SAMPLE VOCATIONAL TRAINING REPORT
ONHINDUSTAN COPPER LIMITED (JHARKHAND)
1.INTRODUCTION
Hindustan Copper Limited (HCL), a public sector undertaking under the administrative control of the Ministry of Mines, was incorporated on 9th November 1967. It has the distinction of being the nation’s only vertically integrated copper producing company as it manufactures copper right from the stage of mining to beneficiation, smelting, refining and casting of refined copper metal into downstream saleable products.
The Company markets copper cathodes, copper wire bar, continuous cast copper rod and by-products, such as anode slime (containing gold, silver, etc.), copper sulphate and sulphuric acid. More than 90% of the sales revenue is from cathode and continuous cast copper rods. In concluded financial year 2006-07, as per provisional estimates, the Company has earned a all time highest net profit pf Rs 331 crore (~USD 75 million ) against a sales turnover of Rs 1800 crore (~ USD 420 million). HCL’s mines and plants are spread across four operating Units, one each in the States of Rajasthan, Madhya Pradesh, Jharkhand and Maharashtra as named below:
» Khetri Copper Complex (KCC) at Khetrinagar, Rajasthan
» Indian Copper Complex (ICC) at Ghatsila, Jharkhand
» Malanjkhand Copper Project (MCP) at Malanjkhand, Madhya Pradesh
» Taloja Copper Project (TCP) at Taloja, Maharashtra
November 1967 Incorporated to take over from National Mineral Development Corporation Ltd.
March 1972 M/S Indian Copper Corporation Limited, Private Sector Company, located at Ghatsila, Jharkhand with Smelter and Refinery was Nationalized and made part of HCL.
February 1975 Fully integrated Copper complex from mining to refining came on stream at Khetri ( capacity 31,000 tonnes of refined copper)
November 1982 The largest hard rock open pit mine in the country came into stream at Malanjkhand in Madhya Pradesh of capacity 2 million tonnes ore
December 1989 Continuous Cast Wire Rod plant of South Wire Technology of capacity 60,000 MT was commissioned at Taloja in Maharashtra.
Located in the state of Jharkhand
• Capacity 16,500 tpa copper cathode
• By products Sulfuric acid, gold, silver, palladium, selenium, tellurium, nickelsulphate
• Mines - Surda
• Reserve
• Surda 19.30 million tonnes @1.17% c
2. PLANT LAYOUT
Plant layout
Fig no. 1
3. POWER PLANT
Def :A complex of structures, machinery, and associated equipment for generating electric energy from another source of energy, ie called as power plant.
3.1 VARIOUS PLANT WORKING IN PP:
A. Coal handling plant
B. DM plant
C. Boiler house
D. Power house
A. COAL HANDLING PLANT:
In this plant purify the coal from any type of impurities ,ie dust,stone etc , after that purify coal transport to boiler house with the help of conveyor system.
• CONVEYOR SYSTEM:
A conveyor belt (or belt conveyor) consists of two or more pulleys, with a continuous loop of material - the conveyor belt - that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idle.
• FLOW DIGRAM:
Fig no.2
Coal system
B. DM PLANT(DEMINERALIZATION PLANT):
In this plant purification the row water to form mineral water by various techniques after that this water store in DM tank and this water use in boiler feed water.
• FLOW DIAGRAM:
Fig no.3
C. BOILER HOUSE:
A boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid exits the boiler for use in various processes or heating applications.
• Configurations:
Boilers can be classified into the following configurations:
"Pot boiler" or "Haycock boiler": a primitive "kettle" where a fire heats a partially-filled water container from below. 18th century Haycock boilers generally produced and stored large volumes of very low-pressure steam, often hardly above that of the atmosphere. These could burn wood or most often, coal. Efficiency was very low.
Fire-tube boiler. Here, water partially fills a boiler barrel with a small volume left above to accommodate the steam (steam space). This is the type of boiler used in nearly all steam locomotives. The heat source is inside a furnace or firebox that has to be kept permanently surrounded by the water in order to maintain the temperature of the heating surface just below boiling point. The furnace can be situated at one end of a fire-tube which lengthens the path of the hot gases, thus augmenting the heating surface which can be further increased by making the gases reverse direction through a second parallel tube or a bundle of multiple tubes (two-pass or return flue boiler); alternatively the gases may be taken along the sides and then beneath the boiler through flues (3-pass boiler). In the case of a locomotive-type boiler, a boiler barrel extends from the firebox and the hot gases pass through a bundle of fire tubes inside the barrel which greatly increase the heating surface compared to a single tube and further improve heat transfer. Fire-tube boilers usually have a comparatively low rate of steam production, but high steam storage capacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to those of the liquid or gas variety.
Water-tube boiler. In this type,the water tubes are arranged inside a furnace in a number of possible configurations: often the water tubes connect large drums, the lower ones containing water and the upper ones, steam and water; in other cases, such as a monotube boiler, water is circulated by a pump through a succession of coils. This type generally gives high steam production rates, but less storage capacity than the above. Water tube boilers can be designed to exploit any heat source and are generally preferred in high pressure applications since the high pressure water/steam is contained within small diameter pipes which can withstand the pressure with a thinner wall.
Flash boiler. A specialized type of water-tube boiler.
• Boiler fittings and accessories:
Safety valve: It is used to relieve pressure and prevent possible explosion of a boiler.
Water level indicators: They show the operator the level of fluid in the boiler, also known as a sight glass, water gauge or water column is provided.
Bottom blowdown valves: They provide a means for removing solid particulates that condense and lie on the bottom of a boiler. As the name implies, this valve is usually located directly on the bottom of the boiler, and is occasionally opened to use the pressure in the boiler to push these particulates out.
Continuous blowdown valve: This allows a small quantity of water to escape continuously. Its purpose is to prevent the water in the boiler becoming saturated with dissolved salts. Saturation would lead to foaming and cause water droplets to be carried over with the steam - a condition known as priming. Blowdown is also often used to monitor the chemistry of the boiler water.
Flash Tank: High pressure blowdown enters this vessel where the steam can 'flash' safely and be used in a low-pressure system or be vented to atmosphere while the ambient pressure blowdown flows to drain.
Automatic Blowdown/Continuous Heat Recovery System: This system allows the boiler to blowdown only when makeup water is flowing to the boiler, thereby transferring the maximum amount of heat possible from the blowdown to the makeup water. No flash tank is generally needed as the blowdown discharged is close to the temperature of the makeup water.
Hand holes: They are steel plates installed in openings in "header" to allow for inspections & installation of tubes and inspection of internal surfaces.
Steam drum internals, A series of screen, scrubber & cans (cyclone separators).
Low- water cutoff: It is a mechanical means (usually a float switch) that is used to turn off the burner or shut off fuel to the boiler to prevent it from running once the water goes below a certain point. If a boiler is "dry-fired" (burned without water in it) it can cause rupture or catastrophic failure.
Surface blowdown line: It provides a means for removing foam or other lightweight non-condensible substances that tend to float on top of the water inside the boiler.
Circulating pump: It is designed to circulate water back to the boiler after it has expelled some of its heat.
Feedwater check valve or clack valve: A non-return stop valve in the feedwater line. This may be fitted to the side of the boiler, just below the water level, or to the top of the boiler.
Top feed: A check valve (clack valve) in the feedwater line, mounted on top of the boiler. It is intended to reduce the nuisance of limescale. It does not prevent limescale formation but causes the limescale to be precipitated in a powdery form which is easily washed out of the boiler.
Desuperheater tubes or bundles: A series of tubes or bundles of tubes in the water drum or the steam drum designed to cool superheated steam. Thus is to supply auxiliary equipment that does not need, or may be damaged by, dry steam.
Chemical injection line: A connection to add chemicals for controlling feedwater pH..
• Steam accessories:
Main steam stop valve:
Steam traps:
Main steam stop/Check valve: It is used on multiple boiler installations.
Combustion accessories
Fuel oil system:
Gas system:
Coal system:
Soot blower
Other essential items
Pressure gauges:
Feed pumps:
Fusible plug:
Inspectors test pressure gauge attachment:
Name plate:
Registration plate:
Controlling draught
Most boilers now depend on mechanical draught equipment rather than natural draught. This is because natural draught is subject to outside air conditions and temperature of flue gases leaving the furnace, as well as the chimney height. All these factors make proper draught hard to attain and therefore make mechanical draught equipment much more economical.
There are three types of mechanical draught:
Induced draught: This is obtained one of three ways, the first being the "stack effect" of a heated chimney, in which the flue gas is less dense than the ambient air surrounding the boiler. The denser column of ambient air forces combustion air into and through the boiler. The second method is through use of a steam jet. The steam jet oriented in the direction of flue gas flow induces flue gasses into the stack and allows for a greater flue gas velocity increasing the overall draught in the furnace. This method was common on steam driven locomotives which could not have tall chimneys. The third method is by simply using an induced draught fan (ID fan) which removes flue gases from the furnace and forces the exhaust gas up the stack. Almost all induced draught furnaces operate with a slightly negative pressure.
Forced draught: Draught is obtained by forcing air into the furnace by means of a fan (FD fan) and ductwork. Air is often passed through an air heater; which, as the name suggests, heats the air going into the furnace in order to increase the overall efficiency of the boiler. Dampers are used to control the quantity of air admitted to the furnace. Forced draught furnaces usually have a positive pressure.
Balanced draught: Balanced draught is obtained through use of both induced and forced draught. This is more common with larger boilers where the flue gases have to travel a long distance through many boiler passes. The induced draught fan works in conjunction with the forced draught fan allowing the furnace pressure to be maintained slightly below atmospheric.
BOILER FLOW DIAGRAM:
Flow diagram
Fig no. 4
• Diagram of water tube boiler:
Fig no. 5
Water tube boiler
• Diagram of boiler:
Fig no. 6
Locomotive boiler
D. POWER HOUSE:
In this house generated the electrical energy from thermal energy ,and this electrical energy supply to various plant in industry.
• Flow diagram of steam:
Fig no. 7
Recycle
• Steam turbine:
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in 1884
Fig no.8
Turbine system
• Cooling tower:
Cooling towers are heat removal devices used to transfer process waste heat to the atmosphere. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or in the case of closed circuit dry cooling towers rely solely on air to cool the working fluid to near the dry-bulb air temperature. Common applications include cooling the circulating water used in oil refineries, chemical plants, power stations and building cooling. The towers vary in size from small roof-top units to very large hyperboloid structures (as in Image 1) that can be up to 200 metres tall and 100 metres in diameter, or rectangular structures (as in Image 2) that can be over 40 metres tall and 80 metres long. Smaller towers are normally factory-built, while larger ones are constructed on site. They are often associated with nuclear power plants in popular culture, although cooling towers are constructed on many types of buildings.
• categorization by air-to-water flow :
Crossflow
Crossflow is a design in which the air flow is directed perpendicular to the water flow (see diagram below). Air flow enters one or more vertical faces of the cooling tower to meet the fill material. Water flows (perpendicular to the air) through the fill by gravity. The air continues through the fill and thus past the water flow into an open plenum area. A distribution or hot water basin consisting of a deep pan with holes or nozzles in the bottom is utilized in a crossflow tower. Gravity distributes the water through the nozzles uniformly across the fill material.
Fig no.9
Counterflow
In a counterflow design the air flow is directly opposite to the water flow (see diagram below). Air flow first enters an open area beneath the fill media and is then drawn up vertically. The water is sprayed through pressurized nozzles and flows downward through the fill, opposite to the air flow.
Fig no. 10
Common to both designs:
The interaction of the air and water flow allow a partial equalization and evaporation of water.
The air, now saturated with water vapor, is discharged from the cooling tower.
A collection or cold water basin is used to contain the water after its interaction with the air flow.
Both crossflow and counterflow designs can be used in natural draft and mechanical draft cooling towers.
• Condenser (heat transfer):
In systems involving heat transfer, a condenser is a device or unit used to condense a substance from its gaseous to its liquid state, typically by cooling it. In so doing, the latent heat is given up by the substance, and will transfer to the condenser coolant. Condensers are typically heat exchangers which have various designs and come in many sizes ranging from rather small (hand-held) to very large industrial-scale units used in plant processes. For example, a refrigerator uses a condenser to get rid of heat extracted from the interior of the unit to the outside air. Condensers are used in air conditioning, industrial chemical processes such as distillation, steam power plants and other heat-exchange systems. Use of cooling water or surrounding air as the coolant is common in many condensers.
• Diagram of condenser
Fig no. 11
Condenser
• Rankine Cycle with Regeneration:
Our Purpose
In thermodynamic power cycles, an improvement of even 0.5% in overall cycle efficiency is an important gain. One of the more common ways to improve the efficiency of a steam cycle is to use regeneration, a process where heat is taken from steam between turbine stages and used to heat water as it goes through pump stages. Using CyclePad, we will modify a Rankine cycle and examine the effects of regeneration on the cycle's thermal efficiency.
The basic Rankine cycle
We will compare our regenerative cycle to a typical Rankine cycle. The Rankine cycle to which we will compare has the following parameters:
The operating limits are
• heater pressure of 5 MPa
• heater exit temperature of 400 C
• cooler pressure of 10 kPa
and its efficiencies are
• Carnot efficiency: 52.6%
• thermal efficiency: 36.2%
The regeneration cycle we examine will operate under the same limits. For reference, the Rankine cycle layout is shown below.
Fig no. 12
Rankine cycle
The Rankine Cycle with Rengeration
Improving cycle efficiencies
Improving cycle efficiency almost always involves making a cycle more like a Carnot cycle operating between the same high and low temperature limits. The Carnot cycle is maximally efficient, in part, because it receives all of its heat addition at the same temperature, which is the highest temperature in the cycle. Similarly, it rejects all of its heat at the same low temperature. The T-s diagram below details the working of a Carnot cycle operating between the same temperature limits as our Rankine cycle.
Fig no 13.1 Carnot cycle T-s diagram
Most cycles don't have all of their heat addition or rejection at one temperature. So, when we look to improve a cycle's efficiency, we often consider the mean temperature of heat addition, Ta and the mean temperature of heat rejection, Tr. These reflect what the temperature would have been if the same amount of heat had been added (or rejected) all at one temperature. They allow us to treat improving cycle efficiencies as we would for a Carnot cycle: by raising Ta or lowering Tr. For reversable heat transfer, the average temperature of heat addition is
Ta = Qin / S
and the average temperature of heat rejection is
Tr = Qout / S
For more efficient cycles, we would like to add heat at a higher temperature and reject it at a lower temperature.
Fig no.13.2
Rankine cycle T-s diagram
• Diagramofcentrifugalpump
Fig no. 14
C pump
4. GARAGE SHOP
garage shop is that section of industry where all kind of industrial vehicles are repaired. It may be a organizations personal’s vehicles such as;
1.Crane
2.lifter
3.loader
4.jeep
5.ambassader
6.rock breaker
7.truck
8.van
9.ambulance
10.gipsy ambulance
11.fire fighter
12.dumper
13.drawer
At hcl moubhander.
• IN TRAINING PERIOD WORK IN GARAGE REPAIR THE BREAKER BODY UNIT:
Name of component:
1.through bolt
2.swivel adapter
3.back head
4.valve group
5.cylinder group
6.accumulater group
7.piston
8.front head group
9.front cover
10. rod
Fig no.15
Breaker unit
Some data :
Per day expense of diesel 180 ltr approx.
Total no, of man power in garage -33
No . of driver 14
No. of mechanics 19
• Assembly of breaker body unit:
fig no.16
Break unit parts
5. WATER TREATMENT PLANT
The water treatment plant function are to purify the water drawn from the river. The river water contains many impurities just as dust ,minerals, acids, hardness etc that is not suitable for drinking or other use in industry ie means bowler house , cooling system. The plant removes all unhygienic materials and preparesfor use.
• Process and flow digram:
Fig no. 17
• WATER QUALITY AND ITS CONSUMPTION
Water and its Quality :
Water is colorless, tasteless, and odorless. It is an excellent solvent that can dissolve most minerals that come in contact with it. Therefore, in nature, water always contains chemicals and biological impurities i.e. suspended and dissolved inorganic and organic compounds and micro organisms. These compounds may come from natural sources and leaching of waste deposits. However, Municipal and Industrial wastes also contribute to a wide spectrum of both organic and inorganic impurities. Inorganic compounds, in general, originate from weathering and leaching of rocks, soils, and sediments, which principally are calcium, magnesium, sodium and potassium salts of bicarbonate, chloride, sulfate, nitrate, and phosphate. Besides, lead, copper, arsenic, iron and manganese may also be present in trace amounts. Organic compounds originate from decaying plants and animal matters and from agricultural runoffs, which constitute natural humic material to synthetic organics used as detergents, pesticides, herbicides, and solvents. These constituents and their concentrations.
• SOFTANIC PLANT:
In this plant remove the hardness from the raw water by various treatment.
TSS type hardness remove
TSS- total suspended solid.
• Flow diagram:
Fig no. 18
Flow diagram
6. FLASH SMELTER
Flash smelting (Finnish: Liekkisulatus) is a smelting process for sulfur-containing ores including chalcopyrite. The process was developed by Outokumpu in Finland and first applied at theHarjavalta plant in 1949 for smelting copper ore. It has also been adapted for nickel and lead production.The process uses the autogenic principle by using the energy contained in the sulfur and iron for melting the ore. In the process dried and powdered ore is discharged from a nozzle into a fluidized bed reactor fed with oxygen. The reduced metal melts, and drops to the bottom of a settling chamber. The flotation produces a large effective surface area of fine-grained concentrate particles. The process makes smelting more energy efficient and environmentally friendly. Sulfur is released mainly in its solid form, thus reducing atmospheric pollution.The process is today used for 50% of the world’s primary copper production. The other 50% is mainly produced from oxide ores, where the process cannot be applied.
• Copper extraction techniques:
Copper extraction techniques refers to the methods for obtaining copper from its ores. This conversion consists of a series of chemical, physical, and electrochemical processes. Methods have evolved and vary with country depending on the ore source, local environmental regulations, and other factors.
As in all mining operations, the ore must usually be beneficiated (concentrated). To do this, the ore is crushed Then it must be roasted to convert sulfides to oxides, which are smelted to produce matte. Finally, it undergoes various refining processes, the final one being electrolytic. For economic and environmental reasons, many of the byproducts of extraction are reclaimed. Sulfur dioxide gas, for example, is captured and turned into sulfuric acid — which is then used in the extraction process.
• Concentration
Most copper ores contain only a small percentage of copper metal bound up within valuable ore minerals, with the remainder of the ore being unwanted rock or gangue minerals, typically silicate minerals or oxide minerals for which there is often no value. The average grade of copper ores in the 21st century is below 0.6% Cu, with a proportion of ore minerals being less than 2% of the total volume of the ore rock. A key objective in the metallurgical treatment of any ore is the separation of ore minerals from gangue minerals within the rock.
The first stage of any process within a metallurgical treatment circuit is accurate comminution, where the rock is crushed to produce small particles (<100 μm) consisting of individual mineral phases. These particles are then separated to remove gangue, thereafter followed by a process of physical liberation of the ore minerals from the rock. The process of liberation of copper ores depends upon whether they are oxide or sulfide ores.[1]
Subsequent steps depends on the nature of the ore containing the copper. For oxide ores, a hydrometallurgical liberation process is normally undertaken, which uses the soluble nature of the ore minerals to the advantage of the metallurgical treatment plant. For sulfide ores, both secondary (supergene) and primary (unweathered), froth flotation is used to physically separate ore from gangue. For special native copper bearing ore bodies or sections of ore bodies rich in supergen native copper, this mineral can be recovered by a simple gravity circuit.Most copper ores contain only a small percentage of copper metal bound up within valuable ore minerals, with the remainder of the ore being unwanted rock or gangue minerals, typically silicate minerals or oxide minerals for which there is often no value. The average grade of copper ores in the 21st century is below 0.6% Cu, with a proportion of ore minerals being less than 2% of the total volume of the ore rock. A key objective in the metallurgical treatment of any ore is the separation of ore minerals from gangue minerals within the rock.
The first stage of any process within a metallurgical treatment circuit is accurate comminution, where the rock is crushed to produce small particles (<100 μm) consisting of individual mineral phases. These particles are then separated to remove gangue, thereafter followed by a process of physical liberation of the ore minerals from the rock. The process of liberation of copper ores depends upon whether they are oxide or sulfide ores.[1]
Subsequent steps depends on the nature of the ore containing the copper. For oxide ores, a hydrometallurgical liberation process is normally undertaken, which uses the soluble nature of the ore minerals to the advantage of the metallurgical treatment plant. For sulfide ores, both secondary (supergene) and primary (unweathered), froth flotation is used to physically separate ore from gangue. For special native copper bearing ore bodies or sections of ore
• Oxide ores:
Oxidised copper ore bodies may be treated via several processes, with hydrometallurgical processes used to treat oxide ores dominated by copper carbonate minerals such as azurite and malachite, and other soluble minerals such as silicates like chrysocolla, or sulfates such as atacamite and so on.
Such oxide ores are usually leached by sulfuric acid, usually in a heap leaching or dump leaching process to liberate the copper minerals into a solution of sulfuric acid laden with copper sulfate in solution. The copper sulfate solution (the pregnant leach solution) is then stripped of copper via a solvent extraction and electrowinning (SX-EW) plant, with the barred sulfuric acid recycled back on to the heaps. Alternatively, the copper can be precipitated out of the pregnant solution by contacting it with scrap iron; a process called cementation. Cement copper is normally less pure than SX-EW copper. Commonly sulfuric acid is used as a leachant for copper oxide, although it is possible to use water, particularly for ores rich in ultra-soluble sulfate minerals.[citation needed]
In general, froth flotation is not used to concentrate copper oxide ores, as oxide minerals are not responsive to the froth flotation chemicals or process (i.e.; they do not bind to the kerosene-based chemicals). Copper oxide ores have occasionally been treated via froth floatation via sulfidation of the oxide minerals with certain chemicals which react with the oxide mineral particles to produce a thin rime of sulfide (usually chalcocite), which can then be activated by the froth flotation plant.
Chalcopyrite
CuFeS2 34.5
Chalcocite
Cu2S
79.8
Covellite
CuS
66.5
Bornite
2Cu2S•CuS•FeS 63.3
Tetrahedrite
Cu3SbS3 + x(Fe,Zn)6Sb2S9 32–45
• Froth flotation:
Froth flotation cells to concentrate copper and nickel sulfide minerals, Falconbridge, Ontario.
The modern froth flotation process was independently invented the early 1900s in Australia by C.V Potter and around the same time by G. D. Delprat.
Copper sulfide loaded air bubbles on a Jameson cell at the flotation plant of theProminent Hill mine in South Australia
All primary sulfide ores of copper sulfides, and most concentrates of secondary copper sulfides (being chalcocite), are subjected to smelting. Some vat leach or pressure leach processes exist to solubilise chalcocite concentrates and produce copper cathode from the resulting leachate solution, but this is a minor part of the market.
Carbonate concentrates are a relatively minor product produced from copper cementation plants, typically as the end-stage of a heap-leach operation. Such carbonate concentrates can be treated by a SX-EW plant or smelted.
The copper ore is crushed and ground to a size such that an acceptably high degree of liberation has occurred between the copper sulfide ore minerals and the gangue minerals. The ore is then wet, suspended in a slurry, and mixed with xanthates or other reagents, which render the sulfide particles hydrophobic. Typical reagents includepotassium ethylxanthate and sodium ethylxanthate, but dithiophosphates and dithiocarbamates are also used.
The treated ore is introduced to a water-filled aeration tank containing surfactant such as methylisobutyl carbinol(MIBC). Air is constantly forced through the slurry and the air bubbles attach to the hydrophobic copper sulfide particles, which are conducted to the surface, where they form a froth and are skimmed off. These skimmings are generally subjected to a cleaner-scavenger cell to remove excess silicates and to remove other sulfide minerals that can deleteriously impact the concentrate quality (typically, galena), and the final concentrate sent for smelting. The rock which has not floated off in the floatation cell is either discarded as tailings or further processed to extract other metals such as lead (from galena) and zinc (from sphalerite), should they exist. To improve the process efficiency, lime is used to raise the pH of the water bath, causing the collector to ionize more and to preferentially bond to chalcopyrite (CuFeS2) and avoid the pyrite (FeS2). Iron exists in both primary zone minerals. Copper ores containing chalcopyrite can be concentrated to produce a concentrate with between 20% and 30% copper-in-concentrate (usually 27–29% Cu); the remainder of the concentrate is iron and sulfur in the chalcopyrite, and unwanted impurities such as silicate gangue minerals or other sulfide minerals, typically minor amounts ofpyrite, sphalerite or galena. Chalcocite concentrates typically grade between 37% and 40% copper-in-concentrate, as chalcocite has no iron within the mineral.
• Roasting
In the roaster, the copper concentrate is partially oxidised to produce "calcine" and sulfur dioxide gas. The stoichiometry of the reaction which occurs is:
2 CuFeS2 + 3 O2 → 2 FeO + 2 CuS + 2 SO2
As of 2005, roasting is no longer common in copper concentrate treatment. Direct smelting is now favored, e.g. using the following smelting technologies;flash smelting, Noranda, ISASmelt, Mitsubishi or El Teniente furnaces.
Smelting
The calcine is then mixed with silica and coke and smelted at 1200 °C (in an exothermic reaction) to form a liquid called "copper matte". The high temperature allows reactions to proceed rapidly, and allow the matte and slag to melt, so they can be tapped out of the furnace. In copper recycling, this is the point where scrap copper is introduced.
Several reactions occur.
Iron oxides and sulfides are converted to slag, a less dense molten mass that is floated off the matte. The reactions for slag formation is:
FeO(s) + SiO2(s) → FeSiO3 (l)
In a parallel reaction the iron sulfide is converted to slag:
2 FeS(l) + 3 O2 + 2 SiO2 (l) →2 FeSiO3(l) + 2 SO2(g)
.
• Conversion to blister
The matte, which is produced in the smelter, contains around 70% copper primarily as copper sulfide as well as iron sulfide. The sulfur is removed at high temperature as sulfur dioxide by blowing air through molten matte:
2 CuS + 3 O2 → 2 CuO + 2 SO2
CuS + O2 → Cu + SO2
In a parallel reaction the iron sulfide is converted to slag:
2 FeS + 3 O2 → 2 FeO + 2 SO2
2 FeO + 2 SiO2 → 2 FeSiO3
The purity of this product is 98%, it is known as blister because of the broken surface created by the escape of sulfur dioxide gas as the copper ingots are cast. By-products generated in the process are sulfur dioxide and slag.
• Reduction:
The blistered copper is put into an anode furnace (a furnace that uses the blister copper as anode) to get rid of most of the remaining oxygen. This is done by blowing natural gas through the molten copper oxide. When this flame burns green, indicating the copper oxidation spectrum, the oxygen has mostly been burned off. This creates copper at about 99% pure. The anodes produced from this are fed to the electrorefinery.
• DIAGRAM OF CONVERTER:
Fig no. 19
Converter
7.CHEMICAL MAINTENCE PLANT
In CPM all pumps,punching machine etc all mechanical device maintence various plant under cpm.
They are :
A.tank house
B. acid plant
A.TANK HOUSE:
In tank house refinery the copper anode and formation the cathode anode.
The tank house consists of :
1. Refinery plant
2. Purification plant
3. Copper sulphate plant
4. Nikel sulphate plant
1.Refinery plant:
The copper is refined by electrolysis. The anodes cast from processed blister copper are placed into an aqueous solution of 3–4% copper sulfate and 10–16% sulfuric acid. Cathodes are thin rolled sheets of highly pure copper. A potential of only 0.2–0.4 volts is required for the process to commence. At the anode, copper and less noble metals dissolve. More noble metals such as silver and gold as well as seleniumand tellurium settle to the bottom of the cell as anode slime, which forms a saleable byproduct. Copper(II) ions migrate through the electrolyte to the cathode. At the cathode, copper metal plates out but less noble constituents such as arsenic and zinc remain in solution.[2] The reactions are:
At the anode: Cu(s) → Cu2+(aq) + 2e–
At the cathode: Cu2+(aq) + 2e– → Cu(s)
• Concentrate and copper marketing
Copper concentrates produced by mines are sold to smelters and refiners who treat the ore and refine the copper and charge for this service via treatment charges (TCs) and refining charges (RCs). The TCs are charged in US$ per tonne of concentrate treated and RCs are charged in cents per pound treated, denominated in US dollars, with benchmark prices set annually by major Japanese smelters. The customer in this case can be a smelter, who on-sells blister copper ingots to a refiner, or a smelter-refiner which is vertically integrated.
The typical contract for a miner is denominated against the London Metal Exchange price, minus the TC-RCs and any applicable penalties or credits. Penalties may be assessed against copper concentrates according to the level of deleterious elements such as arsenic, bismuth, lead or tungsten. Because a large portion of copper sulfide ore bodies contain silver or gold in appreciable amounts, a credit can be paid to the miner for these metals if their concentration within the concentrate is above a certain amount. Usually the refiner or smelter charges the miner a fee based on the concentration; a typical contract will say a credit is due for every ounce of the metal in concentrate above a certain concentration; below that if it is recovered the smelter will keep the metal and sell it to defray costs.
Copper concentrate is traded either via spot contracts or under long term contracts as an intermediate product in its own right. Often the smelter sells the copper metal itself on behalf of the miner. The miner is paid the price at the time that the smelter-refiner makes the sale, not at the price on the date of delivery of the concentrate. Under a Quotational Pricing system, the price is agreed to be at a fixed date in the future, typically 90 days from time of delivery to the smelter.
A-grade copper cathode is of 99.999% copper in sheets that are 1 cm thick, and approximately 1 meter square weighing approximately 200 pounds. It is a true commodity, deliverable to and tradeable upon the metal exchanges in New York (COMEX), London (London Metals Exchange) and Shanghai (Shanghai Futures Exchange). Often copper cathode is traded upon the exchanges indirectly via warrants, options, or swap contracts such that the majority of copper is traded upon the
• FLOW DIGRAM OF TANK HOUSE:
FIG NO. 20
AT THE END THIS BLACK COLOUR TYPE DRY POWDER STORE IN P.M.R PLANT AND SELLING TO OTHER COUNTRY..
B.ACID PLANT:
In this plant formation of conc H2So4 and selling them.
Flow diagram:
Fig no.21
Acid plant
• Diagram Tank house :
Fig no.22
Tank house
• 99% pure copper cathode:
Fig no 23
Copper plate
8. MACHINE SHOP
a cutting tool (or cutter) is any tool that is used to remove material from the workpiece by means of shear deformation. Cutting may be accomplished by single-point or multipoint tools. Single-point tools are used in turning, shaping, plaining and similar operations, and remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny chip.
Cutting tools must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal-cutting process. Also, the tool must have a specific geometry, with clearance angles designed so that the cutting edge can contact the workpiece without the rest of the tool dragging on the workpiece surface. The angle of the cutting face is also important, as is the flute width, number of flutes or teeth, and margin size. In order to have a long working life, all of the above must be optimized, plus the speeds and feeds at which the tool is run.
• Materials:
To produce quality parts, a cutting tool must have three characteristics:
• Hardness — hardness and strength at high temperatures.
• Toughness — toughness, so that tools don’t chip or fracture.
• Wear resistance — having acceptable tool life before needing to be replaced.[2]
Cutting tool materials can be divided into two main categories: stable and unstable.
Unstable materials (usually steels) are substances that start at a relatively low hardness point and are then heat treated to promote the growth of hard particles (usually carbides) inside the original matrix, which increases the overall hardness of the material at the expense of some its original toughness. Since heat is the mechanism to alter the structure of the substance and at the same time the cutting action produces a lot of heat, such substances are inherently unstable under machining conditions.
Stable materials (usually tungsten carbide) are substances that remain relatively stable under the heat produced by most machining conditions, as they don't attain their hardness through heat. They wear down due to abrasion, but generally don't change their properties much during use.
Most stable materials are hard enough to break before flexing, which makes them very fragile. To avoid chipping at the cutting edge, most tools made of such materials are finished with a sightly blunt edge, which results in higher cutting forces due to an increased shear area. Fragility combined with high cutting forces results in most stable materials being unsuitable for use in anything but large, heavy and stiff machinery.
Unstable materials, being generally softer and thus tougher, generally can stand a bit of flexing without breaking, which makes them much more suitable for unfavorable machining conditions, such as those encountered in hand tools and light machinery.
• Types of tools:
Broom •Brush •Feather duster •Ice resurfacer •Floor buffer •Hataki •Mop •Mop bucket cart •Office cleaning cart •Pipe cleaner •Sponge •Squeegee •Steam mop •Tawashi •VCleaning tools
acuum cleaner
Cutting and
abrasive tools
Blade •Bolt cutter •Broach •Ceramic tile cutter •Chisel •Coping saw •Countersink •Diamond blade •Diamond tool •Draw knife •Drill bit •Emery cloth •File •Fretsaw •Froe •Glass cutter •Grater •Grinding wheel •Hand saw •Knife •Miter saw •Nail clipper •Pipecutter •Plane •Rasp •Razor •Reamer •Sandpaper •Saw •Scalpel •Scissors •Steel wool •Surform •Switchblade •Utility knife •Water jet cutter •Wire brush •Wire cutter •Wire stripper
Garden tools
Adze •Axe •Billhook •Bow saw •Chainsaw •Cultivator •Earth auger •Edger •Garden fork •Garden hose •Garden trowel •Hatchet •Hedge trimmer •Hoe •Hori hori •Irrigation sprinkler •Lawn aerator •Lawn mower •Lawn sweeper •Leaf blower •Loppers •Loy •Machete •Mattock •Pickaxe •Pitchfork •Plough (plow) •Post hole digger •Pruning shears (secateurs) •Rake •Roller •Rotary tiller •Scythe •Shovel •Sickle •Slasher •Spade •Splitting maul •String trimmer
Hand tools
Block plane •BNC inserter/remover •Brace •Bradawl •Breaker bar •Card scraper •Cat's paw •Caulking gun •Clamp •Crimping pliers •Crowbar •Grease gun •Fish tape •Hammer •Hand truck •Hawk •Hex key •Jack •Lug wrench •Locking pliers •Mallet •Mitre box •Monkey wrench •Nut driver •Paint roller •Paintbrush •Pipe wrench •Pliers •Punch •Punch down tool •Putty knife •Ratchet •Sink wrench •Scratch awl •Screwdriver •Sledgehammer •Socket wrench •Spike maul •Staple gun •Stitching awl •Strap wrench •Tire iron •Torque wrench •Trowel •Upholstery hammer •Wrench (spanner)
Machine and
Metalworking tools
Automatic lathe •Ball-peen hammer •Broaching machine •Drill press •Endmill •English wheel •Gear shaper •Grinding machine •Hacksaw •Hobbing machine •Jig borer •Lathe •Metalworking lathe •Milling cutter •Milling machine •Planer •Plasma cutter •Screw machine •Shaper •Tap and die •Thread restorer •Tool bit •Turret lathe •Welder
Measuring and
alignment tools
Architect's scale •Beam compass •Caliper •Chalk box •Compass •Engineer's scale •Flexible curve •Jig •Laser level •Laser line level •Laser measuring tool •Micrometer •Plumb-bob •Protractor •Ruler •Scale •Sliding T bevel •Spirit level •Square •Straightedge •Tape measure •Template
Power tools
Angle grinder •Bandsaw •Belt sander •Blow torch •Chop saw •Circular saw •Concrete saw •Crusher •Cutting torch •Die grinder •Drill •Glue gun •Heat gun •Impact wrench •Jackhammer •Jigsaw •Jointer •Nail gun •Needlegun scaler •Power trowel •Radial arm saw •Random orbital sander •Reciprocating saw •Rotary tool •Router table •Sander •Scroll saw •Soldering gun •Soldering iron •Steam box •Table saw •Thickness planer •Wood router •Wood shaper.
• PARTS OF LATHE:
FIG NO 24
Parts of lathe
• SEPECIFICATION OF LATHE;
Head Stfff
Technical Specifications
Model No NL 6mm NL 8mm NL 10mm NL 12Amm NL 12Bmm NL 12Cmm
Length of Bed 6ft/1828mm 8ft/2438mm 10ft/3048mm 12ft/3657mm 12ft/3657mm 12ft/3657mm
Width of Bed 14inch/350mm 16inch/400mm 18inch/450mm 20inch/500mm 22inch/550mm 24inch/600mm
Height of Center 12inch/300mm 14inch/350mm 16inch/400mm 18inch/450mm 20inch/50mm 22inch/550mm
Swing over Slide 17inch/430mm 21inch/533mm 25inch/635mm 29inch/736mm 31inch/787mm 34inch/863mm
Swing in Gap 36inch/914mm 40inch/1016mm 44inch/1117mm 54inc/1370mm 56inch/1422mm 58inch/1473mm
Admit Between Centers 33inch/838mm 54inch/1371mm 78inch/1980mm 95inch/2413mm 95inc/2413mm 93inch/2363mm
Table no. 1/fig no 25
• Sepecification of boring machine:
i
Fig no. 26
Technical Specifications
Model No NHB 65 NHB 80 NHB 100 NHB 110 NHB 125 NHB 130
Alloy Steel Work Spindle Hardened & Ground-Diameter 65 80 100 110 125 130
Morse Taper Number 4 5 6 6 6 6
Max. Longitudinal Movements of Working Spindle 410 510 510 510 600 600
Number of Spindle Speeds 9 9 9 9 9 9
Range of Spindle Speeds – R.P.M. 20 to 300 15 to 300 15 to 300 15 to 250 15 to 250 15 to 250
Longitudinal Work Spindle Feeds Nos. 9 9 9 9 9 9
Max. Height of the Spindle Axis from Table Surface 800 925 1000 1100 1200 1300
Min. Height of the Spindle Axis from Table Surface 20 25 30 30 30 30
Dimensions of the Rotary Table 840*1050 900*1105 1030*1375 1100*1450 1220*1675 1220*1675
Longitudinal table Traverse 1500 1625 1775 1925 2050 3000
Long. Table Traverse Feeds (Including one Rapid) 10 10 10 10 10 10
Transversal Table Travel Feeds (Including one Rapid) 10 10 10 10 10 10
Vertical Head Stock Travel Feeds (Including one Rapid) 4 4 4 4 10 10
Rotary Table Automatic Feeds (Including one Rapid) Nil 10 10 10 10 10
.Max. Cross Movement of the Table 910 1000 1100 1300 1500 2000
Max. Distance between Stay Bearing & Facing Head 2150 2400 2690 2800 2950 2950
Facing Head Diameter 450 505 555 600 650 650
Weight Approx. in Kgs. 7000 8500 9500 11000 13500 15000
Table no.2
• Sepecification of slotting machine:
Fig no.27
Slotting machine
Specifications
Model SSM-125 SSM-150 SSM-200 SSM-250 SSM-300 SSM-375 SSM-450 SSM-500
Working Stroke 125 150 200 250 300 375 450 500
Length of Ram 200 560 560 735 810 900 1300 1300
Vertical Adjustment of Ram 90 150 150 250 300 300 325 325
Center of Cutting Tools of Col 165 250 250 380 455 550 750 750
Working Surface of Table 200 280 280 355 500 600 900 900
Longitudinal Transverse of Table 165 250 250 300 530 530 800 800
Bore of Base 28 38 38 75 75 75 100 100
Cross Transverse of Table 215 250 250 300 455 500 600 600
Table Top to Tam 200 330 330 380 400 525 700 700
No. of Speeds 2 2 2 2 4 4 6 6
Range of Speeds 90-170 60-150 60-150 46-70 20-70 20-70 20-70 20-70
Table no.3
• Specification of hacksaw machine:
Fig no. 28
Hacksaw machine
Technical Specifications
Model M-175 M-200 M-250 M-300 M-350 M-400 M-500 M-600
Cap. Of Round Bar 175 200 250 300 350 400 500 600
Cap of Square Bar 125 150 200 250 275 325 350 425
Stroke 135 135 140 140 140 135 150 150
Stroke per min. (approx) 100-120 100-120 85-100 85-100 85-100 70-85 70-85 70-85
Blade size 12”-14” 14”-16” 16”-18” 18”-20” 20”-22” 22”-24” 24”-32” 30”-36”
Electric Motor 1H.P. 1H.P. 2H.P. 2H.P. 2H.P. 3H.P. 5H.P. 5H.P.
RPM of Motor 1440 1440 1440 1440 1440 1440 960 960
Length 1000 1000 1150 1250 1300 1500 1650 1750
Width 600 600 625 650 650 675 700 725
Height 800 800 1000 1000 1100 1200 1300 1400
Weight (approx) 325Kg. 335Kg. 450Kg. 550Kg. 650Kg. 750Kg. 1100Kg. 1200Kg.
Weight with Packing 400Kg. 450Kg. 550Kg. 650Kg. 775Kg. 900Kg. 1300Kg. 1400Kg.
V-Belts Required 4Pcs. 4Pcs. 4Pcs. 4Pcs. 4Pcs. 5Pcs. 6Pcs. 6Pcs.
Table no.4
• Specification of shaper machine:
Fig no. 29
Technical Specifications
Model No NSM 24 NSM 30 NSM 36 NSM 40
Length of ram stroke 660 800 930 1025
Length of ram 1225 1600 1750 1900
Width of ram 300 300 300 330
Max. Distance from table to ram 450 520 560 600
Min. Distance from table to ram 50 50 60 60
Vertical travel of tool slide 140 160 185 200
Swiveling range of tool on either side 60 degree 60 degree 60 degree 60 degree
Table size 610 * 380 760 * 400 900 * 450 1015*508
Horizontal travel of Table 600 700 810 940
Vertical travel of Table 350 430 500 550
Nos. of speeds 4 4 4 4
Table no. 5
• Specification of planner machine:
-
Fig no. 30
Technical Specifications
Model No NP 8 NP 10 NP 12 NP 14 NP 16 NP 18 NP 20 NP 22 NP 24 NP 26 NP 28 NP 30
Size ft. mm 8' 2438 10' 3048 12' 3657 14' 4267 16' 4876 18' 5486 20' 6096 22' 6705 24' 7315 26' 7925 28' 8535 30' 9144
Length of Bed V'S ft. mm 12' 3657 15' 4572 18' 5486 21' 6400 24' 7315 27' 8229 30' 9144 33' 10059 36' 10973 39' 11887 42' 12802 45' 13716
Length of bed all over ft. mm 13 3962 16 4877 19 5791 22 6705 25 7620 28 8534 31 9449 34 10364 37 11278 40 12192 43 13107 46 14021
Stroke of table ft. mm 8 2428 10 3048 12 3657 14 4267 16 4876 18 5486 20 6096 22 6705 24 7315 26 7925 28 8535 30 9122
Length of table all over ft. mm 9 2743 11 3553 13 3962 15 4572 17 5181 19 5791 21 6401 23 7010 25 7620 27 8230 29 8840 31 9449
Thickness of Table inch mm 7-1/2 190 7-1/2 190 7-1/2 190 9 225 9 225 9 225 9 225 9 225 9 225 9 225 9 225 9 225
Planning Width ft. mm 4 1219 4-1/2 1371 5 1524 5-1/2 1676 6-1/4 1905 6-1/4 1905 6-1/2 1981 6-1/2 1981 6-1/2 1981 6-1/2 1981 6-1/2 1981 6-1/2 1981
Height under cross rail ft. mm 40 1219 4-1/2 1371 4-1/2 1371 5 1524 5 1524 5 1524 5 1524 5 1524 5 1524 5 1524 5 1524 5 1524
Table no.6
9.RESULT
The final result of hindustan copper limited is to prepared copper cathod by the electrolysis process upto 99% pure.
• Its byproduct are:
1.cuso4(copper sulphate)
2.niso4(nikel sulphate)
3.au (gold)
4.silver
10. CONCLUSION
The final product is copper upto 99% pure is found but during this purification process nither any particals are wasted nor damaged
We found that during whole process the four other byproduct are formed
So we can say that it is a best unit for extarction of copper&we can say that the byproduct ara vary costly as compare to main product which show the high economical condition of hindustan copper limited(ghatsila,jharkhand).
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