Tag Archives: India

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.”

FLSmidth FerroCer wear panels increase uptime at Hindustan Zinc operation

FLSmidth’s FerroCer® Impact wear panels have proven their worth in the mineral processing circuit at Hindustan Zinc’s Rampura Agucha operations in Rajasthan, India, having significantly outlasted the previous manganese liners the lead-zinc mine was using.

By the end of 2018, the mine couldn’t say exactly just how good FerroCer wear panels were as they were still in place over a year since installation.

However, by March 2019, it was confirmed the FerroCer liners had completed about 480 days (16 months approximately) in operation and had withstood some 2.45 Mt of lead-zinc ore conveyed through the U-13 tripper chute, located after the primary crusher at the mine.

This is a significant improvement on the previous 40 mm-thick manganese steel liners, which had a life span of only 23-25 days, according to FLSmidth.

The constant wear on these liners meant the material handling system needed to be frequently shutdown so the worn-out liners could be replaced with new manganese steel liners, which weighed about 50 kg each.

“Because of the elevated location of several chutes, replacement of the liners required safety preparations (such as scaffolding and other access and handling arrangements), with five to six workers required to get inside the chutes to handle the liners,” FLSmidth said.

FLSmidth visited officials at the Rampura Agucha mines in June 2017 and recommended FerroCer wear panels to address the high wear issues in the material handling chutes.

“Each panel comprises a set of abrasion-resistant ceramic inserts enclosed in a matrix of malleable steel, which ensures only the top surface of the insert is exposed to material impact,” FLSmidth said. “The sides of the inserts are tapered within the matrix, keeping them in place and preventing material particles and fluids from damaging the panels.”

Some in-situ results from the 220-day mark showed the wear on the panels measured only 8-10 mm and had withstood around 1.5 Mt of lead-zinc ore conveyed through the U-13 tripper chute.

“This means FerroCer outlasted the previous panels by over 10 times, meaning a much longer replacement cycle,” FLSmidth said.

Clearly delighted with this outcome, Hindustan Zinc is now looking to use FerroCer impact wear panels across its high-impact wear locations, according to FLSmidth.

Praveen Bhardwaj, Assistant General Manager (Mechanical), HZL – RA Mines, Rajasthan, said: “FerroCer has reduced maintenance time due to the much longer replacement cycle, eliminated possible damage to the mother plate and spillage of material due to the highly abrasive nature of ore, and significantly reduced safety hazards. HZL intends to install FerroCer impact wear panels in all the high impact wear locations.”

The results at the Hindustan Zinc site follow on from results from two mines in Australia. One mine operated for more than a year without replacing its wear liners and the other site is on the same track, approaching its first year without the need for liner replacement.

Meanwhile, in a Peruvian copper mine, 24 smaller and lighter FerroCer panels, each made of steel plates with ceramic inserts, replaced six generic liners. After a total of 12.6 Mt passed, with a feed of 7,500 t/h, wear was no more than 3%, FLSmidth said.

“At that rate, FerroCer lasts at least 10 times longer than the most expensive and recognised wear liner on the market.”

RCT brings teleremote options to Hindustan Zinc’s Rampura Agucha mine

Autonomous solutions specialist RCT has entered into its first automation project in India, commissioning its technology on machinery at Hindustan Zinc’s Rampura Agucha zinc-lead mine in Rajasthan province.

The agreement with Hindustan Zinc Limited and its mining services provider Barminco will see ControlMaster® Guidance Automation installed on two Cat R2900 underground LHDs at the mine. These loaders will now undertake teleremote mining in open stopes developed by Barminco.

Barminco, in February, was awarded a three-and-a-half-year underground mining services contract at Rampura Agucha. The mine, meanwhile, is currently undergoing an expansion to boost production to 5 Mt/y of ore.

RCT will install two underground ControlMaster Automation Centres, as well as four ControlMaster Area Access Cabinets into mine stopes, as part of this package. These will collectively enable machine operators to safely manage the machines away from the mine face, according to RCT.

The Automation Centres will also be equipped with Multiple Machine Selection and Multiple Machine Control options, enabling a single operator to manage both machines at one time, according to RCT.

The project represents the first time RCT has deployed its proprietary digital communications network RCT Connect into a mine site anywhere in the world, the company said, adding that RCT will carry out training programs to empower local operators and maintenance personnel then machine servicing works on an ongoing basis.

India’s first all-electric, heavy-duty truck ready for 2020 launch, reports say

Infraprime Logistics Technologies (IPLT) says India’s first all-electric, heavy-duty 60-t truck has had its initial commercial run, with a launch for the country’s construction and mining sectors scheduled for next year, according to local reports.

IPLT says its electric truck, the IPLT Rhino 5536, is the first of its kind to be integrated and deployed in India.

Some of its distinguishing features include the transmission based electric drivetrain, proprietary vehicle control software for improved mileage in material logistics and a battery pack “designed for optimal performance in local conditions”.

The latter has an in-built air-conditioned secondary cooling system to maintain the temperature around each cell at below 35° C even when ambient temperature climbs above 50° C, according to the company. IPLT said the 265 kWh battery pack weighs in at more than 2 t, making it one of the largest packs in use in India, and a 160-kW “twin gun fast charging” system is used to recharge it. This system, it says, could also offer a “blueprint for a pan-India network” of charging devices, it said.

Aemetis increases biodiesel market share in India mining sector

Aemetis’ Universal Biofuels India subsidiary has been awarded a biodiesel supply contract with the three India government-owned oil marketing companies (OMC) in a public tender process.

The contract provides for ongoing deliveries of biodiesel to a variety of blending locations in an aggregate amount of more than $23 million during 2019 and is tied to the mining sector, Aemetis said. Biodiesel shipments are scheduled to begin this month.

The company said: “The total diesel market in India is approximately 25 billion gallons per year with 80% imported, of which less than 250 million gallons per year of biodiesel is currently blended.

“The 2018 National Biofuels Policy stated a plan to increase biodiesel blending to 5% of the diesel market, equal to more than 1.2 billion gallons per year. The OMCs in India supply about 70% of the fuel consumed in India, and the diesel fuel market has been growing at a rate of more than 5% per year.”

Eric McAfee, Chairman and CEO of Aemetis, said: “With the recent completion of our plant pre-treatment unit and expansion to 50 million gallons of capacity per year from low cost, high free fatty acid feedstock, the Aemetis team in India is executing on a rapid increase in production and revenues this year by broadening our customers to include government, logistics, mining, retail fuel stations and other sectors.

“As the only US company producing biofuels in India, Aemetis built and has now fully upgraded our India biodiesel and refined glycerin plant to use low cost feedstocks as a leader in this rapidly expanding market.”