Complete Technology Handbook on Mining, Quarrying, Mineral and Ore Processing, Coal, Iron Ore, Limestone, Chromite, Graphite, Gold, Granite and other Mining Projects with Profiles

Complete Technology Handbook on Mining, Quarrying, Mineral and Ore Processing, Coal, Iron Ore, Limestone, Chromite, Graphite, Gold, Granite and other Mining Projects with Profiles

Book contain chapters on Coal Mining, Limestone Mining, Granite Mining, Rock Mining and Crushing, Graphite Mining, Gold Mining, Gypsum Mining, Copper Mining, Smelting and Refining, Potash Mining, Green Metallurgical Processing of Chromite and Applications, Processing of Alumina- Rich Indian Iron Ore Slime, Conversion of a Waste to a High Valued Product, Definitions and Properties of Limes, Analytical Testing of Limestone and Lime, Limestone Processing Technology, Lime Manufacturing Process, Silica Ramming Mass (Acidic Ramming Mass), Ferrosilicon (Ferro silicon), Limestone Quarrying and Processing Operations, Conveyor Idlers and Other Mining Equipment and Accessories, Stone Crushing Unit, Beneficiation of Chromite Ore Processing Charge Chrome, Emery Stone, Iron Ore Mining and Processing, Calcined Petroleum Coke Rotary/ Horizontal Kiln Based), Calcined Petroleum Coke (Vertical Shaft Kiln Based), Megnesium Metal, Iron Ore Pelletization Plant, Cobalt Carbonate from Ore, Concentrated Manganese Ore Production Granite Tiles Cutting and Polishing, Plant Economics of Benefication of Graphite Ore (Capacity: 1000 Ton/Per Month), Plant Economics of Chrome Beneficiation Plant (Beneficiation of Chromite Ore Processing Charge Chrome), Plant Economics of Gold Mining, Plant Economics of Granite Mine, Plant Economics of Graphite Mining and Benification Plant, Plant Economics of Hydrated Lime, Plant Economics of Iron Ore Mining and Manufacting of Sponge Iron, Plant Economics of Iron Ores Pelletization Plant, Plant Economics of Lime Stone Mining, Plant Economics of Lime Stone Powder (Grinding), Plant Economics of Marble Quarrying, Plant Economics of Open Cast Mining of Chrome Ore, Plant Economics of Quick Lime/Slaked Lime, Plant Economics of Stone Mining, Plant Economics of Stone Quarry.

Contents-cum-Index

Chapter 1

Coal Mining

Processing coal

Transporting coal

The Coal Mining Life Cycle

Exploration

Mine development

Open-pit mining

Underground mining

Ventilation

Monitoring and control

Haulage

Coal preparation

Transporting

Rehabilitation

Safety in Coal mines

Safety Policy of CIL

Statutory Framework for Coal Mine Safety

Major Activities for Safety & Rescue Division

Mechanism for monitoring of mine environment:

Strengthening Water Danger Management

Steps for prevention accidents in OCPs:

Steps for control of dust in mines

Training on Mine Safety:

Other steps for enhancing Safety awareness

Mine Safety Inspection

Mine Emergency Response System

Rescue Services for Emergency Response System in CIL:

Safety measures at NLCIL

Safety and R&D Initiatives

Usage of Drones

Electronification of Ground Water Control and Conveyor System

Emergency response System

Safety Trainings

Occupational Health services

Chapter 2

Limestone Mining

Source of Limestone

Status Quo of Limestone Mining and Utilization

Low resource utilization

The scale of the mine is small and the mining technology is backward

Application of Limestone

Production process

Uses of Limestone

Relation to Mining

Surface Limestone Mining

Underground Limestone Mining

Future of limestone mining

Strong growth for cement in construction industry

Increasing demand of GCC and PCC in packaging industry

Exploration

Extraction

Processing

Crushing and washing

Classifying

Calcination

Environmental Impact of Limestone Mining

Chapter 3

Granite Mining

Type

Rock

Description

Relation to Mining

Uses

Stages of the Extraction Process in a Granite Quarry

Geological Study and Prospecting

Transport Development and Initial Loading

Initial Extraction

Granite Extraction

Block Cutting and Lifting

Cleaning and Waste Transport

Environmental and Social Considerations

Granite product quality control at granite factories

Checking granite quality

Packing and Delivery of final products

Chapter 4

Rock Mining and Crushing

Primary Crushing

Secondary Crushing

Tertiary/Quaternary/Final Reduction Crushing

Types of Rock Crushers

Jaw Crushers

Types of Jaw Crushers

Gyratory Crushers

Cone Crushers

Types of Cone Crushers

Portable vs. Stationary Crushing Plants

Impact Crushers

Types of Impact Crushers

High Quality Mobile Stone Crusher Rock Gold Mining Crusher

Mobility and Portability

Components and Features

Benefits of Mobile Crushing Plants

Advanced Technologies

Process of stone crushing production line

Stone crushing plant

Stone crushing plant machinery equipment

Mobile stone crusher plant

Chapter 5

Graphite Mining

Structure of Graphite

Properties of Graphite

Physical Properties of Graphite

Types of Graphite

Uses of Graphite

Types Of Graphite Extraction

Open Pit Mining

Underground Mining

Important Facts About Graphite

Modern Manufacture

Graphite Processing Equipment

Graphite Vertical Stirring Mill

Flotation Cell

03XC3 Hydrocyclone

Thickener

Drum Dryer

Agent Agitation Tank

XHGY-B Series Numerical Control Agent Feeder

Chamber Filter Press

Chapter 6

Gold Mining

Introduction

Overview of the gold mining industry in India

Gold reserves and resources in India

Gold Mines in India: India’s First Private Gold Mine to Commence Full-Scale Production

Gold Discoveries in Three Odisha Districts

Karnataka Gold Mines

Kolar Gold Fields

Jharkhand Gold Mines

Uttar Pradesh Gold Mines

Mine Production

Producer Hedging

The Lifecycle of a Gold Mine

Gold Mine Exploration: 1-10 years

Gold Mine Development: 1-5 years

Gold Mining Operation: 10-30 years

Gold Mine Closure and Decommissioning: 1-5 years

Gold Mine Reclamation and Post-Closure

Digital Transformation of Gold Mining Operations

Role of data to optimize Gold Operations

Digital Platforms and Technologies

Benefits

Environmental Impacts of Gold Mining

Poisoned Waters

The Biggest Polluters:

Chapter 7

Gypsum Mining

Introduction

Common Uses

Classification of Gypsum

How is Gypsum Formed

Distribution of Gypsum

Gypsum production process

Gypsum production line

Basic stages in gypsum processing

Gypsum Production Processed

Environmental Impact of Gypsum Mining

Environmental Consequences of Gypsum Mining

Health and Safety Concerns

Socio-economic Implications

Mitigation Measures

Promoting Alternatives and Recycling

Chapter 8

Copper Mining, Smelting and Refining

Types of copper ore

Uses

The Copper Mining Process

Copper processing method

Flotation processing method

Magnetic separation processing method

Gravity separation method

Copper Smelting and Refining Process

Refined Copper Smelting and Refining Process

Formulation of copper concentrate

Flash smelting furnace

Converter furnace

Anode furnace

Anode casting wheel

Refinery

Chapter 9

Potash Mining

Introduction

Potash in Nature

Functions of Potash

Human Needs

Potash in Plants & the Environment

Uses for granulated potash:

Fertilizer

Animal Feed

Food Products

Soaps

Water Softeners

DEICER (snow and ice melting)

Glass manufacturing

Other uses for potash

Potash Mining

Conventional Underground Mining

Solution mining

Techniques to solution mine potash

Potash extraction techniques

Chapter 10

Green Metallurgical Processing of Chromite and Applications

Introduction

Uses

Applications

Ferrochrome

High carbon ferrochrome

Charge chrome

Silicochrome

Medium carbon ferrochrome

Low carbon ferrochrome

Exothermic ferrochrome

Stainless steel

Nickel chromium alloys

Other alloy steels

Chromium metal

Nonferrous alloys

Foundry

Chrome-plating

Metallization

Chemicals

Green manufacturing process of chromium compounds

Description of the traditional process

Green Manufacturing Process

Analysis of the Green Process for Manufacturing Chromium Compounds

High Efficiency of Chemical Reaction in the Fluid Salt Medium

Zero Emissions of Chromium-Containing Residue

Production of Chromic Oxide

Advantages of the green process

Chapter 11

Processing of Alumina-Rich Indian Iron Ore Slimes

Introduction

Beneficiation of Indian Iron Ores

Froth Flotation and Selective Flocculation of Iron Ores and Ore Slimes

Design and Development of Highly Selective Reagents for the Beneficiation of Indian Iron Ore Slimes

Hematite [a-Fe2O3], Gibbsite [a-Al(OH)3] and Kaolinite [Al2Si2O5(OH)4] Crystal Structures

Hematite (0001) Surface

Gibbsite (001) Surface

Kaolinite Surface

Reagent Molecules

Mineral–Starch Complexes and Interaction Energies

Templating Effect for Starch Interactions with Hematite Surface

Selective Dispersion-flocculation Studies on Iron Ore Slimes

Chapter 12

Conversion of a Waste to a High Valued Product

Rock or Solid Mine Waste

Overburden

Gangue

Mine Tailings

Liquid Mine Waste

Mine Water

Water Treatment Sludge

Mine Waste Management

Lasting Environmental Impact

Tailings Management and Storage

Solid waste disposal techniques

Water management in mining waste management

Rehabilitation and post-closure care

Green Mining: A Sustainable Approach to Extracting Minerals

Cutting-Edge Technologies

Novel Practices

Projects of Mining Waste Management

Project

Parameters of selected pumping equipment

Features of pumping equipment

Project 2

Parameters affecting the project:

Parameters of selected pumping equipment

Features of pumping equipment

Valves

Medium parameters

Parameters affecting the project:

Valves parameters:

Waste recycling plant equipment

Bag openers

Bag opener–overview

Ballistic separators

Ballistic separator–overview

Bio-drums

Windsifters

Windsifter–overview:

Trommels

Features of our equipment

Trommel–overview:

Chapter 13

Definitions and Properties of Limes

Introduction

Types of lime

Quicklime

Hydrated Lime

Hydraulic Lime (HL) and Natural Hydraulic Lime (NHL)

Natural Hydraulic Lime Grades

What should you consider when working with lime?

Physical Properties of Quicklimes

Physical Properties

Preparation of Quicklime

Uses and Applications of Quicklime

Types of Quick Lime

Benefits of Quicklime

Physical Properties of Hydrated Limes

Calcium Hydroxide Explained

Physical Properties

Uses of Calcium Hydroxide

Native American Uses

Differences between Hydrated lime and Quicklime

Chemical Properties of Quicklime

Chemical Properties of Hydrated Lime

Chapter 14

Analytical Testing of Limestone and Lime

Procedure

Calculations and Analysis

Tests on Limestone

Physical test

Heat Test

Acid Test

Ball Test

Limestone: Use Specifications

Limestone: Chemical Analyses

Physical Tests of Lime

Chemical Test

Heat Test

Ball Test

Lime Materials Specifications

Lime: Chemical Analysis

Chapter 15

Limestone Processing Technology

Use of lime in building construction

Use of lime in water and sewerage treatment

Use of lime in Chemical Industries

Use of lime in sugar industries

Agricultural uses of Limes

Lime use in Metallurgical Industries

Innovation in lime sector

Cycle of Lime

Limestone Crushing Plant Processing Flow

Primary Crushing

Jaw Crusher

Gyratory Crusher

Secondary Crushing

Cone Crusher

Impact Crusher

Tertiary Crushing

Vertical Shaft Impactors (VSI)

Roll Crusher

Process Optimization

Enhancing Limestone Crushing Efficiency with Portable Crusher

Advantages of Portable Crusher Plant in Limestone Crushing Plant

Types of Limestone Portable Crusher Plant

Chapter 16

Lime Manufacturing Process

Vertical Kiln Construction

Construction

Vertical Shaft Kiln Structures & Working Principles

The Preheating Zone

The Calcining Zone

The Cooling Zone

Roller Press Cement Pre Grinding System

Fig. 16.3 The cement pre-grinding system

Combined Grinding System of Cement Roller Press & Ball Mill

Two Stage Cement Grinding System

Rotary Kiln Refractory Lining

Zones in a cement rotary kiln

The Discharge Port and Discharging Zone

The Sintering Zone

The Transition Zone

The Cooling Zone

The Calcining Zone

The Preheating Zone

The Preheater System

The Cooler System

Analysis of Refractory Material

Requirements for Refractory Materials of Cement Rotary Kilns

Thermal Shock Resistance

Corrosion Resistance

The Moderate Thickness of Kiln Skin

Some Refractory Materials for Rotary Kiln Sintering Zone

Magnesite-chrome Brick

Magnesite-spinel Brick

Lime Production process

Dolomite Brick

Raw Material Storage and Transportation System

Calcination System

Finished Product Conveying System

Flue Gas Treatment System

Lime production equipment

Raw material preparation equipment

Belt Conveyors

Stacker and reclaimer

Cement crusher

Calcination equipment

Industrial Cyclone Dust Collector

Vertical Lime Kiln

Lime Rotary Kiln

Baghouse Dust Collector

Grate cooler

Cyclone Preheater

Control of Kiln Particulate Emissions

Processes in Manufacturing Cement that Release Fugitive Emissions

Methods for Controlling Air Pollution

Emission prevention

Emission control technologies

Emerging technologies

Find out about devices

ESP or Electrostatic Precipitator

Baghouse Filters

In-Situ Monitoring Device

Selective Non-catalytic Reduction

Dead-Burned Dolomite Production

Description

Uses

Preparation

Manufacturing Process

Risk factors

Oystershell Lime

Antacids

Calcium Supplements

Pharmaceutical Excipient

pH Adjuster

Antidiarrheal Medications

Oral Care Products

Calcium Fortification

Gastric Ulcer Treatment

Pharmaceutical Research

Lime Production From Oyster Shells

Precipitated Calcium Carbonate

Precipitated Calcium Carbonate Production

Precipitated Calcium Carbonate Production Process

The Slaker in Precipitated Calcium Carbonate Production

Uses

Hydraulic Lime

Raw materials

Selective Calcination

Calcination Process Description

Lime Plant Safety

Importance of Mining Safety

Most Common Mine Hazards

Ways to Ensure Worker Safety in the Mines

Training and Education

Best Practices

Use of Safety Equipment

Risk Assessment and Management

Chapter 17

Silica Ramming Mass (Acidic Ramming Mass)

Complete Process of Using Silica Ramming Mass

Mixing the ingredients together

Grinding the mixture

Sintering the mixture

Testing the product

Drying the mixture

Benefits of Using Silica Ramming Mass in Induction Furnace Refractory Lining

Grades of Acidic Ramming Mass

Specification

Application of Products

Manufacturing Process

Packaging

Silica Ramming Mass Manufacturing Plant

Primary Competitive Advantage/USP

Chapter 18

Ferrosilicon (Ferro silicon)

Chemical Composition

Applications

Ferrosilicon Production

Submerged arc furnace for production of Fe-Si

Production process of Fe-Si

The reactions

Refining and casting of Fe-Si

Production Process

Chapter 19

Limestone Quarrying and Processing Operations

Limestone Quarrying Operations

Process flow diagram for limestone quarrying operations

Limestone Processing Operations

Process flow diagram for limestone processing operations

Common uses for limestone

Fine/Ultrafine Ground

Coarse/Medium Ground

Limestone Aggregates

 Chemical Stone

Lime (burnt lime)

Chapter 20

Conveyor Idlers and Other Mining Equipment and Accessories

Premium heavy-duty rollers

Energy saving idlers (ESI)

Troughing idlers

Impact idlers

Picking table idlers

Flat belt idlers

Self-training idlers

Live shaft idlers

V-return idlers

Mining Equipment

Mining Equipment Parts

Blasthole Drills

Bucket-Wheel Excavators

Dozers

Dragline Excavators

Graders

Highwall Miners

Mining Trucks

Shovels

Wheel tractor scrapers

Underground Mining Equipment

Crane lifts

Continuous miners

Drones

Jumbo drills or mining drills

Loaders and haulers

Longwall mining machines

Personnel vehicles transport miners

Refuge chambers

Roof bolters

Ventilations systems

List of other mining tools

Chapter 21

Stone Crushing Unit

Working of Stone Crushing Unit

Factors to consider when setting up a Stone Crushing Unit

License for Stone Crusher/Screening Plant and Storage License

License for operating Stone Crushing Unit

Consent Certificate from SPCB

Environmental Clearance

Non-Forest land certificate

Stone Crushing Plant Technological Process

Work Process

Choose different crusher machines for different crushing stages

Primary crushing stage (coarse crushing)

Seondary and tertiary crushing (medium and fine crushing)

Sand making and shaping stage

Sand washing stage

Mobile stone crushing plant

Types of mobile crushing plant

Features of mobile crusher plant

Chapter 22

Beneficiation of Chromite Ore Processing Charge Chrome

Steps of chromite ore beneficiation

Crushing and grinding

Gravity separation

Magnetic separation

Flotation

Drying and smelting

Common Chrome Ore Beneficiation Process and Equipment

Chrome ore washing + screening process

Chrome ore gravity separation process

Chrome ore strong magnetic separation process

Chrome ore strong magnetic separation + flotation process

Chromium ore pyrochemical enrichment process

Chrome ore beneficiation process

Chapter 23

Emery Stone

Applications

Features of the Emery Stone Mill

Working Principle of Emery Stone Mill:

Chapter 24

Iron Ore Mining and Processing

Steps to process iron ore

Screening

Crushing and stock piling

Feeding the crusher (Reclaim)

Grinding

Spiral gravity separation

Magnetic separation

Stages of iron ore processing

Chapter 25

Calcined Petroleum Coke(Rotary/Horizontal Kiln Based)

The production of calcined petroleum coke

Use OfCalcined Petroleum Coke

Diagram of clacined petroleum

Coke Calcining Technology

Rotary Kiln

Rotary Hearth Calciner

Shaft Calcining

Chapter 26

Calcined Petroleum Coke (Vertical Shaft Kiln Based)

Vertical Shaft Kiln Solutions

AC Vertical Shaft Kiln

Product Features

Differential Discharging Kiln

Key Features

Chapter 27

Megnesium Metal

Properties

Characteristics

Sources of Magnesium

Production

Applications

Industrial Uses of Magnesium

Benefits of Magnesium for Metal Parts Manufacturing

The Two Most Common Characteristics of Magnesium

Tool Life

Versatility

Alloy Choices

Thin Wall Capabilities

Galvanic Corrosion Issues

Surface Finish

Special Fasteners for Magnesium

Major benefits of Magnesium Die-Casting

Work with a Trusted Magnesium Manufacturing Sourcing Servicer

Chapter 28

Iron Ore Pelletization Plant

Introduction to Iron ore Pellets and Pelletizing processes

The typical properties of the iron ore pellets

Preparing Iron Ore for Pelletizing (Balling)

The Pelletizing Process

Raw material preparation

Formation of green balls or pellets

Induration

Pelletization processes

Straight travelling grate process

Grate kiln process

Iron Ore Pelletizing Equipment

Disc Pelletizers

Balling Drums

Induration

The process development behind iron ore pelletizing

Chapter 29

Cobalt Carbonate from Ore

Structure of Cobalt II Carbonate

Preparation of Cobalt II Carbonate

Physical Properties of Cobalt II Carbonate

Chemical Properties of Cobalt II Carbonate

Uses of Cobalt (II) carbonate

Cobalt metal extraction process flow sheet

Chapter 30

Concentrated Manganese Ore Production

Manganese Ore

Manganese Alloy

Beneficiation of manganese ore

Washing and screening for manganese ore processing

Gravity separation method in manganese ore processing

Manganese ore high-intensity magnetic separation method

Manganese ore processing Flotation method

Fire enrichment method of manganese ore processing

Chemical beneficiation method of manganese ore processing

Chapter 31

Granite Tiles Cutting and Polishing

Introduction to Granite

Granite Cutting

Grinding, Granite Resining and Polishing

Shaping and Edging

Quality Control

Packaging and Shipping

Tools for Cutting Granite Tile

Cutting Granite Tile With a Wet Saw

Polish the Granite Tile Edge

Chapter 32

Plant Economics of Benefication of Graphite Ore (Capacity: 1000 Ton/Per Month)

Uses and application

Plant Economics

Land & Building

Process Flow Chart

Plant & Machinery

Other Fixed Assets

Fixed Capital

Working Capital Requirement/Month

Total Working Capital/Month

Cost of Project

Total Capital Investment

Cost of Production/Annum

Turn Over/Annum

Chapter 33

Plant Economics of Chrome Beneficiation Plant (Beneficiation of Chromite Ore Processing Charge Chrome)

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 34

Plant Economics of Gold Mining

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 35

Plant Economics of Granite Mine

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 36

Plant Economics of Graphite Mining and Benification Plant

Land & Building

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 37

Plant Economics of Hydrated Lime

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 38

Plant Economics of Iron Ore Mining and Manufacting of Sponge Iron

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 39

Plant Economics of Iron Ores Pelletization Plant

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 40

Plant Economics of Lime Stone Mining

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 41

Plant Economics of Lime Stone Powder (Grinding)

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 42

Plant Economics of Marble Quarrying

Land & Building

Plant & Machinery

Machinery Requirements

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 43

Plant Economics of Open Cast Mining of Chrome Ore

Land & Building

Plant & Machinery

Other Fixed Assets

Fixed Capital

Working Capital Requirement/Month

Total Working Capital/Month

Turn Over/Annum

Chapter 44

Plant Economics of Quick Lime/Slaked Lime

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 45

Plant Economics of Stone Mining

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 46

Plant Economics of Stone Quarry

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum