Tag Archives: India

Crushing and washing plant inaugurated at Tata’s Khondbond iron and manganese mine

Tata Steel’s Ores, Mines & Quarries (OMQ) Division has opened an 8 Mt/y crushing and washing plant at its Khondbond Iron and Manganese Mine (KIMM) near Joda in the Keonjhar district of Odisha, India.

The facility was inaugurated today by T V Narendran, CEO & Managing Director, Tata Steel, in the presence of D B Sundara Ramam, Vice President (Raw Materials), Tata Steel; Avneesh Gupta, Vice President (TQM and Engineering & Projects), Tata Steel; Atul Kumar Bhatnagar, General Manager (OMQ Division), Tata Steel; Mukesh Ranjan, Chief Projects OMQ Division, Tata Steel; Pervez Akhtar, Chief Projects Raw Materials, Tata Steel; and other senior officials and vendor partners of the company.

Speaking on the occasion, Narendran emphasised the need to focus more on resource efficiency, productivity and technology with the requirement of raw materials growing in line with the growth of the company. He congratulated the OMQ Division and the engineering and projects team for achieving this great milestone.

The iron ore processing plant will cater to the rapidly growing raw material requirements of Tata Steel and will provide raw material security. In line with the company’s core objective of building sustainable mining and manufacturing processes, the facility incorporates the latest technology for ore processing, enabling efficient resource usage and reduced wastage.

The plant design includes three stage crushing and screening. To reduce the inherent alumina from the ore, two rotary drum scrubbers have been installed, which can reduce the alumina of the incoming ore, thereby improving the ore quality.

The slurry from the scrubbing screens is processed through hydrocyclone clusters, maximising ore recovery and reducing wastage, the company said. The overflow from the hydrocyclone is fed to a high rate settling thickener which facilitates recovery of process water from the slime. To further minimise water use, the water recovered from the thickener is recycled back into the plant for recirculation, minimising the requirement of makeup water for plant operation.

An in-plant rainwater harvesting reservoir has also been created to store and reuse the rainwater runoff from the hill slopes for dust suppression, plant operations and ground water charging in and around Khondbond. A paste thickener facility is also being set up within the premises for further improving the recovery of water. The plant is equipped with a dry fog dust suppression system and water sprinklers for controlling fugitive dust emissions within the product stockpiles.

Metso Outotec expands India facility on track-mounted crushing/screening equipment demand

Metso Outotec is to invest in extending its current manufacturing capacity of mobile track-mounted crushing and screening equipment in Alwar, India.

The total Alwar production value is planned to grow by 30% from the current level and global track-mounted mobile machine capacity by 15%, the OEM said. Construction of the new factory facilities is planned to start in early 2022, and be completed by the end of the year.

The increased capacity in India will be used for the manufacturing of McCloskey mobile and Lokotrack equipment, employing approximately 200 additional people. After the extension is completed, the Alwar factory will be one of the biggest manufacturing sites of Metso Outotec, employing some 800 people, the company said.

“This is another step in developing our domestic and export business in India,” Markku Simula, President of the Aggregates business area of Metso Outotec, said. “At the same time, we are also investing significantly in engineering and R&D resources in Alwar and making it one of our global engineering hubs.”

SafeAI targets Japan and India in latest automation expansion drive

SafeAI has announced a major global expansion of its autonomous solutions business with entry into two new countries, Japan and India.

With new offices and growing local teams in both markets, the company says it is poised to significantly accelerate the rollout of autonomous equipment across heavy industry, worldwide.

Both Japan and India represent tremendous opportunities for growth with large heavy equipment markets. Japan, in particular, boasts a massive construction sector, recently estimated at a value of more than $530 billion, SafeAI said.

Already, SafeAI has a successful year-long partnership with Japanese construction company Obayashi. The two companies are currently retrofitting an autonomous Caterpillar 725 articulated dump truck to complete load-haul-dump cycles.

India, meanwhile, has a construction industry worth more than $35 billion and a significant mining sector that produces 95 minerals and has an export value of approximately $4 billion, it said.

To support this continued global growth, SafeAI has also announced four new leaders to its team:

  • Dr Ryo Hiratsuka, SafeAI’s Japan Country Head, will oversee initiatives from the new office in Tokyo. Hiratsuka brings over 20 years of experience developing Japanese markets for start-up companies, including Cisco, HP (former Colubris Networks) which deployed Wi-Fi on airplanes, trains and cruiser ships, and Hexagon (former Romax Technology) focused on the electrification of cars and trucks. Prior to joining SafeAI, he served as the Japan Sales Manager of Quectel for V2X, telematics and location tracking technology across a number of industries;
  • Sudarshan Singh joins the team as the India Country Head to oversee operations at the new office in New Delhi. Singh brings over 30 years of executive leadership experience to the role, including 14 years at Caterpillar, where he launched the company’s India operations, expanded product offerings and the used machinery business and ultimately led the Asia-Pacific region. Singh also spent time at DEUTZ AG, where he expanded India operations with OEMs and defence projects, and at the SANY Group, where he grew the company’s footprint in India, with a focus on manufacturing concrete and construction machinery;
  • Lisa McGinty joins the team in the US as Global Head of Marketing. McGinty brings over 30 years of growth, marketing and branding experience across multiple industries to the role. Most recently, she was an early stage growth executive at FreightWaves, a global digital news, data and software as a service company focused on transportation and logistics; and
  • Rob Reid joins SafeAI’s growing Australia team as Principal Autonomy Engineer. Over the last 15 years, Reid has built autonomous solutions for a variety of applications, ranging from space to the energy industry, and gained experience across a range of technical areas, including mobility, perception, planning and controls and machine learning. Prior to joining SafeAI, Reid was the Principal Robotics Engineer at Woodside Energy, deploying robots at oil and gas facilities, and a Robotics Engineer at the NASA Jet Propulsion Laboratory for four years.

“Companies across heavy industry, and across the world, are eager to deploy autonomous solutions for safer, more productive sites,” Bibhrajit Halder, Founder and CEO of SafeAI, said. “To meet this skyrocketing demand, we need both the geographic reach and the expertise to meet our customers where they are and ensure a successful deployment. Lisa, Ryo, Sudarshan and Rob all bring invaluable experience to guide our team through the next chapter.”

This expansion comes on the heels of a busy year for SafeAI’s growing business that has also included launching in Canada and Australia, securing a $21 million Series A round and launching an industry-first operating system.

MOBISCREEN MS EVO screening plants hit the mark at Orissa Mining’s iron ore site

Wirtgen Group’s Kleemann MOBISCREEN MS EVO screening plants have been helping Kalina Commercial Corp and Orissa Mining hit their goals at the Keonjhar iron ore mine in Orissa, India, classifying material into the desired grain sizes.

Kalinga, which is responsible for iron ore extraction on behalf of the state-owned company Orissa Mining, has been using six MOBISCREEN EVO mobile screening plants from Kleemann to classify the iron ore in up to four fractions.

More than 20 excavators are deployed for extraction, handling and loading of the ore, with 140 large dump trucks transporting the material from the mines for further processing by the screening plants.

Five double-deck screening plants MOBISCREEN MS 952 EVO and a triple-deck screening plant MS 953 EVO make classification of the blasted and then crushed material into up to three or four (with the MS 953 EVO) fractions possible.

With the use of these six mobile classifying screens, Kalinga has achieved a continuous daily production target of 30,000 t in two shifts and the desired final grain sizes of 0-10 mm and 10-40 mm.

The MOBISCREEN MS EVO screening plants are able to operate precisely and efficiently under extreme conditions: in the open-pit mining site in Keonjhar, they process feed material with a moisture content of 6-7% without issue.

Dr SR Samal, Managing Director, Kalinga Commercial Corp, said: “We have been using Kleemann screening plants for more than two years. These plants have proved their value with regard to product quality and output. Over the years, they have become an indispensable element of our operation. The service, above all, is exemplary. The co-operation with the Wirtgen Group was crowned with success.”

The classifying screens in the EVO series provide high productivity, good transport properties and first-class screen results, according to Wirtgen. The product series includes the two double-deck classifying screens MS 702 EVO and MS 952 EVO, as well as the triple-deck classifying screens MS 703 EVO and MS 953 EVO. Thanks to the particularly large screening surfaces of 7 sq.m or 9.5 sq.m, high production outputs, combined with effective screening of up to four first-class final products, can be achieved, the company says. Depending on the application case, throughputs of up to 350 t/h (MS 702 and MS 703 EVO) or 500 t/h (MS 952 and MS 953 EVO) are possible.

With the MOBISCREEN EVO screening plants, Kleemann has also considered safety. The plants can be operated with an intuitive control system via a mobile control panel that can be attached at three different points of the plant. This increases work and operational safety.

Easily accessible work platforms mean service activities can be carried out quickly and screen surfaces can be replaced without any problems, the company says. All other service components can be accessed from the ground so maintenance tasks can be executed without complications.

GHH India’s contract mining arm wins plaudits for work with Hindustan Zinc

GHH India’s recently established contract mining arm, GHH Bumi Mining Service, has notched up its first significant award, being recognised by Vedanta Group/Hindustan Zinc Ltd (HZL) for the work it is doing at the Zawar Mala zinc-lead underground mine in Rajasthan, India.

In a recent online event, GHH Bumi Mining Service, established late last year, was named as the recipient of the Best Performing Business Partner by the companies.

The award winner was chosen out of all business partners and recognised a job well done, GHH said.

Over the last six months, GHH Bumi has been carrying out contract mining at Zawar Mala, and was presented the award, GHH says, based on excellent performance involving all contract mining activities, including those related to safety, production and asset optimisation.

Since January, GHH BUMI has been responsible for production and mine development with more than 350 employees at Zawar Mala. For this purpose, the company has access to more than 20 LHDs, dump trucks and drilling rigs from the GHH Group.

Dr Jan Petzold, CEO of GHH Group, said: “With this award, we as GHH Group see ourselves confirmed in our efforts as a reliable business partner for HZL – a cooperation that started almost four years ago with the supply of mining machinery and has resulted in being awarded as mining contractor and OEM.

“This is a special incentive to be able to conclude the second mine developer and operator contract with HZL, which is currently in preparation.”

The latest generation of GHH mining equipment, with its new dump truck MK-42, LF-14 and LF-10 LHDs as well as two FM 2.3 boom drill rigs from GHH group company, Mine Master, are on their way to India and are expected to be on site beginning of August, GHH said.

GHH says GHH Bumi is also currently working on preparing for the expansion of the Mochia Balaria Decline project, where a rapid development proposal is under way.

Tata Steel’s Jharia Division receives coal prep plant, ventilation power supply boost

In line with its mechanisation and modernisation program, Tata Steel’s Jharia Division has commissioned a “state-of-the-art” 2 Mt/y coal preparation plant and 400 kVA uninterrupted power supply (UPS) for the main ventilation fan at the Jamadoba Colliery in India.

On the occasion, D B Sundara Ramam, Vice President (Raw Materials), Tata Steel, said: “Introduction of appropriate technology is key to the success of underground mining. At Tata Steel, we leverage our innovation capabilities, technology leadership with focus on safety and sustainability to create long-term value. This state-of-the-art beneficiation plant not only addresses issues like productivity, safety and environment but, at the same, time ensures production of coal at a competitive price.”

Built using cutting-edge technology, the 2 Mt/y preparation plant has been transformed from the oldest running washery in Asia (in operation since 1952) to one of the most modern washeries across the globe, Tata Steel said.

The washery is a major upgrade from the conventional set-up, consisting of a dense media separation cyclone circuit for coarse material, reflux classifier for the intermediate circuit and flotation for the fines circuit – all geared towards improving production efficiency. This is also the first washery in the country with a 100% dewatering facility built within its plant, thereby completely eliminating the need for a tailings pond, auto sprinklers and dry fog systems.

The giant UPS provides uninterrupted power supply to the 450 hp (336 kW) mine fan and automatically changes over during power failure from DVC, keeping the fan running for 40 minutes – enough time for power restoration or change-over to captive supply. This battery back-up UPS is the first-of-its-kind in the country for any mine ventilation fan, according to Tata Steel, enhancing the safety and ergonomics within the mines and providing a more comfortable environment for the miners to work.

Tata Steel says its Jharia Division has been at the helm of innovation and modernisation since its inception, with initiatives like its chair lift man riding system, cooling plant, low capacity and low cost continuous miner with the haulage system setting benchmarks when it comes to underground mining in the country. The Jharia Division has undertaken several initiatives of automation and digitalisation which has helped in improving operational excellence.

Metso Outotec to deliver India’s first large scale Grate-Kiln iron ore pellet plant

Metso Outotec has signed a contract with an Indian customer for the supply of a large capacity Grate-Kiln pellet plant in the State of Odisha, India.

The contract is booked in the Metals business line March quarter orders received. Typically, the value for this type of an order is in the range of €30-40 million ($35.6-47.5 million), depending on the scope of delivery.

Metso Outotec’s scope of delivery includes basic engineering and process technology for the Grate-Kiln pellet plant, including the core proprietary equipment consisting of traveling grate, kiln and cooler, as well as supervisory services for commissioning, and spare parts.

“The energy-efficient Metso Outotec Grate-Kiln process produces pellets of uniform quality with low emissions, high availability, and it has low investment and operating costs,” Jari Ålgars, President, Metals business area at Metso Outotec, said. “With its annual pellet production capacity of 6 Mt, the new plant will be the first large scale Grate-Kiln pellet plant in the country.”

FLSmidth to deliver dry-stack tailings solution at Hindustan Zinc’s Rajpura Dariba mine

FLSmidth has been contracted to deliver an integrated dry-stack tailings solution and a paste fill plant to Hindustan Zinc’s lead-zinc mine in Rajpura Dariba, Rajasthan.

The solution will ensure environmental sustainability and significant process water recovery, as well as reduce the footprint of the tailings storage facility, the mining OEM said.

The new order, which was booked in the December quarter, includes design, engineering, procurement, supply of equipment and the commissioning for integrated dry tailings and stacking along with tailings paste fill plant. FLSmidth will also supply two Automatic Filter Presses (AFP-IV™, pictured), two E-Disc filters and one 26 m diameter High-Density Thickener as the main pieces of equipment. The project is expected to be completed by February 2022.

This new order follows a previous tailings-related order for Hindustan Zinc at its Zawar mine site in 2018.

Hindustan Zinc operates beneficiation plants at Rajpura Dariba and Sindesar Khurd, which both discharge tailings to the same tailings pond. The tailings dam was reaching capacity for conventional wet tailings deposition and so Hindustan Zinc needed a way to resolve this issue, FLSmidth said.

The solution the company required would involve creating a small dry-stack tailings area with minimal environmental and physical footprint and also a method to backfill the mine by using an adjusted dry filter cake mix.

By choosing FLSmidth’s hybrid technology – a combination of the E-Disc filter and the AFP-IV Automatic Pressure Filter – Hindustan Zinc will now be able to achieve this and recover around 85% of process water, according to FLSmidth. This recovered process water can be reused by the process plant located at the mine site with minimum operating and capital expenses.

The cake from the E-disc filter will contain below 16% moisture and can be used for mine backfilling, while the cake from the automatic filter press, with below 12% moisture, can be stacked on the surface in a safe and compact manner, FLSmidth says.

“The solution will also significantly reduce industrial water consumption, something that is of heightened importance in water-scarce areas, such as Rajasthan,” the company said. “The site will also have zero effluent discharge, further boosting its sustainable mining goals.”

Manfred Schaffer, Mining President, FLSmidth, said the order was another strong “proof point” for the quality and flexibility of the company’s technology for filtration and engineering solutions for tailing management.

“This project resolves the customer’s challenge through optimum utilisation of available space and ensures the paste backfill requirements are met with the lowest possible operating and capital costs,” he added. “Importantly, it also secures a high level of reusable water for the mine site, which helps their sustainability efforts and supports our own MissionZero ambition.”

Hindalco achieves aluminium industry first with red mud utilisation

Hindalco Industries has entered into a Memorandum of Understanding (MoU) with UltraTech Cement, India’s largest manufacturer of cement and concrete, to deliver 1.2 Mt/y of red mud to UltraTech’s 14 plants located across seven states. This agreement will see Hindalco become the world’s first company to achieve 100% red mud utilisation across three of its refineries, it says.

Red mud generated in the alumina manufacturing process is rich in iron oxides, along with alumina, silica and alkali, with the cement industry, Hindalco says, having developed the capability to process red mud as a replacement for mined minerals such as laterite and lithomarge in its process.

Hindalco is supplying red mud to UltraTech Cement plants where it has proved to be an effective substitute for mined materials, successfully replacing up to 3% of clinker raw mix volume, according to the company.

“Use of red mud reduces the cement industry’s dependence on natural resources and promotes a circular economy,” Hindalco said.

Hindalco’s alumina refineries are currently supplying 250,000 t/mth of bauxite residue to cement companies, making Hindalco the world’s first company to have enabled such large scale commercial application of bauxite residue. In the current year, Hindalco aims to achieve 2.5 Mt of bauxite residue utilisation, which will be another global milestone, it says.

Satish Pai, Managing Director of Hindalco, said: “Hindalco has been working with cement companies to develop high-grade inputs for the construction industry. Hindalco has built a strong customer base and supplies red mud to over 40 cement plants every month. We have achieved 100% red mud utilisation at three of our refineries and our vision is to achieve zero-waste alumina production across our operations. Hindalco’s actions underscore our commitment to embracing solutions that have the potential to deliver long-term sustainability impact and transform the future.”

Globally, 160 Mt of red mud is produced annually and stored in large tracts of land which is a serious industry challenge, Hindalco says. To find a sustainable solution, Hindalco has invested in infrastructure and collaborated with cement companies, with UltraTech Cement being a key partner.

KC Jhanwar, Managing Director of UltraTech Cement, said: “UltraTech has been among the early adopters in India on the use of alternative raw materials and fuels in manufacturing and invested to build storage, handling and processing facilities. Use of waste like red mud as an alternative raw material for manufacturing cement requires infrastructure and process modification to ensure a win-win for both business and the environment.”

Last year, UltraTech consumed about 15.73 Mt of industrial waste as alternate raw material and about 300,000 t as alternative fuel in its kilns.

Jhanwar added: “With an annual supply of 1.2 Mt of red mud from Hindalco, we expect to conserve more than 1 Mt of mined natural resources like laterite in our manufacturing process. Enhancing our contribution to the circular economy by strategically increasing the use of waste as raw material and fuel in the cement manufacturing process is in line with our aim to achieve our long-term sustainability goals.”

thyssenkrupp wins semi-mobile-crushing-plant contract in India coal hub

thyssenkrupp has been awarded a contract to supply three semi-mobile-crushing-plants (SMCP) to a major open-pit coal mine in the Singrauli district of Madhya Pradesh, India, namely the Jayant mine of Northern Coalfields Ltd, a division of state compay Coal India. The plants will be used for a new 15 Mt/y coal handling plant (CHP).

Looking to boost production from 10 Mt/y to 25 Mt/y, the miner is implementing an in-pit crushing and conveying system utilising the in-pit SMCP for the CHP, which will, thyssenkrupp says, make the production process more efficient and stable.

thyssenkrupp won the contract from an India-based engineering procurement and construction contractor, SK Samanta. It involves the complete design, engineering, manufacturing and supply, and “TAG services” for the three semi-mobile crushing plants.

The plants consist out of three separate modules. The receiving hopper module comes with a 2.2 m wide and 10.5 m long, heavy-duty apron feeder, which can be fed by trucks and has a capacity of around 150 tons (136 t).

The heart of each plant is the crusher module, which uses a RollSizer DRS 1,000 x 2,250 (centre distance x length of the roller) for a maximum feed capacity of 1,900 t/h.

The third module is the electrical building with the operator room. By separating this module from the crusher module, the operators and electrical equipment are not exposed to any vibrations from the crushing process. This ensures the plants meet all requirements from a health and safety perspective, while guaranteeing a long life of the electrical equipment, thyssenkrupp said.

“Compared to stationary crushing plants, SMCPs are more flexible and can be relocated when the distance between the mining area and the crushing plant increases and, thereby, can reduce the cost for transport of the run of mine material significantly,” thyssenkrupp said.

“thyssenkrupp can look back on a long history of supplying fully-mobile, semi-mobile, and stationary crushing plants, which makes the company a leading partner for the engineering, construction and service of industrial plants and systems for the coal industry.”