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DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITY OF RUHUNA
INDUSTRIAL TRAINING REPORT SUBMITTED IN PARTIAL FULFILMENT OF THE
DEGREE OF BACHELOR OF SCIENCE IN ENGINEERING
29th of April 2016
LANKA MINERAL SANDS LIMITED
PULMODDAI
(From 11th January 2016 to 01st April 2016)
TENNAKOON T.M.M. (EG/2012/2096)
i
PREFACE
As an undergraduate from Mechanical & Manufacturing Department of Faulty of Engineering,
University of Ruhuna I was able to have my industrial training at Lanka Mineral Sands Limited
(LMSL) from 11th of January 2016 to 1st of April 2016. This report is basically about the training
experience for the training period at LMSL. Mineral sands are one of the valuable resources found
in Sri Lanka. Mainly I was trying to learn the mechanical engineering related process at the only
commercially exploited Mineral sand processing company in Sri Lanka. The theories and practical
knowledge which I achieved from the University was much useful in my internship period.
In the first chapter I have given an introduction to the training establishment at LMSL, the function
of the company, the current organization structure, Vision, Mission & Objectives of the company,
types of end products, present performance and the profitability of LMSL, the strengths, the
weaknesses, the opportunities for improvement, threats for survival, its usefulness to the Sri
Lankan society and suggestions to improve the performance of the company.
Second chapter describes the training experience which I had in Pulmoddai IRZ plant. The
personal involved in my training period is also mentioned in the second chapter. The training
experience I achieved from different sections such as Mechanical Workshop, Mobile Equipment
Section and Mineral Processing Plants is described in this chapter.
The third chapter includes a description about the Management Practices, Safety Measures and
Cooperate Social Responsibility of the company.
Conclusion and the summery are in my final chapter. The weakness of me which I identified in
my training period and the steps to overcome weakness are commented in this chapter. Training
establishment’s ability to training, comments & suggestions to improve industrial training program
are also in my last chapter.
ii
ACKNOWLEDGMENT
First of all I would like to express my gratitude to our University for the excellent guidance and
instructions given to successfully complete the industrial training programme at Lanka Mineral
Sands Limited, Pulmoddai. Therefore I express my gratitude to Dr. Ruwan Appuhamy, the training
coordinator, Mechanical and Manufacturing Department head Dr. Sumith Baduge, My academic
advisor Dr. Munjula Wickremasinghe and all the staff and colleagues of the faculty. And the
support given by National Apprentice and Industrial Training Authority (NAITA) is also
appreciated.
My grateful thank goes to my training supervisors at LMSL Mr. Rajapaksha Bandara (Mechanical
Engineer), Mr. Gnaneshwaram (Mechanical Engineer, Acting DGM -Plant & Operation) and Mr.
S. Rajaguru (Senior Mining & Processing Engineer) for the highly appreciated support given and
all the other executive officers and all the staff members of IRZ plant Pulmoddai who helped me
in numerous ways to successfully complete my training period.
Finally, my thanks go to my family members and my colleagues who was with me at IRZ Plant
Pulmoddai, for the provided great support to complete my training period. Last but not least I
would like to express my appreciation too, to my batch mates who helped me in many ways during
my training period.
Thanking you.
Tennakoon T.M.M.
EG/2012/2096
Department of Mechanical and Manufacturing Engineering
Faculty of Engineering
University of Ruhuna
iii
CONTENTS
PREFACE ........................................................................................................................................ i
ACKNOWLEDGMENT................................................................................................................. ii
LIST OF FIGURES ........................................................................................................................ v
LIST OF TABLES ........................................................................................................................ vii
LIST OF ACRONYMS ............................................................................................................... viii
CHAPTER 1 ................................................................................................................................... 1
1 INTRODUCTION TO THE TRAINING ORGANIZATION ............................................ 1
1.1 About Lanka Mineral Sands Limited (LMSL) ............................................................. 1
1.2 Vision, Mission & Objectives of LMSL ...................................................................... 2
1.3 Types of End Products of LMSL .................................................................................. 3
1.4 Organization Structure .................................................................................................. 5
1.5 Present Performance and Profitability of LMSL .......................................................... 5
1.6 SWOT Analysis ............................................................................................................ 7
1.7 Usefulness to the Sri Lankan Society ........................................................................... 8
1.8 Suggestions to Improve the Performance ..................................................................... 8
CHAPTER 2 ................................................................................................................................. 10
2 TRAINING EXPERIENCE ............................................................................................... 10
2.1 Introduction ................................................................................................................ 10
2.2 Production Flow ......................................................................................................... 14
2.3 Separation Machineries Used ..................................................................................... 17
2.4 Mechanical Workshop ................................................................................................ 30
2.5 Mobile Equipment Section ......................................................................................... 38
2.6 Wet Gravity Upgrading Plant (Block A) .................................................................... 44
2.7 Training Facilities ....................................................................................................... 45
iv
2.8 Social Functions ......................................................................................................... 45
CHAPTER 3 ................................................................................................................................. 46
3 LANKA MINERAL SANDS LIMITED MANAGEMENT ............................................. 46
3.1 5S Concept .................................................................................................................. 46
3.2 Human Resource Management ................................................................................... 47
3.3 Safety Management .................................................................................................... 48
3.4 Welfare Management ................................................................................................. 48
3.5 Environmental Management ....................................................................................... 48
3.6 Corporate Social Responsibility ................................................................................. 49
CHAPTER 4 ................................................................................................................................. 50
4 SUMMERY AND CONCLUSION ................................................................................... 50
4.1 Summery ..................................................................................................................... 50
4.2 Conclusion .................................................................................................................. 51
REFERENCES ............................................................................................................................. 53
v
LIST OF FIGURES
Figure 1-1: Lanka Mineral Sands Limited company logo .............................................................. 1
Figure 1-2: ILMENITE (FeO.TiO2) ............................................................................................... 3
Figure 1-3: RUTILE (TiO2) ............................................................................................................ 3
Figure 1-4: ZIRCON (ZrO2.SiO2)................................................................................................... 3
Figure 1-5: LEUCOXENE (Hi-Ti-Ilmenite) .................................................................................. 4
Figure 1-6: Available mineral sand percentages in Pulmoddai deposit .......................................... 4
Figure 1-7: Organizational Structure of LMSL .............................................................................. 5
Figure 1-8: LMSL IRZ PLANT, PULMODDAI ............................................................................ 9
Figure 2-1: Production Flow of LMSL Pulmoddai plant ............................................................. 16
Figure 2-2: Strainer at Block A ..................................................................................................... 17
Figure 2-4: Spiral Concentrator .................................................................................................... 18
Figure 2-3: Splitter in a canal of a Spiral Concentrator ................................................................ 18
Figure 2-5: Magnetic Drum Separator .......................................................................................... 19
Figure 2-6: Wet High Intensity Magnetic Separator (WHIMS) ................................................... 21
Figure 2-7: Spiral classifier ........................................................................................................... 21
Figure 2-8: Attritioners ................................................................................................................. 22
Figure 2-9: Hydrosizer .................................................................................................................. 23
Figure 2-10: Wilfley table ............................................................................................................. 24
Figure 2-11: Process of Wilfley table ........................................................................................... 24
Figure 2-12: Cone Filter................................................................................................................ 25
Figure 2-13: Schematic Diagram of High Tension Electro Dynamic Separator .......................... 25
Figure 2-14: High Tension Electro Dynamic Roll Separator ....................................................... 26
Figure 2-15: Schematic Diagram of High Tension Electro Static Plate Separator ....................... 27
Figure 2-16: High Tension Electro Static Plate Separator ............................................................ 28
Figure 2-17: Schematic Diagram of High Tension Electro Static Screen Separator .................... 28
Figure 2-18: Schematic Diagram of High Intensity Induced Roll Magnetic Separator ............... 29
Figure 2-19: High Intensity Induced Roll Magnetic Separator .................................................... 29
Figure 2-20: Stores Issue Requisition Form ................................................................................. 31
Figure 2-21: Job Card ................................................................................................................... 31
Figure 2-22: Fabricating Bins ....................................................................................................... 32
vi
Figure 2-23: Deformed Drum Shell .............................................................................................. 33
Figure 2-24: Repaired Drum Shell ................................................................................................ 33
Figure 2-25: Broken Bolt .............................................................................................................. 34
Figure 2-26: Machining the Bolt in Lathe Machine ..................................................................... 34
Figure 2-27: Machined Bolt .......................................................................................................... 35
Figure 2-28: Butt Fusion Welding Machine ................................................................................. 35
Figure 2-29: Welded Pipe ............................................................................................................. 36
Figure 2-30: Pressure Test ............................................................................................................ 36
Figure 2-31: Lifespan of PE 100 Pipes ......................................................................................... 37
Figure 2-32: Schematic Diagram of a Turbocharged System ....................................................... 39
Figure 2-33: Cross Section of Turbocharger ................................................................................ 39
Figure 2-34: Cross Section of an Alternator ................................................................................. 40
Figure 2-35: Circuit Diagram of a Typical Alternator .................................................................. 41
Figure 2-36: Schematic Diagram of HST ..................................................................................... 41
Figure 2-37: Caltex Rando Hd 68 Hydraulic Oil .......................................................................... 42
Figure 2-38: Simplified Flow Sheet of Wet Gravity Upgrading Plant ......................................... 44
Figure 2-39: Bachelor Quarters .................................................................................................... 45
Figure 2-40: Arms Giving Ceremony ........................................................................................... 45
vii
LIST OF TABLES
Table 1-1: Income Statement .......................................................................................................... 6
Table 1-2: Balance Sheet ................................................................................................................ 6
Table 2-1: physical properties of Heavy Minerals ........................................................................ 12
Table 2-2: Relative Magnetic Susceptibility of Heavy Minerals .................................................. 13
Table 2-3: Functions and Properties of Hydraulic Oil .................................................................. 43
viii
LIST OF ACRONYMS
LMSL Lanka Mineral Sands Limited
IRZ Ilmenite Rutile Zircon
DGM Deputy General Manager
SFM Senior Finance Manager
FM Finance Manager
SM Supplies Manager
SO Supplies Officer
MA Management Assistant
PL Permanent Labour
MPE Mining & Processing Engineer
ME Mechanical Engineer
CE Civil Engineer
EE Electrical Engineer
TA Technical Assistant
MES Mechanical Equipment Section
MWS Mechanical Workshop
CEB Ceylon Electricity Board
WHIMS Wet High Intensity Magnetic Separators
LIWDMS Low Intensity Wet Drum Magnetic Separator
HTEDS High Tension Electro Dynamic Separator
HTESPS High Tension Electro Static Plate Separator
HTESSS High Tension Electro Static Screen Separator
ix
HIIRMS High Intensity Induced Roll Magnetic Separator
WGUP Wet Gravity Upgrading Plant
WMSP Wet Magnetic separation Plant
WMP Wet Mill Plant
FNC Final Non Conductors
REE Rare Earth Element
1
CHAPTER 1
1 INTRODUCTION TO THE TRAINING ORGANIZATION
1.1 About Lanka Mineral Sands Limited (LMSL)
A well-known mineral sand deposit in Sri Lanka is at Pulmoddai, north of Trincomalee. Lanka
Mineral Sands Corporation was established in 1957 to mine and process heavy beach mineral
sands. The corporation was converted to a limited liability company fully owned by the
Government under the name Lanka Mineral Sands Limited in 1992 and now the company is under
the Ministry of Industry and Commerce. Pulmoddai is located 55 km north of Trincomalee.
It has been an active mine since 1957. The functions of this company are mining, processing and
exporting of heavy mineral beach sand. The deposit is one of richest occurrences of heavy mineral
sand along the beach from Nilaveli to Mulativu. These deposits were formed by marine processes,
probably at the intersection of shorelines and Yan Oya. It has been estimated that a total quantity
of 12.5 million tons of unexploited valuable mineral sands are available in and around Pulmoddi.
Nowadays the heavy mineral percentage of the Pulmoddai area is around 40%.The average heavy
Figure 1-: Lanka Mineral Sands Limited company logo
2
mineral assemblage comprises 65% Ilmenite plus Leucoxene (Hi-Ti), 10% Zircon and 10% Rutile.
The remaining non-valuable heavy minerals are predominantly Monazite, Garnet and Sillimanite.
Processing plant is located at Pulmoddai. Head office is located at Rajagiriya. Fresh water
requirement for the plant is pumped from Yan Oya which provides continuous supply of water
throughout the year. Pulmoddai has access by road from Colombo via Anuradhapura or
Trincomalee with distance of 330 km and 310 km respectively. Air transport is also available from
Colombo to Trincomalee.
Currently LMSL is mining beach sand from Kokkilai lagoon to Arisimalei, a 7 Km long shore and
about 20 m towards the land side along the shore line. Much of the production is exported by the
company. Mainly the mineral sand is exported to India, China, Japan, Pakistan, USA and United
Kingdom. Main local buyers are Alchemy Heavy Metals (PVT) LTD, Lanka Minerals & chemicals
(PVT) LTD and Olecmo Minerals & Processing Company. I had my industrial training programme
at IRZ plant Pulmoddai from 11th of January 2016 to 1st of April 2016.[1][2]
1.2 Vision, Mission & Objectives of LMSL
1.2.1 Vision
To be one of the leading foreign exchange earners in the country.
1.2.2 Mission
To optimize the worth of heavy mineral beach sands and other natural resources
accessible to the company.
1.2.3 Objectives of the Company
Main objective
To promote a business culture that would enhance the benefits to the various
stakeholders.
Other Objectives
Enhance servicing to the Industrial sector
Diversify into other value added products
Survey and identify new deposits
Continue assessment of market opportunities
3
1.3 Types of End Products of LMSL
Figure 1-: ILMENITE (FeO.TiO2)
Figure 1-: RUTILE (TiO2)
Figure 1-: ZIRCON (ZrO2.SiO2)
4
LMSL had an annual capacity to produce 125,000 tons of Ilmenite, 12 000 tons of rutile and 8,000
tons of zircon with the facility to separate available monazite and garnet. But now plant
machineries are depreciated so the plant capacity reduced. Estimated annual plant production is
approximately as follows.
Ilmenite - 50,000 tons
Rutile - 2,000 tons
Zircon - 500 tons
Figure 1-: LEUCOXENE (Hi-Ti-Ilmenite)
Ilmenite60%Rutile
12%
Zircon8%
Others2%
Quartz 18%
Figure 1-: Available mineral sand percentages in Pulmoddai deposit
5
1.4 Organization Structure
1.5 Present Performance and Profitability of LMSL
Income Statement describes the financial performance of LMSL. Annual net profit of this
company is 19 million in 2013 and 325 million in 2014. Therefore the profitability of the company
has increased by 306 million in 2014 compared to 2013. But when it comes to 2016 the situation
is much more different. Financial position of LMSL is described by the balance sheet. Gross profit
has been increased in 2014 by 38.8 % with respect to the year 2013, according to the Income
statement. But the financial income has been decreased by approximately 9 million in 2014 respect
to the year 2013.
Competent Authority
General Manager (GM)
DGM (Human Resources)
Personnel
Administration
Security
Transport
DGM (Plant & Operation)
Chief Chemist
Chemist
Lab Assistat
Lab Attendant
Chief Engineer (M & S)
EE
SP
TA
PL
CE
SP
TA
PL
ME (MWS)
SP
TA
PL
ME (MES)
SP
TA
PL
Chief MPE
MPE
SP
TA
PL
DGM (Finance)
SFM
SM
SO
MA
PL
FM
Accounts
Officer
MA
PL
Figure 1-: Organizational Structure of LMSL
6
Table 1-: Income Statement
For the Year Ended 31st December
Description 2013 2014
Gross Revenue 678,946,617 1,219,804,738
Value Added Tax (3,266) (23,861)
Net Revenue 678,943,262 1,219,780,877
Cost of Sales (178,861,152) (625,602,242)
Gross Profit 500,082,162 694,178,635
Other Operating Income 11,506,361 20,576,111
511,588,461 714,764,746
Distribution Cost (4,009,763) (7,105,969)
Administrative Expenses (164,367,320) (166,780,929)
Other Operating Expenses (358,091,466) (268,806,844)
(526,468,539) (422,692,742)
Operating Profit (14,880,078) 292,062,004
Finance Income 44,724,716 35,547,169
Profit before Income Tax for the year 29,844,638 327,609,174
Income Tax Expenses (9,939,925) (1,882,404)
Net Profit for the year 19,904,713 325,726,770
Table 1-: Balance Sheet
As at 31st December
Description 2013 2014
Assets
Total Non-Current Assets 1,059,382,558 1,089,928,917
Total Current Assets 1,340,195,344 1,738,661,953
Total Assets 2,399,577,902 2,828,590,870
Equity & Liabilities
Total Equity 1,684,350,306 1,981,173,067
Non-Current Liabilities 58,456,171 77,198,511
Current Liabilities 656,771,425 770,219,292
Total Equity & Liabilities 2,399,577,902 2,828,577,902
7
1.6 SWOT Analysis
1.6.1 Strengths of LMSL
LMSL is the one and only commercially exported mineral sand exporting company in Sri Lanka.
The deposit at Pulmoddai area is one of the richest mineral sand containing beach deposit. This
deposit is from the nature and LMSL don’t have to pay any money to get that deposit. The deposit
can be easily accessed, mining and transporting is much easy due to the close distance between
the deposited shore line and the plant. Most of the working staff is from the village (Pulmoddai)
so the workers are in a delighted situation because it’s like working in their home. Village people
think that it’s an honor to work in LMSL. Workers are much respected and the workers have a
good state in the society if they work in the LMSL. This impression from the society is a great
strength to LMSL. When it comes to foreign exchange, LMSL plays a major role in the Sri Lankan
economy. The working staff is around 600, it is a great opportunity for the local Engineers,
technical officers and other working staff to serve for their mother country.
1.6.2 Weaknesses of LMSL
In the past LMSL directly exported end products via Pulmoddai Jetty but now the Jetty is not in
proper condition. So to transport final products nowadays the management and the buyers are
using the available road. So the transport cost of the end products is much high. So the transports
are taking a much profit by transporting. That profit should definitely come to LMSL to earn a
good profit. That is a major weak point when analyzing the company present situation. Regular
power failure is also a major problem weak situation at LMSL. This situation can be overcome by
the use of generators, capacitors & battery linked system but the authorities don’t take necessary
steps to overcome this situation. The process of the plant isn’t doing well with, over 30 year’s old
machineries in the plant such as Wet High Intensity Magnetic Separators (WHIMS) at Block B,
High Tension Separators at Rutile Zircon plant. That is a huge wastage of mineral sands. Also the
most of the staff such as mechanics, welders and other laborers do not hold the proper educational
and professional qualifications. They were hired in order to gain political advantages by politicians
without considering their qualifications.
8
1.6.3 Opportunities for Improvement
Rebuilt the jetty and start mineral sand export directly via sea using jetty at Pulmoddai.
Encourage the foreign investments and get the technology for value addition process.
Identify available nearby deposits.
Identify new locations & build new plants to extract the far away new deposits.
Identify and apply modern technology to processing plants.
1.6.4 Threats
The quality of the deposit is getting decrease in the current mining area.
The bad political influence to the company.
Lack of modern technology.
Old machinery system in the processing plans.
Helplessness in the fully government frame.
Long and time consuming process of decision making.
1.7 Usefulness to the Sri Lankan Society
Mineral Sand is a treasure to Sri Lankan society and economy. Over the last fifty years LMSL is
mining and exporting mineral sand and absorb foreign exchange to Sri Lanka in a great amount.
This is the only commercially exploited mineral sand deposit in Sri Lanka. It accommodates and
occupies around 600 employees and it’s a great service to the Sri Lankan society.
1.8 Suggestions to Improve the Performance
Rebuilt the jetty at Pulmoddai and start to export the upgraded sand directly to foreign
countries.
Don’t sell any product to local buyers unless they are value adding.
Replace old machinery and equipment to enhance the separation process and to minimize
the wastage.
Start the Value addition process.
Increase the accuracy and efficiency of correct decision making process in executive staff.
Reduce the isolated feeling of the workers from their homes and the negative mind in the
working staff and labors.
9
Increase the satisfaction and the feeling of working at LMSL of the workers to obtain a
better service and support.
Figure 1-: LMSL IRZ PLANT, PULMODDAI
10
CHAPTER 2
2 TRAINING EXPERIENCE
2.1 Introduction
In my 12weeks training period at LMSL I was able to train in Mechanical Workshop, Mobile
Equipment Section and Wet Gravity Upgrading Plant (Block A).
1. Mechanical Workshop – 6 weeks
2. Mobile Equipment Section – 4 weeks
3. Wet Gravity Upgrading Plant (Block A) – 2 weeks
In the University I learned the basics about workshop practices, Manufacturing Engineering,
Design of Machine Elements, Automobile Engineering and Fluid Mechanics. It was a great
foundation for me in the training period at LMSL. I gained a good knowledge about maintenance
practices, mineral processing as well as beach sand mining activities, not only that but also the
management skills. The library of the LMSL is at the laboratory and I gathered a good knowledge
by reading books and manuals available at library.
2.1.1 Personal Involved
Mr. Gnaneshwaram
He is the acting DGM (Plant & Operation) in LMSL & charted mechanical engineer in the
MES, graduated from University of Peradeniya. Even though he is a very busy with his
responsibilities, he gave me an introduction about which areas I should focus in the MES
& it was really helped me to cover things within 4 weeks I spent in MES. I engaged with
him when I was undergone the training at MES.
Mr. Rajapaksha Bandara
He is a very experienced mechanical engineer in LMSL mechanical workshop, graduated
from University of Peradeniya. I engaged with him when I was undergone the training at
MWS. With the experience and ability he think & tries to execute new ideas for the
betterment of the company, while in this process he actually admit and handle the risk of
work. He asked questions & explained reasons, solutions in an effective manner.
11
Mr. Rajapaksha
He is the civil engineer in LMSL has a very deep knowledge in construction & maintenance
fields. I had a great opportunity to visit ‘Yan Oya’ fresh water intake site under his
concession. I engaged with him when I was undergone the training at civil section.
Mr. Sisira Kumara
He is a chemist in LMSL graduated from University of Sri Jayewardenepura. He is also
the in charge person at library at LMSL. He helped me to use the library to gather
knowledge. The guidance and the experience given can be greatly appreciated.
Mr. Susantha Rajaguru
He is the senior Mining & Processing Engineer in LMSL. Currently he is the chief of all
the processing plants. Graduated from University of Moratuwa, Department of Earth
Resources. He has a good knowledge & experience in beach sand mining as well as in
heavy mineral processing industry. He supervised me during my training period at Block
A.
2.1.2 Heavy Minerals
Mineral sands contain suites of minerals with high specific gravity known as ‘heavy minerals’.
They include economically important minerals rich in titanium, zirconium and rare earths.
Rutile (TiO2) is a red to black, naturally occurring titanium dioxide with a theoretical TiO2
content of 100%, but impurities such as Fe2O3 and Cr2O2 reduce this to 93–95%.
Ilmenite (FeTiO3) is black and opaque when fresh, but has typically undergone some
weathering and iron removal, so TiO2 contents are between 45 and 65%.
Leucoxene is the name given to highly altered Ilmenite. Grains are brown or grey with a
waxy luster and TiO2 content of 68%.
Zircon (ZrSiO4), a colorless to off-white mineral, is the world’s major source of zirconium
products.
2.1.3 Origin and formation of heavy mineral sand deposits
Mineral sand deposits are formed from the erosion and weathering of pre-existing igneous rocks
such as granite, pegmatite and basalt. Beach placers are formed when the mechanical or chemical
breakdown of rock masses is followed by a redistribution of the material along the continental
shelf. Over 60 to 200 million years the combinations of wind and water from ancient rivers and
12
seas have leached the minerals from their past rocks and concentrated them into beach and dune
deposits. The movement of the sea gradually sorts the sediments, directing the finer materials into
deep water and the coarser materials towards the shore.
The valuable minerals are generally resistant to weathering and hence become concentrated with
the coarser grained sediments, the final distribution of values being affected by the sedimentation
properties of the particles and the strength and direction of the wind and ocean currents. In many
cases there is a constant interchange between the beaches and the bars (deposits in the sea). The
result is that today, mineral sand deposits can occur at varying levels above the present sea level.
Generally, the minerals in the top 3-5 meters have a high titanium dioxide (TiO2) content and a
concentrate of zircon and monazite at the base of the deposit.
2.1.4 Physical properties of Heavy Mineral sands
Table 2-: physical properties of Heavy Minerals
Mineral Colour Hardness Specific
Gravity
Magnetic
property
Conductivity
Ilmenite Iron black 5.5 4.5-5.0 magnetic conducting
Rutile Reddish brown 6.0 4.2-4.25 Non-magnetic conducting
Zircon yellow-golden 7.5 4..2-4.9 Non-magnetic Non-conducting
Leucoxene yellow to brown 5.5 3.5-4.5 magnetic conducting
Monazite yellowish 5.0 5.2 weakly-magnetic Non-conducting
Garnet Pink 6.5 3.5-4.2 weakly-magnetic Non-conducting
Sillimanite yellow 7.5 3.25 Non-magnetic Non-conducting
Quartz Colourless 7 2.65 Non-magnetic Non-conducting
13
Table 2-: Relative Magnetic Susceptibility of Heavy Minerals
Mineral Relative Magnetic Susceptibility
Magnetite 40.19
Ilmenite 11.67
Garnet 6.68
Hematite 4.64
Monazite 4.11
Rutile 0.93
Zircon 0.47
Quartz 0.40
2.1.5 Uses of Heavy Minerals
Ilmenite is used to manufacture Titanium metal and it is mostly used to manufacture Titanium
dioxide white pigment. Which has its peculiar characteristics such as pure whiteness and
brightness than any other pigment can achieve. Nontoxic in contract to lead pigment, stand high
temperature, does not change it color when it continuously exposed to sunlight. Therefore, the
ultimate use of this mineral is in paper, plastic, rubber, textile, cosmetics, sunscreens, leather, and
food coloring and ceramics industries and to make printing ink.
Rutile is the raw material for the manufacture of world's "present and future". Titanium metal is
very light as aluminum and very strong as steel. Highly resistant to corrosion and have a very high
melting point. So it is ideal for use in aircraft engines, spacecraft, missiles, cars, sports equipment
such as racing car parts, tennis racquets and bike frames, wrist watches, underwater craft, and
general industrial equipment. Its non-toxicity also makes it useful for surgical implants such as
pacemakers, artificial joints and bone pins. Titanium is also used to manufacture chlorine. Rutile
is widely used as a welding electrode covering.
14
Zircon sand is resistant to corrosion and can withstands high temperatures. Therefore, it is widely
used in furnaces as refractory liners and in foundry casings. Another major use is that it is a glazing
material in Ceramic industry which is widely growing today. Zirconium compounds extracted
from zircon are commonly used in television sets, leather, water proofing of fabrics, lacquers,
drugs as catalysts in chemical processes and also in high temperature works.
Monazite even though is a radioactive mineral due to the presences of thorium its main use is as a
good source of rate earth compounds. Monazite is therefore important for the electronic and
computer industry. It is also used in glass manufacture and polishing lighter flints and in high
strength permanent magnets. In the meantime, the areas of application for REE have undergone a
drastic change. Nowadays they are almost exclusively used in a very large spectrum of high
technology applications after having undergone elementary and high-purity processing. Owing to
technical advances, new areas of application continuously arise, while others decline in
significance.
2.2 Production Flow
In IRZ plant sand is mined and heavy valuable minerals are separated. This separation process is
based on the physical properties mentioned above. First the raw sand is cleaned in order to remove
large unnecessary objects such as large stones, tree roots and seashells using strainers and vibrating
screens. Then this cleaned sand is pump to the gravity upgrading plant to extract the heavy minerals
from the row sand mixture. This processes performed using spiral concentrators (gravity
separators). Here the process is based on the specific gravity property of minerals. The specific
gravity of heavy minerals are higher than that of quartz. During this process the light sand part
which contains mostly quartz is removed and the extracted heavy mineral part which contains
Ilmenite, Rutile, Zircon, Garnet, Monazite and Magnetite is pumped to the next plant, Block B
using slurry pumps.
In the second process at Block B the heavy minerals mixture is subjected to a separation process
based on the magnetic properties of the minerals. According to the relative magnetic properties,
minerals which have high magnetic properties are separated from the minerals which have low
magnetic properties. Here at first the minerals mixture is flew through two Magnetic Drum
Separator which contains permanent magnets to remove magnetite from the mixture. This is due
to magnetite shows high magnetic properties. Then the separated minerals mixture is flew through
15
an electromagnetic field which extract the rest of minerals which have low magnetic properties
leaving Ilmenite. This process is also a wet process. Therefore this extracted Ilmenite part is
pumped to the Ilmenite go-down and sent through a hydro-cyclone to dry the wet Ilmenite. Then
the extracted minerals mixture is sent to wet mill and dry mill to continue the separation process.
At the wet mill gravity separation is further performed using spiral concentrators and wet tables.
And the heavy minerals are extracted which contains Zircon, Garnet Monazite, Rutile and High
Titanium Ilmenite (Hi-Ti). Hi-Ti and Rutile shows good electric conductivity relative to Zircon,
Garnet and Monazite. Based on these properties Hi-Ti and Rutile are separated from the mixture
using Electro Dynamic Roll Separators and Electro Static Plate Separators at Dry Mill. This Hi-Ti
and Rutile mixture is the separated into Hi-Ti and Rutile using High Intensity Magnetic Separators
based on the magnetic properties of the relevant minerals.
The dried Zircon, Garnet and Monazite mixture is also separated according to the electric
conductivity properties. Here Zircon is extracted from the mixture. Then the remaining Garnet and
Monazite mixture is subjected to magnetic separation using High Intensity Magnetic Separators
and Monazite and Garnet are separated. Following figure illustrate the production flow diagram.
16
Figure 2-: Production Flow of LMSL Pulmoddai plant
17
2.3 Separation Machineries Used
Followings are the important machineries used and their process to perform separation processes
according to the production flow.[2]
2.3.1 Strainer
Used to clean and filter raw sand to remove large size particles and obtain very small sized mineral
sands mixture.
2.3.2 Spiral Concentrators
Used to separate heavy mineral mixture from raw sand. The sand pulp is inserted from the top of
the spiral and let the pulp flow under gravity within the limited circular space. The spiral canal
surface have a smooth surface. There are splitters in the canals of spirals which can be adjusted to
obtain various concentrations of the heavy sand mixture. The separation takes place due to the
centripetal force when the flow of the pulp is from top to bottom of the spiral. Because of
centripetal force heavy minerals mixture concentrates near the inner wall of the spiral canal
(Centre) while the light weighted quartz and other unwanted sand mixture concentrates near the
outer wall of the canal (circumference). Then the heavy minerals mixture is collected from gates
located near the inner wall of the canal at the bottom of the spiral. There are three gates as Heavy
Cut Gates, Middling’s Gates and Tailings Gates. Heavy cut is directly pumped to the next process
plant while the middling’s are further separated using spirals and tailings are pumped to tailings
go-down.
Figure 2-: Strainer at Block A
18
2.3.3 Magnetic Drum Separators
The ERIES low intensity wet magnetic separator (LIWDMS) is mounted to remove highly
magnetic susceptible material such as magnetite. This particular magnet is a double drum counter
rotation unit rated at 106 m3/hr. This double drum Eriez magnet is designed as a method by which
highly magnetic material is removed from the magnetic circuit before enter to wet high intensity
magnetic separator machine. Basically, each drum consists of a set of permanent magnet
occupying a certain radius of rotating metallic shell. Dilute slurry is introduced onto the shell. This
conveys the magnetic past the magnet. The non-magnetics are not influenced by the magnetic
field, and fall into nonmagnetic launder. These drums will comfortably accept feed densities up to
20 % solids by weight per single counter rotation operation. Heavy minerals mixture is inserted to
the Magnetic Drum Separator to extract Magnetite which have higher magnetic properties. The
Separator contains permanent magnets. The magnetic field intensity is low in permanent magnets
Figure 2-: Spiral
Concentrator
Figure 2-: Splitter in a canal of a Spiral Concentrator
19
with compared to Electro Magnets. So only the particles which have high magnetic properties such
as magnetite are extracted by this separator.
2.3.4 Wet High Intensity Magnetic Separator (WHIMS)
Wet High Intensity Magnetic Separator[3] is produced by Readings of Lismore private limited.
Sixteen pole WHIMSs are mount on Wet Magnetic Separation Plant (WMSP). The Readings
WHIMS machines are relatively complex machines compare to other devices in Block B plant.
The machine setup a stationary magnetic field at eight points around the circumference. A rotating
rotor takes feed through alternating high and low intensity areas of the field, thus separating
paramagnetic and non-magnetic particles. The separated slurry is washed through the rotor into
the relevant collection boxes bellow, and then to the correct piping and laundering.
The machine frame
The machine consists of a yoke. This constructed of heavy cross section low carbon mild steel.
This is rolled to form a continuous circular member of carefully selected diameter. This heavy
yoke is mounted upon a hollow and square tubular frame which supporting crosses members.
The magnetic coils
The magnetic circuit originates within the magnet core blocks which are equally spaced around
the internal circumference of the yoke. These large section core block permit ready development
Figure 2-: Magnetic Drum Separator
20
of a magnetic flux as induced from the intense power capability of the magnetic coils. The magnet
coils are constructed from a flat copper foil conductor with inter winding polyester film insulated
rated to withstand 1300 0C. This complete winding is encased in stainless steel tank and forced oil
cooled with a suitable coolant. The cooling oil is forced through the system by means of electric
motor drive pump coupled with a water cooled heat exchanger. This oil is passed through the
exchanger into the coil casing and finally returned to the pump for recirculation. The pattern of
the flow of current permits each coil to develop a magnetic flux between adjacent poles of
dissimilar polarity, while null zones are developed between adjacent poles of like polarity. In this
manner the required field intensities are available to enable the separation process to be
continuously and effectively carried out. This particular magnetic configuration creates eight
identical feed points upon the sixteen pole machine. The magnetic flux is developed within the
core block, passes through the salient plates of the rotor to return to its point of origin through the
retaining yoke.
The Salient plates
The salient plates are manufactured from number of highly magnetic stainless steel laminations.
These laminations are stacked together. The whole assembly welded to form a single unit. The
required numbers of plates are then welded between parallel bands of stainless steel which form
the outer circumference of the rotor at the desire air gap spacing.
The wash water jets
Nonmagnetic product wash water jet is used for the washing of the nonmagnetic product. The
magnetic product wash water jet is utilized for the cleaning of the magnetic product.
The catch boxes and splitters
These are located beneath the machine. These devices are relevant to the catching, grading and
distribution of the separated products. The product pass through the rotor plates into catch boxes
after grading by the splitter. And ore then gravitated through hoses into the production collection
boxes. The catch boxes are manufactured from a stainless steel sheet.
21
2.3.5 Spiral classifier
The EIMCO-KCP manufactured spiral classifier is using in the Wet Mill plant to remove fines.
When the feed is introduced to spiral classifier, particle of lower settling velocity is carried away
in a liquid overflow and the particles of higher velocity is deposited on bottom and dragged upward
against the flow of liquid by spiral like rotating shaft.
Figure 2-: Wet High Intensity Magnetic Separator (WHIMS)
Figure 2-: Spiral classifier
22
2.3.6 Attritioner
Attritioners are doing a great function that is much useful to enhance the actual physical qualities
of the minerals by removing clay coat and polishing the sand. The Attritioner is having seven cells.
There are three impellers inside the shell fixed to cartridge. There are separate seven motors for
seven cells. Feed material pulp density should be in 70-80 % range to achieve better polishing. In
the cell one impeller rotates right hand side and next impeller rotates left hand side.
2.3.7 Hydrosizer
Hydrosizer is also using in the Wet Mill. It is also a one of the classifiers which classify the coarse
and fines. It is used to remove separated clay coats from polished sand. The fines & coarse sand
are pumped out to separate locations and fines are discharged while coarse sand is feeding to the
Dry Mill Rutile section.
Figure 2-: Attritioners
Unpolished
Minerals Polished
Minerals
23
2.3.8 Wilfley tables
Wilfley table is one of the most efficient mineral processing devices. It is one kind of shaking
table. It consists of slightly inclined deck with riffles. When a flowing film of water flows over a
flat, inclined surface the water closest to the surface is retarded by the friction of the water absorbed
on the surface, the velocity increases towards the water surface. If mineral particles are introduced
into the film, small particles will not move as rapidly as large particles, since they will be
submerged in the slower-moving portion of the film. Particles of High specific gravity will move
more slowly than lighter particles, and so a lateral displacement of the material will be produced.
The flowing film effectively separates coarse light particles from small dense particles. It consists
of a slightly inclined deck, on to which feed, at about 25% solids by weight is introduced at the
feed box and is distributed. Wash water is distributed along the balance of the feed side from
launder. The table is vibrated longitudinally using a slow forward stroke and a rapid return, which
causes the mineral particles to "crawl" along the deck parallel to the direction of motion. The
minerals are thus subjected to two forces that is due to the table motion.
The net effect is that the particles move diagonally across the deck from the feed end and, since
the effect of the flowing film depends on the Size and density of the particles, they will fan out on
the table, the smaller, denser particles tiding highest towards the concentrate launder at the far end,
Figure 2-: Hydrosizer
24
while the larger lighter particles are washed into the tailings launder, which runs along the length
of the table.[4]
2.3.9 Cone filter
Cone filter is used to filter the moisture in the final zircon concentrate in Wet Mill. Moisture
content is reduced up to 6% in cone filter then it allows feed to dryer at Dry Mill. Here the cone is
coupled with a gear unit and cone is allowed to rotate continuously and the zircon concentrate
slurry pours from a Hydro cyclone. When the blower starts, then it will suck the air inside the cone
and vacuum created. So the water in zircon layer above very fine aperture screen will be sucked
into cone and it will drain to the bin through the hole in the bottom of cone. The filtered crude
Figure 2-: Wilfley table
Figure 2-: Process of Wilfley table
25
zircon layer gradually cut by a scrapper and it allows to, fall the crude zircon in to a large bin under
cone filter.
2.3.10 High Tension Electro Dynamic Roll Separator
Carpco manufactured high tension electro dynamic separator are mount on this plant Lots of high
tension electro dynamic separator are mount on this plant to separate minerals A large percentage
of the commercial applications of high-tension separation has been made using the "pinning
effect", in which non-conducting mineral particles (zircon, monazite), having received a surface
charge from the electrode, retain this charge and are pinned to the oppositely charged separator
surface by positive-negative attraction. Following figure the principle of separation
diagrammatically.
Figure 2-: Cone Filter
Figure 2-: Schematic Diagram of High Tension Electro
Dynamic Separator
26
The mixture of rutile, zircon, leucoxene & monazite minerals are fed on to a rotor made from mild
steel which is earthed through its support bearings. An electrode assembly, comprising a brass tube
in front of which is supported a length of fine wire, spans the complete length of the roll, and is
supplied with a fully rectified DC supply of up to 30 kV, usually of negative polarity. The voltage
supplied to the assembly should be such that ionization of the air takes place. This can often be
seen as a visible corona discharge. Arcing between the electrode and the roll must be avoided, as
this destroys the ionization. When ionization occurs, the minerals receive a spray discharge of
electricity which gives the poor conductors a high surface charge, causing them to be attracted to
and pinned to the rotor surface. The particles of relatively high conductivity (rutile, leucoxene) do
not become charged as rapidly, as the charge rapidly dissipates through the particles to the earthed
rotor. These particles of higher conductivity follow a path, when leaving the rotor. The electrode
gap is kept at minimum distance where no sparking occurs. Factors affecting the separation are,
Rotor speed
Particle size
Feed rate
High tension voltage
Electrode position
Figure 2-: High Tension Electro Dynamic Roll Separator
27
2.3.11 High Tension Electro Static Plate Separator
Carpco manufactured electro static plate separators are mounted in Dry Mill. Electro static plate
separators are mounted on two stage of mineral separation for a specific reason. One set of ESPS
are mount at final stage of rutile circuit. In HTEDS oversize non-conductor may not pin the rotor
due to high centrifugal force so it will throw to conductor fracture so the ESPSs are installed to
remove these non-conductor over size material from rutile. Other set is installed on non-conductor
purification circuit. In HTEDS very fine conductors may be pinned the rotor and go to non-
conductor fracture. So ESPS is mounted to separate these fine conductors from non-conductor.
The attraction of particles carrying one kind of charge towards an electrode of the opposite charge
is known as the "lifting effect", such particles are lifted from the separating surface towards the
electrode. Materials which have a tendency to become charged with a definite polarity may be
separated from each other by the use of the lifting effect even though their conductivities may be
very similar. Pure electrostatic separation is relatively inefficient, even with very clean mineral
and is much sensitive to changes in humidity and temperature.
Figure 2-: Schematic Diagram of High Tension Electro Static Plate
Separator
28
2.3.12 High Tension Electro Static Screen Separator
Final cleaning of the production is often carried out in purely electrostatic separators. The feed
particles gravitate down a sloping, grounded plate into an electrostatic field induced by a large,
oval, high-voltage electrode. The electrostatic field is effectively shorted through the conducting
particles, which are lifted towards the charged electrode in order to decrease the energy of the
system. Non-conductor grains are poorly affected by the field. The fine grains are most affected
by the lifting force, and so fine conductors are preferentially lifted to the electrode, whereas coarse
non-conductors are most efficiently rejected.
Figure 2-: High Tension
Electro Static Plate Separator
Figure 2-: Schematic Diagram of High
Tension Electro Static Screen Separator
29
2.3.13 High Intensity Induced Roll Magnetic Separator
Very weakly paramagnetic minerals can only be effectively removed from an ore feed if high
intensity fields are used. Nonmagnetic particles are thrown off the roll into the tailings
compartment, whereas magnetics are gripped, carried out of the influence of the field and deposited
into the magnetics compartment. The gap between the feed pole and rotor is adjustable and is
usually decreased from pole to pole to take off successively more weakly magnetic products. There
are three induced roll magnetic separators are mount in Dry Mill to separate magnetic minerals
from non-magnetic minerals. When the feed passes through a high intensity magnetic field
generated between a feed rotor and an adjacent pole piece, the magnetic particles are attracted to
the rotor while non-magnetic particles throw away. The attracted particles are removed by a
tension brush.
Figure 2-: High Intensity Induced Roll Magnetic
Separator
Figure 2-: Schematic Diagram of High Intensity
Induced Roll Magnetic Separator
30
2.4 Mechanical Workshop
Mechanical workshop is a service and maintenance section of the plant which provides services
required in plant operations. There are 21 personals in this section. Mr. Rajapaksha Bandara
(Mechanical Engineer) is the head of this section. He was my supervisor during my training period
at Mechanical Workshop. There was a Supervisor and a Technical Assistant also. The labor crew
was consisted with a foreman, two lathe machine operators and three welders.
There are three fixed bed type lathe machines, one horizontal milling machine, one shaping
machine, one bending machine, one hydraulic press, one vertical milling machine, two drilling
machines and a hack saw machine. Most of the tools required for these machine works are stored
in the workshop stores.
I had opportunity to engage with several important works performed in this section.
2.4.1 Work Procedure
There is a standard procedure in mechanical workshop to be performed when there is a job to be
done. First of all the person or the section who need the service of the Mechanical Workshop
should fill a form called the “JOB CARD” describing the required service, the priority of the
required service and further details. If necessary, Drawings and diagrams related to the required
service must be attached with this document. This document should be signed and approved by
the relevant section’s head which requires the service. Then this document will be examined by
the Mechanical Workshop Head and approve and sign if the job can be performed. While and after
completing the job, the labors who performed the job and the relevant officers and executives fill
the same document mentioning the types and amount of material required for the job, type and
number of labors performed the job and number of general and over time work hours spent to the
job. And then they all sign the document. Then this document along with the Stores Issue
Requisition form will be handover to the Finance Section to calculate the cost.
Stores Issue Requisition form is used to order required items for any job or for workshop from the
Main Stores.
Gate passes are used to gain permission if any kind of item inside the plant should be sent outside
from the plant.
31
Figure 2-: Job Card
Figure 2-: Stores Issue Requisition Form
32
2.4.2 Fabricating works of bins for Wet Gravity Upgrading Plant
Fabrication works of 6 different sized bins were performed during my training period. We
fabricated these bins using 7.5mm thick Mild Steel plates. Gas cutting and welding works were
performed to cut the plates and to assemble them. We also used L angle bars.
The major difficulty we faced during the bin fabrication process is handling the bins. Due to limited
space available inside the workshop we had to move the bins to another shelter time to time. And
the plant does not own a crane or any suitable machinery to perform this transportation except a
fork lifter which can lift maximum of 5 tons. My supervisor guide me to calculate the weight of
the largest bin using the density of Mild Steel and volume of the bin by taking relevant
measurements. Density of Mild Steel is 7850 kg/m3 and the volume of the largest bin was 0.39843
m3. So the approximate weight of the bin was 3128 kg. According to this information we decided
to transport the bins using the fork lift.
2.4.3 Repair Works of the Magnetic Drum Separator
One of the Magnetic Drum Separator was damaged by a heavy roof bar fallen on to it. The shell
of the drum was deformed as the drum separator could not be operated. We managed to fix the
shell by bending the shell plate in bending machine. The shell was made of Stainless Steel. The
drum assembly weights about 3 tons. A figure of a labor was injured during repair works of the
drum by falling the shell on to his hand. Following figure shows the deformed drum shell.
Figure 2-: Fabricating Bins
33
Following figure shows the repaired drum shell.
Figure 2-: Deformed Drum Shell
Figure 2-: Repaired Drum Shell
34
2.4.4 Manufacture a Bolt in Lathe Machine
Machining works of 4 screw bolts were performed on the lathe machine. These bolts are used to
fix a motor bed to the supporting concrete bed. One of the bolts were broken. They sent us a job
to machine 4 of the required bolts. They sent us the broken bolt to machine identical 4 bolts using
the broken bolts details.
The bolt was 91mm in length, 13mm diameter screwed 25mm long end which should have 11
threads per inch (11 TPI), the next 62mm length shaft part having 22mm diameter and the top cap
is 4mm in length having 35mm diameter.
Following figure shows the Machined Bolt.
Figure 2-: Broken Bolt
Figure 2-: Machining the Bolt in Lathe Machine
35
2.4.5 PE Pipes for the Fresh Water Line
The fresh water required to the plant operations and the general uses of the plant is pumped from
the Yan Oya. There is an ongoing project for the new fresh water supply line. They are using PE
Pipes (Polyethylene Pipes) for this new supply line. My Supervisor, Mr. Bandara Rajapaksha is
one of the leading supervisor of the project who selected the PE Pipes for the project. I had the
opportunity to examine Butt Welding Processes and Pressure Tests of this line during several field
visits on the project with Civil Engineer Mr. Rajapaksha.
The PE Pipes for this project was bought from a leading Turkish PE Pipe manufacturing company
named “FIRAT”. These PE Pipes categorized to the PE 100 series PE Pipes which can withstand
a maximum 10 bar pressure. “PE 100” stands for Polyethylene pipes which can bear a maximum
pressure of 10 bars.[5]
These PE Pipes were joined by Butt Fusion welding
Figure 2-: Machined Bolt
Figure 2-: Butt Fusion Welding Machine
36
We did a pressure test on a part of the supply line by filling the pipes with water and sealing the
both ends and then further we filled water using a pressure pump until the water pressure inside
the pipe line reaches 10 bars. Then the pipe line is fully sealed and kept for 30 minutes and
examined the pressure gauge for any pressure decrement. If a pressure drop occur, there should be
a leakage at any point such as in a butt weld.
Figure 2-: Welded Pipe
Figure 2-: Pressure Test
37
Advantages of PE Pipes can be listed as follows,
Have high flexibility features, thus ensures ease of installation. Elongation at break is
minimum 350%
Not affected from underground movements
Have high impact resistance and rapid crack propagation resistance
Figure 2-: Lifespan of PE 100 Pipes
38
Low interior surface roughness
Not affected from sea water and sea movement. Therefore suitable for installing in sea
bottom
No installation wastage due to joining method
Black colored pipes are resistant to UV rays
Resistant to chemical substances
Do not effect on changing the odor or taste of water
Plants and tree roots cannot penetrate into these pipes
2.5 Mobile Equipment Section
Mobile Equipment Section (Also known as the Garage) is the service section of mobile equipment
of the plant. The work procedure is same as it is in Mechanical Workshop. This section also
supplies wheeled loaders, tractors and fork lifter for the plant operations. There are 5 Wheeled
Loaders (One Caterpillar loader, two Komatsu loaders and two JCB loaders), One Fork Lifter and
4 Tractors.
All the service works of above mentioned mobile equipment and vehicles in transport section also
done at this section.
There are 53 personals in this section. The head of this section is Mr. Gnaneshwaram (Mechanical
Engineer), the acting DGM (Plant & Operation).
2.5.1 Turbo Charger of JCB wheeled loader
Turbochargers and Intercoolers are used in heavy vehicles and heavy earthmoving machineries in
order to speed up the engines. Following figure express how the Turbocharger and Intercooler
system works.
39
Normally the speed of the turbocharger in idle condition is about 5000 rpm. When the engine is in
load it increases to 25000 rpm. The turbocharger is forced lubricated by the same lubrication
system of the engine. When engine cut off, the lubrication process also stops. But the turbocharger
rotation does not stop suddenly when the engine is cut off. If we cut off the engine power suddenly
after running with load the turbocharger rpm will be high and lubrication will be stopped. So the
turbocharger will work without lubrication oil and it will damage the bearings which will block
the turbocharger.
This was the trouble occurred in the turbocharger unit in the JCB loader. This Turbocharger could
not be repaired. It should be replaced with a new on which is expensive. This kind of losses occur
due to irresponsible handling of this much of valuable machineries.
Figure 2-: Schematic Diagram of a Turbocharged System
Figure 2-: Cross Section of Turbocharger
40
2.5.2 Alternator of the Toyota Dyna Truck
The alternator brushes are worn out. They were replaced with brushes made with scratches by the
MES mechanics due to lack of spares in the stores. Alternator is the electromotive power generator
of a vehicle. It generates Direct Current for recharging battery and for power up vehicle electrical
loads.
Maintenance tips related to the alternator can be listed as follows,
Check alternator drive belt tension
Check vehicles charging system
Do not charge dead batteries (Alternator only can charge slightly discharged batteries.
Charging dead batteries can overload the alternator and damage it)
Check for irregular noise, smell, dim headlights or dashboard warning lights)
Figure 2-: Cross Section of an Alternator
41
2.5.3 Hydrostatic Transmission (HST) in Komatsu WA320-5 Wheeled Loader
Unlike in other wheeled loaders in the plant in KOMATSU WA320-5 Wheeled loader it use
Hydrostatic Transmission system[6]. It uses one axial piston pump and an axial piston motor.
There are no clutches and separate mechanism to brakes. Acceleration, Deceleration, reversing
and braking is done by changing the angle of the swash plates of the pump and motor.
Figure 2-: Schematic Diagram of HST
Figure 2-: Circuit Diagram of a Typical Alternator
42
Advantages of HST over other transmission types can be listed as follows.
No clutch mechanism required
Simple operation
No special mechanism required for brakes
No gear box
Ease of Maintenance
HST is applicable in high power require mobile equipment and machineries such as Tractors,
Forklifts, Excavators and Wheeled loaders.
2.5.4 Service Operations in Wheeled loaders
Engine oil of wheeled loaders are changed for every 250 hours of running and the Hydraulic Oil
is changed for every 500 hours of running. They use “CALTEX RANDO” HD 68 (SAE 20W),
HD 46 (SAE 20) and HD 32 (SAE 10W) hydraulic oil types.
The numbers 68, 46 and 32 are ISO viscosity grading. Unlike in Engine Oil (SAE grade) in
Hydraulic Oil it use ISO grading as a standard.
Functions and Properties of Hydraulic oil can be listed in a table as follows
Figure 2-: Caltex Rando Hd 68 Hydraulic Oil
43
Table 2-: Functions and Properties of Hydraulic Oil
Function Properties
Power transfer and Control medium Non compressibility
Fast air release
Low forming tendency
Low volatility
Heat transfer medium Good thermal capacity and
conductivity
Sealing medium Adequate viscosity and viscosity index
Shear stability
Lubrication Viscosity for film maintenance
Low temperature fluidity
Thermal and oxidative stability
Hydrolytic stability
Cleanliness and filterability
Demulsibility
Anti-wear characteristic
Corrosion control
Pump efficiency Proper viscosity to minimize internal
leakage
High viscosity index
Special function Fire resistance
Friction modifications
Radiation resistance
Environmental impact Low toxicity
Biodegradability
Functioning life Material compatibility
44
2.6 Wet Gravity Upgrading Plant (Block A)
The WGUP is designed to separate heavy minerals from raw sand by considering the specific
gravity of each mineral. Wet gravity upgrading plant consisting almost entirely of several spiral
stages, it is considered as the successful unit for upgrading the ore. The plant is designed to accept
feed material of varying heavy mineral contents and in order to produce heavy mineral concentrate
for the WMSP. Tailing are pumped to tailing yard. The feed rate to the WGUP is approximately
50 tons per hour.
Figure 2-: Simplified Flow Sheet of Wet Gravity Upgrading Plant
45
2.7 Training Facilities
I, as a trainee at Lanka Mineral Sand Limited, was granted with certain facilities. I received
accommodation facilities during the training period. My accommodations were located at
“Bachelor Quarters” which fulfilled all the facilities for accommodation. Also I received an
allowance of Rs.500 per day during my training period.
2.8 Social Functions
I had the opportunity to join to a “Pirith and Arms Giving” function organized by the Buddhist
Society of the LMSL. At LMSL there is also an Annual Cricket Tournament. There are also certain
societies to support the Cooperate Social Responsibility of the company.
Figure 2-: Bachelor Quarters
Figure 2-: Arms Giving Ceremony
46
CHAPTER 3
3 LANKA MINERAL SANDS LIMITED MANAGEMENT
Managing strategies which are faced by a firm is handled by the management level of the firm.
Lanka Mineral Sand Limited possess a great management organization.
3.1 5S Concept
Seiri (Sort)
Remove unnecessary items and dispose of them properly
Make work easier by eliminating obstacles
Reduce chances of being disturbed with unnecessary items
Prevent accumulation of unnecessary items
Evaluate necessary items with regard to cost or other factors
Remove all parts or tools that are not in use
Segregate unwanted material from the workplace
Need fully skilled supervisor for checking on regular basis
Don't put unnecessary items at the workplace & define a red-tagged area to
keep those unnecessary items
Waste removal
Seition (Systematic Arrangement)
Arrange all necessary items so that they can be easily selected for use
Prevent loss and waste of time by arranging work station in such a way that
all tooling / equipment is in close proximity
Make it easy to find and pick up necessary items
Ensure first-come-first-served basis
Make workflow smooth and easy
All above work should be done on regular basis
Seiso (Shine)
Clean your workplace completely
Use cleaning as inspection
Prevent machinery and equipment deterioration
Keep workplace safe and easy to work
47
Keep work place clean and pleasing to work in
When in place anyone not familiar to the environment must be able to detect
problems in 5 seconds within 50 feet
Seiketsu (Standerize)
Standardize the best practices in the work area
Maintain high standards and workplace organization at all times
Maintain orderliness. Maintain everything in order and according to its
standard
Everything in its right place
Every process has a standard
Shitsuke (Sustain)
To keep in proper working order
Also translates as "do without being told"
Perform regular audits
Training and Discipline
Training is goal oriented process. Its resulting feedback is necessary
monthly
3.2 Human Resource Management
In a firm, Human Resource is the most important resource it owns. The company survives because
of the capabilities and performance of its people. Maximizing those capabilities and that
performance are necessary. The Human Resource Manager carries this responsibility.
The Human Resource Management work on recruiting the skilled employees. Organize
workshops, seminars and Evaluations to improve the skills and knowledge of the employees.
Pulmoddai IRZ plant is consist of Sinhala, Tamil and Muslim employees. The Human Resource
Management has successfully managed to protect the cooperation of all nationalities without
conflict.
48
3.3 Safety Management
The Safety Management of Lanka Mineral Sand Limited perform at their best to ensure the safety
of their employees and the society while achieving the company’s targets. All the required safety
measures are taken in order to ensure safety.
All the Personal Protective Equipment (PPE) are provided to the employees despite of the
hierarchy. They are provided with safety shoes, eye protective goggles, helmets and overalls.
3.4 Welfare Management
The Welfare Management perform their duty by providing welfare facilities such as
Providing uniforms
Providing Personal Protective Equipment
Organizing an annual trip
Organizing sports tournaments
Providing nutrition packages monthly
Organizing national and religious ceremonies
3.5 Environmental Management
Achieving company goals with ensuring the protection of the environment is guaranteed by the
company. They guarantees about following point about environment protection.
We will not compromise on safety
We will comply with legislative requirements
We will work closely with our customers and provide them with best quality products
We will identify, assess and manage environmental, health and safety hazards, risks and
impacts of our operations
We will promote continuous improvement practices
We will strive to use resources more efficiently by reducing, reusing and recycling waste
products
We encourage and support our employees to make positive lifestyle changes
We will understand and work to meet the expectations of the community
49
We will provide appropriate training to employees and contractors to ensure
environmental, health and safety issues and responsibilities are clearly understood.
3.6 Corporate Social Responsibility
The company discharges its corporate social responsibility. Giving university and other
institutional student like us the opportunity to train in their company with great facilities is also a
great Corporate Social Responsibility.
Under their Corporate Social Responsibility, Street lamps and water tanks were provided for the
Pulmoddai village and a wall constructed for the village cemetery, assistance was given to religious
institutions and public places such as hospitals and schools, financial assistance was also given to
ten needy employees to repair/renovate their houses.
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CHAPTER 4
4 SUMMERY AND CONCLUSION
4.1 Summery
The Industrial Training programme was a valuable opportunity to obtain practical training in
industry, in the training period of 12 weeks I had the opportunity to apply the knowledge and
principles I learned at the university to attain the knowledge required. The theories and principles
were the basement and there was much more to accomplish within that period to understand the
practical situation. In the training period the identified problems in the industry and the solutions
were much exciting.
Pulmoddai is an isolated location from the capital Colombo and the near main district Trincomalee,
the variation of cultures and the deviation of people to each other who work in LMSL and around
the near village is quite considerable. I actually tried to attain awareness of working in a multi-
cultural environment. I developed my technical skills, communication skills, presentation skills as
well as time management skills and also identified the suitable professional culture of work.
Truly the knowledge I gained in university was always the foundation but the other literature was
much cooperative to study about the machineries used in IRZ plant. Actually I identified the value
of lifelong learning, the better you study the better you understand was a real story in my industrial
training programme too.
The practical knowledge given by the university is desperately low due to busy schedules of the
lectures and the students, but its better if the department can actually once visit these much related
places and have and achieve the basic awareness of this type training locations.
As a nation blessed with natural resources value addition is a much required process to LMSL and
to Sri Lanka. The wide range of end product applications, as diverse as pigments, paints and
coatings, metal and specialist alloys, ceramics and a range of chemical and specialty applications,
which have both industrial and end consumer applications can generate a better tomorrow for Sri
Lanka.
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4.2 Conclusion
As far as this training period is concerned, it has been a Good experience of life and a highly
effective gaining of an Industrial knowledge of many disciplines in Mechanical & Manufacturing
engineering. This ‘Industrial Training’ module is having a good influence in the degree of B.Sc.
Engineering. Even though I was unable to experience the long period of this company, the
knowledge I absorbed is not so small. I gained knowledge as much as possible during this 3 months
period. The theories and practical things we studied in the University were seen to be applied in
the Mechanical & Manufacturing engineering field. So this industrial training is a good time to
learn the things practically. It helps to sharp our knowledge and concepts learnt in the lectures.
And also it increases our self confidence in a working place and making decisions before taking
actions. This is the one and only chance to grow our self in our working field. Not only was the
process engineering I was able to learn more about the Project management.
This module is very helpful to reduce the gap between the theoretical knowledge and the practical
applications. In this time only the undergraduates can implement their interesting tasks in their
lectures and it is increasing their hopes to work in their respective fields. So this is having a good
role to make undergraduates to do their works with interest.
The company has skilled staff and all of them are friendly and helpful. All of them are given idea
about their relative fields. Especially the workers were very helpful, friendly and they were
professionals of their Knowledge. Lanka Mineral sand Limited is a good organization for trainees.
As Mechanical & Manufacturing engineering undergraduates we can get knowledge about plant
operations. Also we were able to get the knowledge on industrial equipment like Spiral
Concentrators, Magnetic Drum Separators, WHIMS, and HTEDS and so on.
The undergraduates can learn some more things addition to gain the knowledge in their respective
field. For me I could learn about the Minerals Separation Process and the management activities
of the company. In a production company these things are merged together. So we can expand our
knowledge to another field also, without limiting with learning only our field tasks. If we want to
develop our chemical and Process engineering knowledge this is a good place to get that.
There are several suggestions I would like to express to improve the company’s role for training
to us in a good manner.
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•If there is any problem inside the plant if need to do project or research related to that, if they give
details of the problem as soon as possible. We can complete it in our 3 months training period. For
this purpose they must keep their problems in proper way and expressed us.
•If we can take the more financial related activities experience it is a good advantage for us to
understand the market need.
The role of our ‘Industrial Training Division’ is also need to be mentioned here. Because they are
the people guided us during this training period and making all necessary arrangements for this
training. They have given good advices to have a good training in our field.
Finally, I am thankful to all the personals involved in my industrial training at Lanka Mineral Sand
Limited.
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REFERENCES
[1] “LANKA MINERAL SANDS LIMITED.” [Online]. Available:
http://www.lankamineralsands.com/.
[2] K. G. Ariyadasa, Minerals in Sri Lanka. .
[3] S. I. Angadi, H.-S. Jeon, A. Mohanthy, S. Prakash, and B. Das, “Analysis of Wet High-
Intensity Magnetic Separation of Low-Grade Indian Iron Ore using Statistical Technique,”
Sep. Sci. Technol., vol. 47, no. 8, pp. 1129–1138, May 2012.
[4] Mill Machines: The Wilfley Table. Copper Country Explorer.
[5] “Firat PE Pipes.” [Online]. Available: http://www.firat.com/.
[6] T. H. Ho and K. K. Ahn, “Modeling and simulation of hydrostatic transmission system with
energy regeneration using hydraulic accumulator,” J. Mech. Sci. Technol., vol. 24, no. 5,
pp. 1163–1175, May 2010.
