.
.1 TYPES OF IDLERS

a) Carrying Idlers – Carry the belt

b) Return Idlers – Help in returning the belt
c) Impact Idlers- Protect belt from wear and tear
d) Adjustment Idlers
e) Self Alignment Idlers
f) Side Idlers.

.2 IDLER SPECIAFICATION
 Number of Carrying Idlers-(199-10%)*3=540
 Number of Return Idlers-(199/2)=100
 Gab b/w two carrying idlers = 1000mm
 Gab b/w two Return idlers =2000mm

2.3.2>BELT
 Length of belt -398m
 Commonly named as primary belt
 Width of belt -1400mm
 Nylon is used to give strength and flexibility
 Thickness of belt is 24mm
 Notation –M24

RUBBER PLY

NYLON PLY

RUBBER PLY

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 MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

SYSTEMATIC VIEW SHOWING DIFFERENT SECTION OF BELT

2.3.3>PULLEY ARRANGEMENT
Total no. of pulley in primary conveyor-12

(2 )HEAD PULLLEY

7
HEAD BEND PULLEY (9)

HEAD SCUP PULLEY (3)

TAIL PULLEY (1)

5 8
TAIL BEND
PULLEY (11)

6
TAIL SCUP
PULLEY (12)
8

TAKE UP PULLEY
SYSTEMATIC PULLEY ARRANGEMENT OF (10)

PRIMARY CONVEYOR

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

2.3.4> PULL CORD

Used to stop conveyor belt in Emergency Condition such
as over loading,breakdown of belt etc.

2.4 MOTOR AND GEAR BOX

 MOTOR
There are basically two motor attached to pulley No. 6
and 8
M1- PULLEY 6 M2-PULLEY 8

150 hp 150 hp
1485 rpm 1485rpm
188A 186A
V-415V V-415V
Frequency- 50 Hz Frequency- 50 Hz

Mgf. By- SIEMENS (GERMANY)

 GEAR BOX
ELECON Mgf.
SERIAL NO-WHG33992LH
TYPE-SCN-355
SPEEED RATIO- 45:1

ELECON ENGINEERING CO. LTD

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 FLUID COUPLING
 Used to reduce Energy
 To safe motor during the condition of high load
 Act as best energy saver

MOTOR GEAR BOX G1

FLUID PULLEY 6
M1 COUPLING C1

FLUID GEAR BOX G2

MOTOR
COUPLING C2 PULLEY 8
M2

2.5 APROON FEEDER

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

SPECIFICATION-:

APROON FEEDER AT PGC APROON FEEDER AT COS

Size-:1219*9000mm 1219*9000mm
Capacity-:200-1000 MTPH 200-530 MTPH
Motor-:37 kw 22.5 kw

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 MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

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 35-550 C, After
making sure about the above points, see that the conveyor to
which the apron feeder is feeding is running .
 Now, start the apron chain drive ,and feed.

SYSTEMATIC VIEW OF APRON FEEDER ARRANGEMENTS

TRACK ROLLER
MOTION

TRACK CHAIN

TAILING PRODUCT
TRETURN ROLLER

RECEIEVING CHUTE

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

2.6 LUBRICATION SYSTEM

 For Eccentric Motion , shaft counter ,Bend gear .
 Servo-system 526 of IDC
 125 lt/min ( circulation volume)
 For crusher head suspension and mantle
 Servo Gem-2 of IOC (grease)
 Once in 16 hrs

NAME OF THE NO. NO. TYPE RECOMME VOLU INTER

UNIT OF OF OF NDED ME OF VAL OF
UNI POIN SYSTEM GRADE OF LUBRI LUBRI
T T PER LUBRICAN CANT CANT
UNIT T
ECCENTRIC 1 1 Circulati Servo- 125 Contin
ng System l/min. ous
526 0F IDC
BEND GEAR 1 1 Circulati Servo- 125 Contin
TRANSMISS ng System l/min ous
526 0F IDC
COUNTER Circulati Servo- 125 Contin
SHAFT ng System l/min ous
BUSHING 526 0F IDC
TOP 1 1 Centrali ServoGem- 1000 Once in
SUSPENSION sed 2 of IOC cc 16 hrs
OF CRUSHING Grease
HEAD AND
MANTLE
DUST SEAL 1 1 Centrali ServoGem- Once in
RING sed 2 of IOC 16 hrs
Grease
ANTIFRICTIO 1 4 Centrali ServoGem- 2.5cc Once in
N BRG. OF sed 2 of IOC 08 hrs
DRIVE Grease

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

2.7 SAFETY DEVICE AND GAMMA RAY INDICATOR

2.7.1 SAFETY DEVICE

 For crusher safety
 Electromagnet
 Metal detector

ELECTROMAGNET

It is used to attract the metallic material

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

METAL DETECTOR It is used to detect those material / metal

which donot show metallic property to avoid choking, damaging
the inner shell of secondary crusher .

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 MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

 For Emergency safety issue

 Pull cord

2.7.2 GAMMMA RAY INDICATOR

When the product from discharge level from crusher increased
in hopper and 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 startas

 Used to avoid choking of hopper .

 Used to avoid breakage of oil pump.
 Safe crusher from wear and tear.

FEED

GAMMA RAY RECIEVER

INICATOR

SYSTEMATIC VIEW OF HOPPER SHOWING GAMMA RAY

INDICATOR

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3.0 CHAPTER 3- SECONDARY UNIT

3.1 SECONDARY CRUSHER

Secondary cone crusher are 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- 350mm
 Recommended max. Feed size- 300mm
 Closed side setting- 30 to 60 mm
 Capacity at minimum recommended setting- 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

-140mm SECONDARY CONE -40mm

CRUSHER(Standard
Belt 1 head)

Secondary crusher

Secondary crusher
BELT 5

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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 should be u8nder 0.3Kg/cm2. If it is more than
that, rotate the filter. If there is no improvement then the filter
has to be cleaned.
 Check the temp. of oil inside the tank. It should be below 50 0C.
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.
 Temp. of oil leaving the crusher should be below 60 0C.
 Check the coupling pad & bolts.
 Start crusher motor.
 Check the crushing head RPM it should be 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 to
45 Lit/Min.
 Start feeding.

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3.2 TERTIAY CRUSHER

Tertiary cone crusher are designed for third stage crushing of
ferrous and 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: 262.5KW/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.

TERTIARY CONE
-40mm -12mm
CRUSHER

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 makings.
 Start the oil pump.
 Check the differential pressure gauge. It should show less than 25
PSI. Higher differential pressure indicate clogging of filter.

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 Check the oil temp. Entering cooler. It should be above 60 0F.

 Check the oil temp. Leaving cooler. It must be less than 115 0F.
 Open the inspection cover of the settling tank & check the oil
drain line from the crusher. Inside the tank to ensure that the 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 of 5-15 PSI.
 Oil temp leaving the crusher should be less than 120 0F.
 Stop the crusher if the temp of oil leaving the crusher reaches 130
0F.

 Temp difference in between the oil entering the crusher & leaving
the crusher should in between 1 &3 0F. if the temp difference is
more than 5 0F 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 if there is any abnormal sound or vibrations.
 Open the Hydraulic seal water & wait till the clear water comes
out from the out-let.
 Start feeding.

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

3.3 CAPACITY, REDUCTION RATIO

 Capacity
 Secondary crusher-584TPH
 Tertiary crusher-360 TPH
 Reduction Ratio
 Secondary crusher-3.5
 Tertiary crusher-3.33
3.4 CONVEYOR SYSTEM
Used for transportation of feed (secondary ) from apron feeder at
coarse ore store(COS) for convience to carry to secondary unit

3.4.1 BELT AND THEIR NOTATION

BELT LENTH (m) WIDTH(m) THICKNESS(m)

NO.
1 380 1200 24
2 265 1400 24
3 32 1400 24
4 280 1400 24
5 270 1200 24
6 140 1200 24

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 BELT 1
Used to carry feed from COS to secondary crusher

SECONDARY
CRUSHER

 BELT 2
Used to carry Crushed product from secondary
and tertiary crusher to conveyor belt 3

BELT 3

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 BELT 3
Used in transferring belt 2 product to belt 4

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

S1 S2 S3

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

 BELT 5
Carry the -12mm product from screening to FOB
(fine ore bin)

3.5 SCREEN AND SURGE BIN

3.5.1 SCREEN
 Double Deck Screen- 8ft X 20ft
 Panel size(mm):-
 Upper Deck: 40 x 40 – 10 nos.
 Lower Deck: - 12 x 20 – 6 nos.
 Single Deck Screen- 8ft X 20ft
 Panel size(mm):- 12 x 20 – 6 nos. 15 x 20 – 4 nos.

3.5.2 SURGE BIN

 There are three surge bin named as S1, S2, S3.

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

3.6 LUBRICATION SYSTEM

 Servo system SP17
 Heat Exchanger
 T1-Serial no-11070, 2.4 kg/cm2 (0-6)
 T2- pressure (1-2) kg/cm2 (0-4)
LUBRICATION CONSISTS OF 4 MOTOR SYSTEM
 M1 and M2 are working
 M3 –Stand by
 M4- Purifier

3.7 MOTOR SPECIAFICATION

EQUIPMENT NOTATIO KW/HP PHAS VOLT( TYPE RPM

TYPE N E V)
TERTIARY MT1 250 3 3300 TEEP 492
CRUSHER AK
TERTIARY MT2 375 3 3300 SYMO 993
CRUSHER NS
TERTIARY MT3 250 3 3300 HEC 492
CRUSHER
LUBRICANT ML1 5.5 - 415+- - 1440
PUMP 10%
PURIPIER MP1 5.5 - 415+- - 1430
PUMP 10%

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

4.0 CHAPTER FOUR-MAIN PROCESS UNIT

4.1 FOB(FINE ORE BIN ) CAPACITY ,REDUCTION

RATIO
 FOB acts like store in which feed materials (-12mm) of mill
are store from where it is fed into mill through different
conveyors arrangements.
 Capacity -10,000MT
 Reduction Ratio-

4.2 BALL MILL

Ball mill receive the crushed fine ore ( - 12mm ) and grind it wet to
the mesh-of-grind i.e. ,60% -200 mesh. Fine ore and water are fed at one
end and the milled product is discharged at the other end. Steel balls are
use as grinding media
 Ball Mill Size - 5791 x 3810 mm
 Drive Motor - 1200 KW
 Speed of the mill - 15.1 RPM
 Type of mill - overflow
 Feed rate - 1515 TPD / 60 TPH
 Pulp density in the mill - 75% solids by weight

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

Before the starting the ball mill check the following and make sure
that they are in satisfactory condition

 Check the oil level of the main bearings, Check the oil wipers, light
contact with the bearing.
 Check the temp. & grease of pinion & drive shaft pillow blocks. It
should not be very hot.
 Check the oil spray system to the girth gear. Be sure that it
operate properly and check that there is lubricant in the
container. Air pressure require for spray is 6 Kg/cm2.
 Open the water cooling valves and adjust it to satisfactory flow
rate (20 Gal. / Min.)
 Start the reducer box oil pump and make sure that oil is
circulating.
 Start the Hydraulic lift, at the trunnion bearings, observe the
pressure gauge. The pressure increases and then drops a little.
 Inform the ground-ore pump area operator and start the main-
drive of the mill.
 Observe that the mill starts smoothly.
 Check the oil distribution in the trunnion bearing.
 Start feeding the fine ore and water. Adjust these two to required
values.

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

PROCESS FLOW CIRCUIT OF GRINDING UNIT-

4.3 FLOATATION CELL

Flotation cells are used to separate out the copper sulphide particles
as a forth containing these minerals, leaving the pulp depleted of it.
There are several stages of flotation operation

SCHEMATIC REPRESENTATION OF FLOTATION CELL

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

 ROUGHER & SCAVENGER

The aim of this stage is to float all the copper sulphide particles and
leaving a trailing which contains as less copper as is possible
 Copper % in Rougher cell – 7 %
 Copper % in scavenger cell – 15%

DETAILS
 Cell Type & Size - 300 CFT double-overflow flotation cells.
 No. of cells - 4 rows of 12 cells each, the first 7 are
rougher
 & second 5 are scavenger
 Drive Motor - 30 HP, 1000 RPM
 V-belt used - C – 168 fenner.
 Forth paddle drive - ¾ H.P. 28 RPM
 Addition of Xanthate in Mill feed to increase conditioning time.
 Diversion of Concentrate of first Scavenger Cell as Rougher
Concentrate to avoid recirculation.
 Removal of old and inefficient recleaner cell (Fagergren cell) of
60 ft3 by efficient and bigger 300 ft 3 cell (Denver D-R cell).
 Diversion of highly floatable minerals (high kinetic minerals)
from the first rougher cell concentrate directly to the thickener.
This procedure is adhered when the head grade that is being
treated is more than 1.0%Cu.

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

4.4 ADDITION OF REAGENT

 LIME: - Is added in the mill feed in order to maintain the
desired pH (8.5-9.5)
 PINE OIL: - Is added in the flotation cells and it helps in
better froth formation
 SODIUM ISOPROPYL XANTHATE:-Is added in the flotation
cells and it acts as a collector for copper ore minerals.

4.5 CLEANER AND RECLEANER

This stage aims at producing a concentrate of definite copper content.

 Copper % in cleaner cell – 17 %

 Copper % in recliner cell – 20 %

DETAILS
 No. of cells - 4 rows contain 1 cleaning cell each, and 1
for Recliner
 Drive motor - 15 KW 1470 RPM
 V-belt used - B-120

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

 Froth paddle drive - 0.75KW 35 RPM

4.7 THICKNER AND FILTER

4.6.1 THICKNER
 MAKERS : THE EI CO-K.C.P LTD MADRAS
 SIZE OF THE UNIT : 83’0” SWD
 TYPE : ‘C’ with C 54 DRIVE, CLDT0 C 54 LIFT having
2shaft and long arms
 Direction of rotation: clockwise
 RPM 0.1
 Drive unit: moter 1 no, HP-3, RPM-1440
 Lifting device: 610mm lift,motor 1 no., HP-1.5
 Purpose of the thickener mechanism: 17500kgs.
 To thickener the dilute concentratc product before
sending to ceramic filter

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

4.0 CONCLUSION
Malanjkhand copper project is a growing
project which is to be expanded in few year . The copper grade is
still not good ,it is about 0 .95% which is very costly ,but recently
many changes has to done in MCP such as changing of filter
,earlier it was Disc filter but changed to ceramic vaccum fliter
(China filter).One other hand thickner is also going to be
changed to High rate thickner ,by doing such changes time
reduce .Their is work going on in planning of underground mine
in MCP hence the project will be expanded to large extent.
We are very thankful to Research and Development department
of MCP as they guided us pretty well.
Earlier we were having theoritical knowledge of crushers and
other equipments used in metal processing but now undergoing
training in prestigious company help us enhancing our concepts
theoretically as well as practically .To a student this plant is a
good place to gain expirence in industry .

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

5.0 REFERENCE
 Research and development department of MCP.
 Ajay Giri (CM,Conc.)
 Kunal ku. Rajak, Sumit Sinha, Ranvijay Singh .
 Shubharaj ( Ju.Manager)

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

Figure 3: Illustration of the flow chart used in the Web application to generate the global estimation error
(GEE).

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

12

5.0 FUNDAMENTAL SAMPLING ERROR MODEL

Fundamental sampling error depends on the number of critical particles in the
sample .For solides, powders and particulate materials, especially at low
concentration of critical particles the fundamental error can be very large

5.1 Application of Gy;s fundamental sampling error Eqn for designing

sample preparation procedures:
If the material to be sampled contain particle of different shape and size, it is
difficult to estimate the number of critical particles in the samples.
Gy’s formula for relative variance of the fundamental sampling error -

( Relative standard deviation of the fundamental sampling error

(FSE)

Where = absolute standard deviation (in concentration units)

; =average concentration of the lot;
d=characteristic particle size = 95% limit of the size distribution;
MS=sample size; ML=lot size; and
C is the sampling constant that depends on the properties of the material
sampled.
C is the product of four parameters:

where f is the shape factor (fig 4)

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

Shape factor-:Shape factor is the ratio of the volume of the sampled particles
having the characteristic dimension d to the volume of the cube having the
same dimension

13

Fig. 4. Estimation of particle shape factor and liberation factor for

unliberated and liberated critical particles. L is the particle size of the
critical particles.

g= size distribution factor

- g=0.25 ,wide –size distribution
-g=1, uniform particle size

c is the constitution factor and can be estimated by using Eq.

Here
aL= av. Concentration of lot
= concentration of the analyte in the critical particle

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

= critical particle density

= diluent particle density

14

6.0 ACCURACY OF GY’S FORMULA FOR THE FUNDAMENTAL

SAMPLING ERROR
-: Gy ‘s TOS consists of the prediction ,estimation or minimization of the
variance of the “fundamental sampling error” denoted by Var (FSE).
-: Var (FSE0 is regarded as the relative variance of the sampling error that is
obtained under through mixing of the population .
-: Var(FSE0 is Gy’s TOS is considered to be minimum possible variance for
incomplete or partial mixing .
-: When population is not thorpoughly mixed ,Gy;s TOS prescribes that an
additional relative variance components
Var (GSE)( variance in grouping and segregation error ) must be added
besides Var (FSE) to get the variance of the total sampling error (TSE)

Var (TSE)=Var(FSE)+ Var(GSE) + additional variance component .

Fundamental sampling error eq.

(FSE Eq.)
V= the sampling variance

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

f= bruntan shape factor

g= size factor
l=liberation factor
c=mineralogical composition factor
D=Nominal size
Msample =Mass of sample

15

6.1 Most common error in applying Gy’s formula in the theory

of mineral sampling and the history of the liberation factor.

a)Error in calculation of liberation factor-:

Taking an example of gold mines ,since the gold inthis case is
almost pulverized down to a nominal size of 40 microns to nominal
size of 1.5 cm
liberation factor (l)=( 0.004/1.5)0.5=0.052
this value is input for formula

Table 1.showng error in calculation .

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

Fig.5 Sampling nomograms 16

While investigating problem ,a author discovered exact source of
thses formula difficulties ,(FRANCOIS-BONGARCON ,1991-1998)

SFSE = Sampling relative variance

MS=Sampling Mass
ML=lot mass
f = 0.5 (approx.)
g= 0.25(approx.)
c=mineralogical factor
d=nominal size
l= liberation factor
when ML>>MS , formula becomes
SFSE2= fgcld3/MS
-:Gy’s proposed experimental model of variation of l with dl and d
l=(dl/d)0.5

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

-:Another model for the liberation factor

l=(dl/d)b ,b= additional parameter; gold (b=1.5)
6.2 CONSEQUENCE OF AN ERRONEOUS MODEL FOR l
EXAMPLE 1- CALCULTION OF A MINIMUN SAMLE MASS

SOLUTION- Given that dl=1.27cm, a grade of I ppm Au (10-6)

density =19.3 g/cm3, f=0.5 ,g=0.25
d=10 microns for gold,SFSE2=0.01 (10%)

SFSE2= fgcld3/MS
= 0.5*0.25*c*(dl/d)0.5d3/MS
=0.5*0.25*c*dl0.5d2.5/MS
=0.5*0.25*19.3/10-0.6*(10-3)0.5*(1.27)2.5/MS

MS=13.9 *106 grams/13.9 tonnes 17

Which is not possible ,the gold is very fine and it is well known by experiment
that sample of few k are all it takes to get an acceptable reproducibility.

EXAMPLE 2-; CALCULATION OF GOLD LIBERATION SIZE.

SOLUTION -: 10% standard deviation ,

MS=15 kg , SFSE=0.10,d=1.27 ,density=19.3 g/cm3
f=0.5 liberation factor =0.25

SFSE2=fgcld3/MS
l=(dl/d)0.5, l= SFSE2*MS/fgcd3
dl= 3.9 *10-9= 0.39 A0, which is absurd result.

Hence from experimental evidence ,it is proved that Gy’s formula is inaccurate

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MALANJKHAND COPPER PROJECT, HINDUSTAN COPPER LIMITED

18
7.0 CONCLUSION
From the report it is cleared that Gy’s sampling theory still not
adopted as accurate one .As we saw that the formula given by Gy’s
totally consists of assumption and factor used did not give better
result and also from the experimental data shown ,it is cleared that
the formula for calculating fundamental sampling error is inaccurate
.Number of process control, product uality control for consumer
safety and environmental control are being carried out with the
help of sampling theory developed by Pierre Gy. Examining and
designing sampling procedures normally decreases the probability
of error in sampling, sampling equipment should be correct,
sampling procedures should be examined by trained person in
regular interval .Hence at last it is concluded that sampling is

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important issue in industries and more work on sampling is

required to least the error in sampling.

19

8.0 REFERENCE:

1) Practical applications of sampling theory by Pentti Minkkinen ,Department of Chemical Technology,

Lappeenranta University of Technology, Lappeenranta, Finland
Received 1 August 2003; received in revised form 1 January 2004; accepted 12 March 2004
Available online 28 July 2004

2) Sampling-Helper: un outil internet pour qualifier la Représentativité de stratégies d’échantillonnage

enréseaux d’assainissement et milieux récepteurs
Rossi L, Rumley L, Ort C*, Minkkinen P** , Barry DA, Chèvre N***

3) Sampling Errors and Control of Assay Data

Quality in Exploration and Mining Geology
Marat Abzalov 37 Belmont Avenue, Belmont, WA6104
Australia

4) Part 1: Understanding the components

of the fundamental sampling error: a
key to good sampling practice
by R.C.A. Minnitt*, P.M. Rice† and C. Spangenberg§

5) A Critique of Gy’s Sampling Theory Dihalu, D.S. Geelhoed, B.

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6)The most common error in applying ‘Gy’s Formula’ in the theory of mineral
sampling, and the history of the liberation factor
by D. François-Bongarçon* and P. Gy†

20

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