Government Engineering College Jagdalpur
(Bastar), C.G.
Department Of Mining Engineering
A
VOCATIONAL TRAINING REPORT
on
NATIONAL MINERAL DEVELOPMENT CORPORATION, BACHELI submitted to:-Mr. S.K. PRAJAPATI BY KULSHRESTH SINGH SEMESTER-5TH BRANCH: MINING ENGINEERING ROLL NO.- 3083913028 SESSION: 2015-16
Vocational Training Report
on National Mineral Development Corporation,
BIOM (Bailadila Iron Ore Mines), Bacheli Complex
ACKNOWLEDGEMENT
We are thankful to our Principal, Mr. G.P.Khare & Mr. S.K.Prajapati, Head of Department of Mining Engineering, GEC Jagdalpur, for their support and guidance without which the successful completion of the training would have not been possible.
We would also like to convey our sincere gratitude and indebtness to the faculty and staff members of Department of Mining Engineering, GEC Jagdalpur, for their help at different times and for his constant supervision, guidance, motivation and support at every stage of this project work.
We would also like to extend our sincere thanks
to:-Sri M.Chandrakantha, Training Officer/Sr. Manager (Min.)T&S; Sri SSN Murthy, HOD/DGM(Min.);
Sri G. Venkatesvarlu, Sr. Manager (Min.), Survey; Sri Dharmraj, Sr. Manager (Min.), Drilling & Blasting; Sri Sanjeev Kr. Sinha, Sr. Manager (Min.), Planning Cell
For their help in providing the necessary information for the dissertation work. Last but not the least, our sincere thanks to all our friends who have extended all sorts of help for completion of this work.
PRESENTED BY :- Mr. S.K.PRAJAPATI KULSHRESTH SINGH H.O.D.
CONTENTS
Chapter 1: NMDC : INTRODUCTION
Chapter 2: BACHELI COMPLEX: PIT No. 5 AT A GLANCE
Chapter 3: LOCATION & GEOLOGY Chapter 4: MINE SURVEY
Chapter 5: MINING MACHINARY DEPLOYED Chapter 6: DRILLING
Chapter 7: BLASTING Chapter 8: EXCAVATING
Chapter 9: EARTH MOVING EQUIPMENTS USED IN NMDC MINES
Chapter 10: MAINTENANCE CARRIED OUT AT SERVICE CENTER, NMDC
Chapter 1:
INTRODUCTION
MISSION OF NMDC
The mission of NATIONAL MINERAL DEVELOPMENT CORPORATION is to produce and market the Planned Quantity of IRON ORE efficiently & economically with due regard to Safety, Conservation, Environment & Quality.
ENVIRONMENTAL POLICY OF BAILADILA
IRON ORE MINES
We are committed to, continual improvement in our environmental performance with emphasis on compliance of environmental legislations, prevention of pollution at all levels, participation of interested parties and reuse of generated wastes.
INTRODUCTION
India produces about 150 Million tons of iron ore and ranks fourth in the world of iron ore production. In India NMDC is the single largest producer and exporter of iron ore. The major mines of NMDC are located in the Bailadila Iron Ore complex of Chhattisgarh. Bailadila Iron Ore is located in the South Bastar District of Dantewara. NMDC is producing about 18 Million Tonnes of Iron from the Bailadila sector.
The iron ore is distributed in the form of thin lenticular deposits in the eastern and western ridges of the Bailadila Iron Ore Series. Deposit No 1-5 are located in the western ridge whereas Deposit No. 6-13 are located in the Eastern ridge. Deposit-5 is located in the southernmost part of the western ridge. Deposit-5 possesses one of the world’s best grades of hard lump ore having +68% iron content, low silica, low alumina and low phosphorous typically free from sulphur and otherdeleterious material. Sometimes the iron content of the ore is found to be as high as 69.5%.
NMDC, Bacheli Complex
Bailadila Iron Ore Mine (BIOM),
Bacheli Complex, Pit No. 5
Chapter 2:
BIOM, Bacheli Complex, PitNo.5: At a Glance
Commissioned : January, 1977 Mining lease area :540.05 Hect. (upto Sept. 2015) Type of Ore : Hematite Maximum grade : +69% Fe Average grade : +66% Fe
Reserve and Resources : 375.55 MT as on 01.04.2015 Recent Exploratory Drilling : 4104 m (from 2012)
Product : Lump (-150 mm +10 mm) Callibrated Lump Ore(-40mm +10mm)
Fines (-10 mm)
Annual Target : 8.2 MT of ROM and 1.5 MT of WASTE
Port of Export : Vishakhapatnam Rail link to Vizag : 471 km
Nearest Airport : Raipur Present Highest Bench RL : 1188 m Present lowest Bench RL : 1020 m Average Rainfall : 315 cm
Certification : ISO 9001:2008, ISO 14001:2004, ISO 18001:2007
No. of Employees : 1777 as on 01.12.2013 Conveyor System-
Tunnel length : 2.14 km Conveyor length : 4.82 km
Chapter 3:
LOCATION & GEOLOGY
LOCATION
The major mines of NMDC are located in the Bailadila Iron Ore Compplex in the South Bastar District of Dantewada, C.G. Based on the detailed mapping, vertical section measurements, petrographic and geochemical analysis, the Bailadila group has been classified into three subgroups viz., Bhansi metapelites, Bacheli metasilicickastic, East Ridge shale/slates, Loa conglomerates and shale and Kailash Nagar Iron formation in the ascending order. The deposit of this area is lump ore and consists of Type-1 and Type-2 ore which are steel grey hematite and blue grey hematite respectively. Iron ore of this area is distributed in the form of lenticular deposits in the Eastern and Western ridges of the Bailadila Iron Ore Series.
GEOLOGY
Deposit-5 is the Southern most deposit in the Western ridge of the Bailadila Iron Ore Range. The deposit has a strike length of 3500 m and has the width varying between 100 m to 400 m. The western side of the mine is marked by a cliff, which goes almost vertically down for about 300 m. The ore body strikes N37˚E and has a deep varying within the range of 45˚-60˚ towards east. The south block has a strike length of 1 km, the central and north-west blocks 1 km and the north block occupying the rest of the area.
Petrographic studies of each ore type have been carried out the ore types encountered in the area have following grade and bulk density.
In Addition to above the waste encountered has following grade and bulk density.
S.no.
Ore Type
Fe%
Bulk Density
( T/M
3)
1.
Shale
35
2.6
2.
Banded Hematite
Quartzite (BHQ)
40
3.2
S.No.
Ore Type
Fe%
Bulk Density
(T/M
3)
1.
Steel Grey Hematite
69
4.5
2.
Blue Grey Hematite
68
4.2
3.
Laminated Hematite
66
3.5
4.
Lateritic/Limonitic Ore
60
3.2
Chapter 4:
MINE SURVEY
In NMDC (Bacheli Complex), two major survey equipment
used to survey the mine
field:-1. TOTAL STATION
1. TOTAL STATION
A total station or TST (total station theodolite) is an electronic/optical instrument used in modern surveying and building construction. The total station is an electronic theodolite (transit) integrated with an electronic distance meter (EDM) to read slope distances from the instrument to a particular point.
Angle Measurement:
Most modern total station instruments measure angles by means of electro-optical scanning of extremely precise digital bar-codes etched on rotating glass cylinders or discs within the instrument. The best quality total stations are capable of measuring angles to 0.5 arc-second. Inexpensive "construction grade" total stations can generally measure angles to 5 or 10 arc-seconds.
Distance Measurement:
Measurement of distance is accomplished with a modulated infrared
carrier signal, generated by a small solid-state emitter within the instrument's optical path, and reflected by a prism reflector or the object under survey. The modulation pattern in the returning signal is read and interpreted by the computer in the total station. The distance is determined by emitting and receiving multiple frequencies, and determining the integer number of
wavelengths to the target for each frequency. Most total stations use purpose-built glass corner cube prism reflectors for the EDM signal. A typical total
station can measure distances with an accuracy of about 1.5 millimeters (0.0049 ft) + 2 parts per million over a distance of up to 1,500 meters (4,900 ft)Reflectorless total stations can measure distances to any object that is reasonably light in color, up to a few hundred meters.
Coordinate Measurement:
The coordinates of an unknown point relative to a known coordinate can be determined using the total station as long as a direct line of sight can be established between the two points. Angles and distances are measured from the total station to points under survey, and the coordinates (X, Y, and Z or easting, northing and elevation) of surveyed points relative to the total station position are calculated using trigonometry and triangulation.
Data Processing:
Some models include internal electronic data storage to record distance, horizontal angle, and vertical angle measured, while other models are equipped to write these measurements to an external data collector, such as a hand-held computer.When data is downloaded from a total station onto a computer, application software can be used to compute results and generate a map of the surveyed area. The newest generation of total stations can also show the map on the touch-screen of the instrument immediately after measuring the points.
Applications:
Total stations are mainly used by land surveyors and civil engineers, either to record features as in topographic surveying or to set out features (such as roads, houses or boundaries).
In Mining:
Total stations are the primary survey instrument used in mining surveying. A total station is used to record the absolute location of the tunnel walls (stopes), ceilings (backs), and floors as the drifts of an underground mine are driven. The recorded data are then downloaded into a CAD program, and compared to the designed layout of the tunnel.
The survey party installs control stations at regular intervals. These are small steel plugs installed in pairs in holes drilled into walls or the back.
For wall stations, two plugs are installed in opposite walls, forming a line perpendicular to the drift. For back stations, two plugs are installed in the back, forming a line parallel to the drift.
A set of plugs can be used to locate the total station set up in a drift or tunnel by processing measurements to the plugs by intersection and resection.
Mechanical and Electrical Construction:
Total stations are the primary survey instrument used in mining surveying. A total station is used to record the absolute location of the tunnel walls (stopes), ceilings (backs), and floors as the drifts of an underground mine are driven. The recorded data are then downloaded into a CAD program, and compared to the designed layout of the tunnel.
The survey party installs control stations at regular intervals. These are small steel plugs installed in pairs in holes drilled into walls or the back. For wall stations, two plugs are installed in opposite walls, forming a line perpendicular to the drift. For back stations, two plugs are installed in the back, forming a line parallel to the drift.
A set of plugs can be used to locate the total station set up in a drift or tunnel by processing measurements to the plugs by intersection and resection.
2. DGPS
Differential Global Positioning System (DGPS) is an enhancement to Global Positioning System that provides improved location accuracy, from the 15-meter nominal GPS accuracy to about 10 cm in case of the best implementations.
DGPS uses a network of fixed, ground-based reference stations to broadcast the difference between the positions indicated by the GPS (satellite)
systems and the known fixed positions. These stations broadcast the difference between the measured satellite pseudo ranges and actual (internally computed) pseudo ranges, and receiver stations may correct their pseudo ranges by the same amount. The digital correction signal is typically broadcast locally over ground-based transmitters of shorter range.
Operation:
A reference station calculates differential corrections for its own location and time. Users may be up to 200 nautical miles (370 km) from the station, however, and some of the compensated errors vary with space: specifically, satellite ephemeris errors and those introduced by ionospheric and tropospheric
distortions. For this reason, the accuracy of DGPS decreases with distance from the reference station. The problem can be aggravated if the user and the station lack "inter visibility"—when they are unable to see the same satellites.
Variations: 1. European DGPS Network 2. United States NDGPS 3. Canadian DGPS 4. Australia Post-processing:
Post-processing is used in Differential GPS to obtain precise positions of unknown points by relating them to known points such as survey markers.
The GPS measurements are usually stored in computer memory in the GPS receivers, and are subsequently transferred to a computer running the GPS post-processing software. The software computes baselines using simultaneous measurement data from two or more GPS receivers.
The baselines represent a three-dimensional line drawn between the two points occupied by each pair of GPS antennas. The post-processed measurements allow more precise positioning, because most GPS errors affect each receiver nearly equally, and therefore can be cancelled out in the calculations.
Differential GPS measurements can also be computed in real-time by some GPS receivers if they receive a correction signal using a separate radio receiver, for example in Real Time Kinematic (RTK) surveying or navigation.
The improvement of GPS positioning doesn't require simultaneous measurements of two or more receivers in any case, but can also be done by special use of a single device. In the 1990s when even handheld receivers were
quite expensive, some methods of quasi-differential GPS were developed, using the receiver by quick turns of positions or loops of 3-10 survey points.
Devices include in DGPS:
1. Base 2. Rover 3. Controller
Base: In India, there is IGS (International Geodatis Station) situated in
Bangalore which works 24 hrs. and collect data from satellites. Base works with reference to IGS data. Base levelled and locate at fixed point in mine field station and leave it for 10-12 hrs. During this period, it receives and records the data which comes from IGS and also it collects data from satellites. The reason for this type of connection in Base is to correct the received data which comes from satellite.
Rover: Rover is the type of Antenna which connects with satellite and Base. It
is connected with Base by Radio waves. Rover receives raw data from satellite and send it to Base where it is corrected by the recorded data from IGS. After correction has been done, Base send back this data to Rover.
Controller: Controller is the digital device which has display unit. Controller
displays the data which comes from Rover. It calculate the received data and gives the exact location of point marked on the field.
In India, DGPS works with GNSS (Global Navigation System Satellite). America has 26 GPS satellite and Russia has 20 GNSS satellite
.
DGPS Survey in Mine Field
BASE CONTROLLER
Chapter 5:
S.No.
Equipment
Make/Model
Capacity
Total
fleet
1
SHOVELS
BEML/TATA HITACHI
4.6, 8 &
8.8
cu.m.
7
2
DUMPERS
BEML/CATERPILLAR
85 &
100 Te
13
3
WATER
SPRINKLERS
BEML
28 & 30
KL
4
4
DOZERS
BEML/CATERPILLAR
7
5
FRONT END
LOADER
CATERPILLAR
8 cu.m.
1
6
MOTOR
GRADERS
BEML
2
7
BLAST
HOLE
DRILLS
INGERSOLLRAND/ATLAS
COPCO
250 mm
4
8
CRAWLER
DRILLS
INGERSOLLRAND/ATLAS
COPCO/SANDVICK
102 mm
3
Chapter 6:
DRILLING
There are two forms of rock breakage viz., rock penetration and rock fragmentation. The former includes drilling, cutting, boring etc., while the latter includes blasting etc. The term rock penetration is preferred for all methods of forming a directional hole in the rock. There are many types of rock penetration depending on the form of energy application, viz. mechanical, thermal, fluid, sonic, chemical etc. The mechanical energy, of course, encompasses the majority (about 98%) of rock penetration applications today. The application of mechanical energy to rock can be performed basically in only one of the two ways: by percussive or rotary action. Combining the two results in hybrid methods termed roller-bit rotary and rotary-percussion drilling.
In surface mining, roller bit rotaries and large percussion drills are the machines in widest current use, with rotary drills being heavily favoured. Drilling is performed in order to blast the overburden, ore deposit, coal seams etc., so that the power requirement for excavators to extract the materials becomes less. This also reduces the wear and tear of the excavators, increases their life, reduces clearing time of materials, and decreases operation cost. Drilling holes are usually made in a zig-zag pattern .The spacing between the rows and column is of equal length.
Classification of Drilling Systems:
Drilling machines used in surface mining projects, construction work, etc., can be classified in the following ways :
i) Percussive Drilling ii) Rotary Drilling
iii) Rotary-percussive Drilling
In the IDM 30 D this is diesel operated machine. It has 900 liter diesel tank capacity and drill bit are 6 & 6.5 inch. By the air pressure cutting material is come out.
General Description of IDM 30 E
:-IDM 30E is a crawler mounted rotary drill, basically a hydraulic drill. Air is used only for flushing, in the case of rotary drill. In the case of DTH drilling, air is used for hammer also.
All other operation are powered through hydraulic system. This enables more air to be available for effective drilling.
SUB SYSTEM :-1. Power Pack 2. Hudraulic System 3. Pneumatic System 4. Propulsion 5. Feed
6. Rotary head system
The basic unit comprises of an undercarriage section, which carries the main frame.
A hydraulic motor and planetary gearbox drives the track.
The power pack and all the auxiliaries, like oil cooler, jacks, cabin, dust collector etc. are mounted on the main frame.
The tower is pivoted on two pillar of the main frame along with a hydraulic cylinder when drilling the machine is supported on 4 jacks.
The rotary head & feed system are mounted on the tower.
The hydraulic jacks are provided with lock check valves to prevent jacks from creeping when on load.
Chapter 7:
Blasting is the process in which the blast holes exploded by the use of explosives and detonator.
Process of Blasting
:-1. PRIMING PROCESS 2. CHARGING PROCESS 3. STEMMING PROCESS 4. FIRING PROCESS
Blasting Pattern Followed in Opencast
Mines-There are mainly two types of blasting pattern followed in opencast mines - a) Single Row blasting pattern
b) Multi-row blasting pattern
1. PRIMING PROCESS
:-In Priming Process, we connect the cast booster with detonating fuse and shock tube and then dip into the blast hole
Accessories :
1. Cast Booster 2. Shock Tube 3. Detonating Fuse
Cast Booster-
Cast Booster deliver the driving force required for generating maximum initiating energy and blasting efficiency.
Chemical Content : PETN+TNT Weight : 100 & 250 gm.
Diameter : 50mm
Shock
Tube-Instead of electric wires, a hollow plastic shock tube delivers the firing impulse to the detonator, making it immune to most of the hazards associated with stray electrical current. NONEL shock tube is a small diameter, three-layer plastic tube coated on the innermost wall with a reactive explosive compound, which, when initiated, propagates a low energy signal, similar to a dust explosion, at approximately 6,500 ft/sec (2,000 m/sec) along the length of the tubing with minimal disturbance outside of the tube.
Chemical Content : PETN (10 mg/m) Reel length : 15 m
Detonating
Fuse-For shallow depth (<3m), and for small number of holes, a detonator is inserted in the cartridge itself and detonated and detonated by ignition of safety fuse or incase of electric detonator, by an exploder. It contains core of PETN enclosed
in a tap wrapped with cloth. It looks like a plastic cord. Its diameter is 5 mm external and weight about 20 g/m length.
It has a VOD of 6500 m/s. A large number of shots connected with detonating fuse can be blasted by a single detonator.
Chemical Content : PETN (10 gm./m) Reel Length : 375 m
2. CHARGING PROCESS
:-In Charging process, we put SME (Site Mix Emulsion) in the Blast Hole. Chemical Composition : Ammonium Nitrate + little amount of fuel+ water + Gasing agent (Sodium Nitrite,0.2%)
Total SME in the container of BMD-Pump Truck : 3745 kg
Explosive
Estimation-1. Volume of Bore Hole= Spacing x Burden x Bore Hole depth
2. After volume find out, then it is multiplied by final cup density of SME called Charging Factor
Example :
Volume of Bore Hole = s x b x h = 6 x 5 x 12 = 360 m3
Charging Factor = Vol. of Bore Hole x final cup density of SME= 360 x 1.1 = 396 kg/m3
Gasing in
SME-1. Due to present of gasing agent in SME, in bore hole after explosive filled, it undergoes to gasing process.
2. The time taking approx. 25-30 min. for gasing.
Cup density of
SME-Fill the cup with the amount of SME and weight The initial weight of SME = 1.32 kg
Now, leave this for 30 min.
After gasing, it’s final weight is 1.15 kg
:-In stemming process, fill the upper left portion of bore hole by overburden and drop the left detonating fuse wire in the bore hole.
4. FIRING PROCESS
:-In the Firing process, we make Trunk Line connection in Drill Block.
This is the connection in which blast holes connected to each other by shock tube and clamped. After this, we make one blast hole as a firing point where safety fuse wire attached to the Ordinary Detonator with the crimp.
Chemical content of OD – PETL + ASA
Rate of burning of Safety fuse wire = 120 sec./m
Chapter 9:
EARTH MOVING EQUIPMENTS USED IN NMDC MINES
SHOVELS :
It is used to excavate the materials and loading it to the Dumpers. Its bucket capacity is 24 Te.
Power- 600 – 750 KW
It is used to shift material from quarry to crushing plant. Its capacity is 50 tons.
Material is loaded in it by shovel.
WATER SPRINKLERS :
It is used to sprinkle water on haul roads of mines.
Water sprinkling is necessary to suppress the dust particle and keeping the environment of mines dust free.
It is used to shift material like boulders and loose iron ore from one
place to other.
It pushes the material by its blade mounted on front side when it
crawls.
FRONT END LOADER :
It is used to fill final product of crushing plant in the wagons.
The bucket mounted in its front side.
It used to maintain haul roads in good condition.
Its main function is done by its blade which is in middle of the equipment. Blade can be adjusted by lifting, tilting, and swirling.
MAINTENANCE CARRIED OUT AT SERVICE CENTER,
NMDC
Following is the process of maintenance :
1. Equipment is thoroughly washed in washing day. 2. Equipment is shifted inside maintenance bay.
3. Equipment is thoroughly inspected and all the defects are listed.
4. A defect list mentioned in the service book by operator of equipment is also checked for his complains.
5. Work is planned and deadlines are made.
6. Spare parts are arranged in advance for uninterrupted flow of maintenance work.
7. Work is started and progress in monitored on shift basis.
8. Whatever work is carried out in a shift is mentioned in a shift log book
