WEL COMEWEL COMEToTo

Sri KLN Rao Sri KLN Rao The General ManagerThe General Manager

DIOM, NMDC LimitedDIOM, NMDC LimitedDonimalai TownshipDonimalai Township

For the questFor the quest29-03-201029-03-2010

Reduction of Wastage Reduction of Wastage in Processesin Processes

ByBySri CK MegharajSri CK MegharajSr. Manager (MP)Sr. Manager (MP)

What is Waste ReductionWhat is Waste Reduction Waste reduction means decreasing the amount Waste reduction means decreasing the amount

of solid wasteof solid waste Waste reduction includes source reduction and Waste reduction includes source reduction and

recycling practices.recycling practices. Source reduction activities attempt to Source reduction activities attempt to

eliminate waste or reduce the amount eliminate waste or reduce the amount generated.generated.

Recycling activities focus on the re-using Recycling activities focus on the re-using wastes after they are generated.wastes after they are generated.

Waste reduction will help our business:Waste reduction will help our business:

Waste reduction will help our Waste reduction will help our BusinessBusiness

Save money by reducing waste disposal costsSave money by reducing waste disposal costs Reduce the number of waste regulations with Reduce the number of waste regulations with

which our business need to complywhich our business need to comply Reduce employees exposure to hazardous Reduce employees exposure to hazardous

chemicalschemicals

Waste reduction techniquesWaste reduction techniques Good operating practicesGood operating practices Material substitutionMaterial substitution Process or Technology modificationProcess or Technology modification Product substitutionProduct substitution Recovery/Recycling/ReuseRecovery/Recycling/Reuse

What is mineral processingWhat is mineral processing Mineral processing is the art of treating crude Mineral processing is the art of treating crude

crust of earth to produce there from the crust of earth to produce there from the primary consumer derivatives.primary consumer derivatives.

The essential operation in all such processes is The essential operation in all such processes is separation of one or more valuable derived separation of one or more valuable derived constituents of the crude from the undesired constituents of the crude from the undesired contaminants with which it occurs associatedcontaminants with which it occurs associated

A crude is any mixture of minerals in the form A crude is any mixture of minerals in the form in which occurs as a part of earth crust.in which occurs as a part of earth crust.

An ore is a solid crude containing a valuable An ore is a solid crude containing a valuable constituent such amounts as to constitute a constituent such amounts as to constitute a promise of possible profit in extraction, promise of possible profit in extraction, treatment, and sale.treatment, and sale.

The valuable constituent of an ore is ordinarily The valuable constituent of an ore is ordinarily called valuable mineral, or often just called valuable mineral, or often just MINERAL, the associated worth less material MINERAL, the associated worth less material is called the gangueis called the gangue

The valuable product of the ore dressing The valuable product of the ore dressing treatment is called concentrate; the discarded treatment is called concentrate; the discarded waste as tailings. waste as tailings.

Fundamental operation of mineral processing Fundamental operation of mineral processing are severance or breaking apart of the are severance or breaking apart of the associated minerals or constituents of the associated minerals or constituents of the crude, and separation of the several crude, and separation of the several constituents.constituents.

Good operating practiceGood operating practice Good operating practice generate less wasteGood operating practice generate less waste Making existing processes more efficientMaking existing processes more efficient Good business practicesGood business practices Many good operating practices are easy and Many good operating practices are easy and

inexpensive to implementinexpensive to implement Practical for business of all sizesPractical for business of all sizes

What are the waste generation What are the waste generation from the minesfrom the mines

Top soilTop soil Waste rejectsWaste rejects Tailings from ore processing plantTailings from ore processing plant Waste from service facilitiesWaste from service facilities

Top soilTop soil Top soil (generally 30 cms thickness) is Top soil (generally 30 cms thickness) is

stripped and staked superior in qualitystripped and staked superior in quality Can be used in future for stabilizationCan be used in future for stabilization

Mining wasteMining waste Cut of point for mining is fixedCut of point for mining is fixed All the ore having Fe below cut off point is classified All the ore having Fe below cut off point is classified

as waste/sub grade materialas waste/sub grade material Future use if Techno-economics permitsFuture use if Techno-economics permits Iron ore deposits of eastern, central and southern zone Iron ore deposits of eastern, central and southern zone

do not contain much waste / rejects, except literate do not contain much waste / rejects, except literate and some low grade ferruginous shales and BHQ and some low grade ferruginous shales and BHQ patchespatches

Western zone (Goa region), the waste is very high to Western zone (Goa region), the waste is very high to the tune of 2.5 to 3.5 per tonne of ore excavatedthe tune of 2.5 to 3.5 per tonne of ore excavated

Tailings from processingTailings from processing BeneficiationBeneficiation Improve Fe contentImprove Fe content Decrease Alumina and silicaDecrease Alumina and silica For smooth blast furnaceFor smooth blast furnace Disposal of tailings is a major environmental problemDisposal of tailings is a major environmental problem Becoming more serious with increasing extraction of Becoming more serious with increasing extraction of

low grade depositslow grade deposits Tailing desposal as slurry of high water content with Tailing desposal as slurry of high water content with

massive pond for cotainmentmassive pond for cotainment

Waste from services facilitiesWaste from services facilities There are three types wastes generatedThere are three types wastes generated Metallic – workshopMetallic – workshop Non-metallic – tyres tubes etc.Non-metallic – tyres tubes etc. Oil contaminated waste –waste cotton, oils, oil Oil contaminated waste –waste cotton, oils, oil

filters, hazardous wastefilters, hazardous waste

Benefits of Beneficiationin improving the quality of Benefits of Beneficiationin improving the quality of iron ore in hot metal productioniron ore in hot metal production

Increase in Fe content in iron ore burden by 1% will Increase in Fe content in iron ore burden by 1% will increase the productivity of the hot metal by 1.5 – 2.0 increase the productivity of the hot metal by 1.5 – 2.0 %, coke rate by 0.8-1.2% and there by reduction %, coke rate by 0.8-1.2% and there by reduction Rs.60-70 per ton of hot metal.Rs.60-70 per ton of hot metal.

Lowering of alumina in iron ore burden by 1% will Lowering of alumina in iron ore burden by 1% will reduce the cost of the hot metal by Rs. 200-250 per reduce the cost of the hot metal by Rs. 200-250 per ton hot metal.ton hot metal.

Lowering of silica by 1% in iron ore burden will Lowering of silica by 1% in iron ore burden will reduce the cost of the hot metal by Rs. 50- 100 per reduce the cost of the hot metal by Rs. 50- 100 per ton of the hot metal.ton of the hot metal.

The effect of high alumina is noticeable above 2% The effect of high alumina is noticeable above 2% and following are the ill effectsand following are the ill effects

The sinter/ pellet strength is lowThe sinter/ pellet strength is low Reduction and degradation properties are highReduction and degradation properties are high Higher slag volume and viscous slag Higher slag volume and viscous slag

formation ( draining problem)formation ( draining problem)

Characterization and data analysisCharacterization and data analysis

The chemical, mineralogical and The chemical, mineralogical and granulometrical characterization. granulometrical characterization.

Bond’s work index determination. Bond’s work index determination. Ore variable data. The goethite %, hematite Ore variable data. The goethite %, hematite

%, aluminous gangue mineral %, slimes (% %, aluminous gangue mineral %, slimes (% <45 microns) <45 microns)

The size analysis. The size analysis.

Base line data (BLD)Base line data (BLD) The plant in a custom mode with variable ore types in The plant in a custom mode with variable ore types in

a discontinuous fashion affecting the operation.a discontinuous fashion affecting the operation. Due to slight change in ore mineralogy result in Due to slight change in ore mineralogy result in

marginally high tail value and marginally low marginally high tail value and marginally low concentrate grade with reference to design values. concentrate grade with reference to design values.

The plant designed rate.The plant designed rate. Little load on primary.Little load on primary. Operation at lower capacity.Operation at lower capacity.

Tonnage and grade of ROM Tonnage and grade of ROM in DIOM in DIOM

YearYear ROMROML TL T

FeFe%%

SiO2SiO2%%

Al2O3Al2O3%%

2009-10 2009-10 (Upto Feb (Upto Feb

10)10)

55.9355.93 64.1564.15 4.104.10 2.372.37

2008-20092008-2009 57.9557.95 64.5164.51 3.313.31 2.572.57

2007-20082007-2008 61.8161.81 65.3465.34 2.812.81 2.022.02

2006-20072006-2007 56.8156.81 65.3965.39 2.572.57 1.911.91

Details of Ore ReservesDetails of Ore Reserves

DepositDeposit Ore qty Ore qty (MT)(MT)

Fe%Fe% Waste Waste qty (MT)qty (MT)

Strip’g Strip’g ratioratio

SBSB 9.779.77 67.9767.97 7.647.64 0.780.78BMMSBMMS 9.809.80 66.5466.54 9.369.36 0.960.962W2W 0.790.79 63.1863.18 0.730.73 0.930.933E3E 2.662.66 64.7164.71 1.801.80 0.680.683W3W 4.894.89 63.4463.44 1.351.35 0.280.28TotalTotal 27.9127.91 66.2366.23 20.8820.88 0.750.75

Deposit-wise Q & Q of Ore & Waste - KIOM

DepositDeposit Ore qty Ore qty (MT)(MT)

Fe%Fe% Waste Waste qty (MT)qty (MT)

Strip’g Strip’g ratioratio

B-blockB-block 31.1231.12 65.0065.00 1.571.57 0.080.08C-blockC-block 101.24101.24 63.8363.83 19.1519.15 0.260.26TotalTotal 132.36132.36 64.1064.10 20.7220.72 0.210.21

4. Quality of Low Grade Ore

Ore typeOre type Fe %Fe % SiOSiO2 2 %% Al2O3 Al2O3 %%

P %P %

Laterite Laterite 53 – 5453 – 54 55 88 0.0700.070

LimoniteLimonite 50 – 5250 – 52 66 1010 0.0700.070

BHJBHJ 40 - 45 40 - 45 3333 11 0.0300.030

ShaleShale 18 – 2818 – 28 30 – 3230 – 32 1818 0.0900.090

Deposit-wise Low Grade Ore AvailableApprox. RecoveryApprox. Recovery

Area Area

In-situIn-situ Lump (-100 +10 mm)Lump (-100 +10 mm) LGFLGF

QtyQty QtyQty Fe %Fe % QtyQty Fe %Fe %SBSB 10.0010.00 3.003.00 + 65.00+ 65.00 7.007.00 50 – 5450 – 54

BMMXBMMX 10.0010.00 2.802.80 + 65.00+ 65.00 7.207.20 50 – 5250 – 522W North2W North 5.005.00 1.251.25 + 64.50+ 64.50 3.753.75 5050 Sub TotalSub Total 25.0025.00 7.057.05 64.9064.90 17.9517.95 51.2051.20

Blue dust mixed with Blue dust mixed with BHJ in 2E & 2WBHJ in 2E & 2W

23.0023.00 9.209.20 40 - 4540 - 45 13.8013.80 58 – 6058 – 60

TotalTotal 48.0048.00 16.2516.25 31.7531.75

• Generated Lump (7.05 LT) will be fed to crushing plant.

• Low grade fine ore of 31.75 LT & BHJ lump of 9.20 LT generated through mobile screen will be stacked in respective deposits for feeding to the beneficiation plant.

(Qty in LT)

Availability of in-situ Banded Hematite Jasper (BHJ)

Area Area

In-situ (MT)In-situ (MT)

2E2E 0.500.503E3E 1.791.792W2W 0.070.073W3W 0.210.21

TotalTotal 2.572.57

In addition to above a total quantity of 11.4 MT of BHJ dumped in valley at five different locations in North Block.

Total BHJ available is 13.97 MT

DIOM PLANT CAPACITYDIOM PLANT CAPACITY Crushing plant is capable of handling 8 MTPACrushing plant is capable of handling 8 MTPA Screening plant is designed to handle a Max of 7 Screening plant is designed to handle a Max of 7

MTPA.MTPA. Loading plant can handle upto 8.4 MTPA.Loading plant can handle upto 8.4 MTPA. Reclaimer with capacity of 2400 tph is adequate to Reclaimer with capacity of 2400 tph is adequate to

handle.handle. S/P is the weakest link in the chain.S/P is the weakest link in the chain. 411 fine ore conveyor is presently not able to handle 411 fine ore conveyor is presently not able to handle

800 tph as against the design requirement of 1000 tph800 tph as against the design requirement of 1000 tph

PRODUCTION DETAILS

Production(In lakh Tons)

2009-10 (Upto Feb,

2010)2008-09 2007-08 2006-07

Excavation 95.48 78.15 91.23 91.41

ROM 56.06 58.11 62 56.95

Lump 17.91 19.68 20.98 18.02

Fines 32.58 34.7 37.2 35.06

Slimes 4.36 3.57 3.63 3.74

0

10

20

30

40

50

60

70

80

90

100

upto Feb2010

2008-2009 2007-2008 2006-2007

Excavation LakhTonsROM Lakh Tons

Lumps Lakh Tons

Fines lakh Tons

Slimes Lakh Tons

Screening Plant detailsScreening Plant details Built 30 years back with 3 screening lines.Built 30 years back with 3 screening lines. Each line capable of handling 600 tph.Each line capable of handling 600 tph. 44thth line was added recently during 2004-2005 line was added recently during 2004-2005 Designed for 100 % wet operation.Designed for 100 % wet operation. Live stock pile capacity 16000 tons.Live stock pile capacity 16000 tons. Present maximum level of production Present maximum level of production

achieved from the plant is 6.2 MTPAachieved from the plant is 6.2 MTPA

WATERWATER 7.45 Cu Sec. is the sanctioned quantity from 7.45 Cu Sec. is the sanctioned quantity from

Narihalla Dam.Narihalla Dam. Presently water is being pumped from Presently water is being pumped from

Narihalla dam at the rate of 400 Cu m/hr.Narihalla dam at the rate of 400 Cu m/hr. A scheme with a total pumping capacity of A scheme with a total pumping capacity of

800 cu m/hr is already approved to meet the 800 cu m/hr is already approved to meet the water requirement for processing ore from water requirement for processing ore from DIOM and KIOM. DIOM and KIOM.

LUMP ORE PRODUCTION AND GRADE, LUMP ORE PRODUCTION AND GRADE, SCREENING PALNTSCREENING PALNT

YearYear Lump. LTLump. LT Fe%Fe% SiO2 %SiO2 % Al2O3 Al2O3 %%

Upto Feb 2010Upto Feb 2010 17.9017.90 64.4564.45 3.983.98 2.192.19

2008-20092008-2009 19.6819.68 65.2765.27 2.692.69 2.212.21

2007-20082007-2008 20.9820.98 65.8065.80 2.542.54 1.771.77

2006-20072006-2007 18.0118.01 65.7765.77 2.292.29 1.721.72

2005-20062005-2006 17.9417.94 65.8865.88 2.082.08 1.771.77

2004-20052004-2005 17.4317.43 65.8865.88 2.182.18 1.741.74

2003-20042003-2004 16.0316.03 66.1666.16 1.771.77 1.561.56

PRODUCTION OF FINE ORE GRADE , PRODUCTION OF FINE ORE GRADE , REC % SCREENING PLANTREC % SCREENING PLANT

YearYear Lakh Lakh TonsTons

Fe %Fe % SiO2 %SiO2 % Al2O3%Al2O3% Rec. %Rec. %

Upto Feb Upto Feb 20102010

32.5532.55 64.1264.12 4.144.14 2.372.37 58.258.2

2008-092008-09 34.7034.70 63.8263.82 3.763.76 2.912.91 59.959.9

2007-082007-08 37.2037.20 64.2564.25 3.523.52 2.632.63 60.260.2

2006-072006-07 35.0635.06 64.6864.68 2.972.97 2.302.30 61.761.7

2005-062005-06 36.1436.14 65.1965.19 2.622.62 2.032.03 62.862.8

2004-052004-05 32.7532.75 65.4565.45 2.502.50 1.931.93 59.859.8

2003-042003-04 28.2728.27 65.8065.80 2.062.06 1.791.79 56.456.4

Performance of primary classifierPerformance of primary classifierClassifier under flow sample analysisClassifier under flow sample analysis

Fe %Fe % SiO2SiO2 Al2O3Al2O3 PP LIOLIO

63.863.8 3.883.88 3.033.03 0.0410.041 1.411.41

Classifier over flow sample analysisClassifier over flow sample analysis

Fe %Fe % SiO2SiO2 Al2O3Al2O3 PP LIOLIO

58.058.0 9.249.24 6.456.45 0.0490.049 3.153.15

Performance of slow speed classifierPerformance of slow speed classifierClassifier under flow sample analysis Classifier under flow sample analysis

Fe %Fe % SiO2SiO2 Al2O3Al2O3 PP LIOLIO

66.066.0 2.532.53 1.031.03 0.0320.032 1.121.12

Classifier under flow sample analysis Classifier under flow sample analysis

Fe %Fe % SiO2SiO2 Al2O3Al2O3 PP LIOLIO

Performance of hydrocyclonesPerformance of hydrocyclonesunder flow at P.D. 1.45-1.50under flow at P.D. 1.45-1.50

Fe %Fe % SiO2 %SiO2 % Al2O3%Al2O3% P %P % LIOLIO

64.764.7 3.433.43 2.442.44 0.0270.027 1.211.21

Performance of hydrocyclonesPerformance of hydrocyclonesover flow at P.D. 1.15-1.20over flow at P.D. 1.15-1.20

Fe %Fe % Sio2 %Sio2 % Al2O3 %Al2O3 % P %P % LIOLIO59.0759.07 6.776.77 4.094.09 0.00280.0028 2.002.00

Energy consumption units per ton in the Energy consumption units per ton in the mine and plantmine and plant

Total Total Exc. Exc. minemine

C/plantC/plantw.r.t.w.r.t.ROMROM

S/Plant S/Plant w.r.tw.r.tROMROM

L/Plant L/Plant w.r.tw.r.tROMROM

% Wet % Wet Screen-Screen-

inging

2009-102009-10Upto Upto Feb’10Feb’10

0.1350.135 0.070.07 1.0941.094 0.6140.614 96.096.0

2008-092008-09 0.2030.203 0.0760.076 .0991.0991 0.6510.651 60.560.52007-082007-08 0.2180.218 0.0640.064 0.8590.859 0.6530.653 59.159.12006-072006-07 0.3280.328 0.0630.063 0.8350.835 0.6500.650 65.765.72005-062005-06 0.3310.331 0.360.36 0.8580.858 0.5390.539 56.156.1

Details of cost of ProductionDetails of cost of ProductionProduction Production

cost cost per ton per ton

C/PRs. cpt

S/PRs. cpt

L/PRs. cpt

Haulage/Transporta

tionRs. cpt

2009-10 upto

Feb 201016..03 39.87 29.69

2008-09 20.54 53.29 38.92 8.45

2007-08 15.36 43.6 23.43 7.33

2006-07 8.59 43.13 52.73 6.49

2005-06 8.25 24.59 21.92 5.58

Plant, Cost per ton Plant, Cost per ton

0

10

20

30

40

50

60 3-D Column 1

2009-10 upto Feb20102008-09

2007-08

2006-07

2005-06

2004-05

Industrial water consumption Industrial water consumption YearYear Cu.m/T.E.Cu.m/T.E. S/PlantS/Plant

Cu.mCu.mWet Wet

screening screening %%

2009-102009-10(Upto (Upto

Feb,10)Feb,10)

0.210.21 0.150.15 96.096.0

2008-092008-09 0.240.24 0.160.16 60.560.5

2007-082007-08 0.220.22 0.160.16 59.159.1

2006-072006-07 0.230.23 0.160.16 65.765.7

2005-062005-06 0.190.19 0.130.13 56.156.1

Industrial water consumptionIndustrial water consumption

0

0.05

0.1

0.15

0.2

0.25

cu.m/T.E cu.m S/pl

2009-102008-092007-082006-072005-06

Mines and industrial operation Mines and industrial operation energy cost w.r.t. ROMenergy cost w.r.t. ROM

Power costPower cost Rs. Per ton Rs. Per ton w.r.t. ROMw.r.t. ROM

2009-10 upto 2009-10 upto FebFeb

15.6115.61

2008-092008-09 12.0212.02

2007-082007-08 12.7812.78

2006-072006-07 14.3314.33

2005-062005-06 17.3517.35

Screening plant performanceScreening plant performance

YearYear Wet screening Wet screening %%

2009-102009-10Upto Feb’10Upto Feb’10

96.096.0

2008-092008-09 60.560.5

2007-082007-08 59.159.1

2006-072006-07 65.765.7

2005-062005-06 56.156.1

Screening plant Screening plant % wet screening% wet screening

0102030405060708090

100

WetScreeing %

2009-102008-092007-082006-072005-062004-05

ConclusionConclusion The grade Fe content of lumps and fines improved in The grade Fe content of lumps and fines improved in

screening plant and reduced Al2O3 and SiO2screening plant and reduced Al2O3 and SiO2 Beneficiation improving the quality of iron is Beneficiation improving the quality of iron is

advantages to the end user and reduces the wastages.advantages to the end user and reduces the wastages. The low grade reserve with Fe content < 58 can be The low grade reserve with Fe content < 58 can be

further treated by beneficiation process for recovery further treated by beneficiation process for recovery of Fe. of Fe.

Recycling of water from the HRT and tailing pond Recycling of water from the HRT and tailing pond increased the efficiency of the wet processincreased the efficiency of the wet process

Al2O3 as alumina is the most deleterious mineral in Al2O3 as alumina is the most deleterious mineral in iron ore and maximum benefit comes from removing iron ore and maximum benefit comes from removing this gangue this gangue

Acknowledgement Acknowledgement The author is thankful to the CMD, Directors, and The author is thankful to the CMD, Directors, and

senior management of NMDC ltd, for giving me an senior management of NMDC ltd, for giving me an opportunity to present this paper.opportunity to present this paper.

The author is thankful to the General Manager, The author is thankful to the General Manager, DIOM, DGM(Min) HRD for giving me this DIOM, DGM(Min) HRD for giving me this opportunity to present the paper.opportunity to present the paper.

The author is thankful to DGM (MP) and all HOD’s The author is thankful to DGM (MP) and all HOD’s and the audience for your presence and patience and the audience for your presence and patience hearing while presenting this paper and thankful to hearing while presenting this paper and thankful to my dear colleagues who have helped directly or my dear colleagues who have helped directly or indirectly in presenting this paper.indirectly in presenting this paper.