sanghi cement L.T.D

1. PARMAR GAURANG R. (100610122042)
PARMAR CHIRAG J. (100610122041)
RANAVASIYA JYOTI K. (100610122051)

2. This project mainly focused on the Performance Of Surface
mining methods in limestone mines in Gujarat and evaluation of
it.
To Illustrate the Methods of Excavation of limestone Strata.
This project is also Illustrates Evaluations of different problems
(likewise weathering, reserve and Geological discontinuities)
occurring while working in limestone mines.
This project is also show the Merits and Limitation of
both(Wind rowing and Direct Loading) methods used in
limestone mining. And directs the solutions to overcome it.

3. Limestone is a sedimentary rock composed primarily of calcium
carbonate (CaCO3) in the form of the mineral calcite.
It most commonly forms in clear, warm, shallow marine waters.
Limestone often contains variable amounts of silica in the form of
chert or siliceous fragment , varying amounts of clay, silt and sand
carried in by rivers.
Limestone is a parent material of Mollisol soil group.

4. Limestone
We mine chemical grade Limestone having following
typical analysis:
Limestone
CaCO3 96.00%
MgO 1.20%
Fe2O3 & Al 2O3 0.2%
Silica(max.) 2.00%
Others 0.6%

5. The Kutch Basin predominantly comprises a marine succession
ranging in age from the Middle Jurassic to the Holocene, deposited
on Archaean and Proteozoic crystalline basement.
The Kutch region preserves one of the best-developed marine
Tertiary sequences in the Indian Subcontinent.
The Kachchh Peninsula, located between latitude 23.13°-24.68°N and
longitude 68.10°-71.80°E, forms the western most part of India and
constitutes the Kachchh district of Gujarat State.
Occupying an area of 45,612 sq km, it has length and width extensions of
320 and 170 km, respectively through which passes the Tropic of Cancer.
The delta land of Sindh (Pakistan), also known in the olden times by the
name Sapta Sindhhu, or the seven distributaries of Indus River, borders it
in the west

6. The archaeological records reveal that the region was first inhabited by
the people of Harappan civilization during 3000-1500 BC.
. Nearly 60 Harappan culture sites have been discovered in the distric,
of which, 40 belong to early and the rest to the late phases. Dholavira,
. It is documented that much later, a series of migrations took place
from Sindh to Kachchh, and in this process, Sama Rajputs, later known as
Jadejas, came to this land and ruled here till the time of India’s
independence
The modern Kachchh belong to Sandh, Banni, Rabari (Desi, Dhebaria
and Vagadiya), Banjara, Magwar, Samma, Jat, Mutwa and Ahir
communities, who are mostly engaged in the professions of agriculture,
animal husbandry, handloom, construction work, etc.

7. Sanghi Cement Ltd. Mines is mechanized mines so they hence heavy
earth moving machines. Which is used for in production limestone.
SR. NO. TYPE OF MACHINERY NO. OF MAHCINES
1. Surface Miner (L&T KSM-304C) 02
2. Bitelli SF-202M Surface Miner 01
3. Wheel Loader (Liebherr – 586 2plus2) 03
4. Dumper 15
NAME OF MACHINERY

8. A surface miner, also called continuous surface miner, is the technology to extract,
crush and load material in one go.
The Surface Miner is a track mounted machine which has 3 or 4 tracks depending
upon the models. In Sanghi Cement Ltd. Has 4 track Surface minter. It has a powerful
diesel engine and hydraulic pumps for delivering the power to the cutting drum.
The cutting drum is made up of special alloy steel with replaceable tungsten carbide
cutting tools. The material cut is loaded on to a primary and discharge conveyors for
loading the same into the hauling equipment.
The machine is provided with Water Tank of sufficient capacity to spray water
continuously on the milling tool to sufficiently cool them and suppress the dust
generate at the source.
Surface miner is a ecological friendly modern technology of surface mining for soft to
midday hard flat mineral deposit it can be used to extract valuable mineral such as coal
lignite, limestone, and phosphate etc.

9. There are two method of mining by surface miner one is WIND ROWING METHOD
and another one is DIRECT LOADING METHOD In to tipper/dumper.
In this method of mining surface miner cut the limestone and left as it on face it
self. This mine limestone is subsequently loaded by pay loader in the tippers.
Output of surface miner in this method is 20% to 30% more than that of direct
loading method generally all follow this method.

10. In this method of mining surface miner excavated limestone directly loaded in to
tippers by belt (in built on surface miner) and hence use of loader is eliminated. Output
of Surface Miner in this method is 20% to 30% less the of windowing method due to
more crushing positioning.

11. Special milling drums (2m) width fast replacement tootls.
In built water storage capacity of 4.2 k.1 for dust suppression.
Transversal automatic leveling device.
Longitudinal automatic leveling device (2 number)
High capacity diesel and water filling dumps.
Fixed conveyor.
Hydrostatic braking.
Emergency shutdown 6 numbers of conveniently located switches drum
clutch protection
Engine isolation general protection

12. A loader is a type of tractor, usually wheeled, sometimes on tracks, that has a front
mounted square wide bucket connected to the end of two booms (arms) to scoop up
loose material from the ground, such as dirt, sand or gravel, and move it from one
place to another without pushing the material across the ground.
The loader assembly may be a removable attachment or permanently mounted.
Often the bucket can be replaced with other devices or tools
Armored Wheel Loaders
Compact front end loaders
Tractor front loaders
Swing loaders
Kawasaki 95ZV-2, John Deere 844K, Caterpillar 950H, Volvo
L120E, Case 921E, or Hitachi ZW310

13. The selection of haulage equipment depends upon the following factors-
Types, size and characteristic of the overburden rock which are to be handled.
Quality of the material to be handled is very important.
operating conditions.
Gradient of haul.
 Mobility, Safety and method of mining
Climatic conditions, like air temperature, arid, rain, frost etc.
Availability of the power
Accessibility in between the mining site to the dumping yard.
Operating condition.

14. DIFFERENT KINDS OF PROBLEMS LIKE:-
Geotechnical Parameters
 Environmental Problems
 Reserve Problems
 Market Value Problems
 Machinery Problems Land use and Output Problems
 Raw Material Problems

15.  If stripping ratio permits the opencast mining system can be used in any type of
rock and even in the country rocks or mineral bodies which are enveloped under
heavy tectonic and geological disturbances like, folds, faults, fractured ground, etc.
 In sanghi cement for extraction they used surface miner. During the extraction of
material natural fault arise that part is easily cut and that big boulder or particles
arise that is not suitable for the crushing mill.
 The other problem to use the surface miner at cement plant is the weathering of
the land. When the land is weathered the land have creates the faults and cracks
then this reason when cutter cuts the limestone the faulted part is suddenly come
out and it forms in big size and don’t cut by the surface miner. So this is the oversize
problem created at the weathered area. So this reason the surface miner is not used
at the weathered area.

16. WASTE WATER DISCHARRGE
 All mining processes generate vast amounts of waste water. Water is used for
tasks such as cutting with high-pressure jets and the lubrication of solid cutting tools.
The waste water can be recycled to a limited degree, but ultimately it will become
befouled and useless for quarrying.
SEDIMANTATION
 Waste water discharge bearing high sediment content and the sediment from
cutting are problematic. Increased sediment loads can choke aquatic species
downstream from mining operations or even begin to calcify the environment.
NOISE AND AIR POLLUTION
 While quarrying the noise produced from mining machinery and the high
levels of dust thrown up into the air. , airborne dust can travel many miles from
a mining site and affect the health of downwind residents. Noise pollution
generated from the heavy earth moving machineries affects the Environment.

17.  Indicated reserve, inferred reserve and proved reserve, etc., has to be
calculated precisely in terms of tonnes. From this result mineable reserves
has to be calculated and ultimately washed or clean mineral which can be
shelled shall be computed.
 Sanghi Cement Industries Ltd. area is about 1500 hector, and they working
in 250 hector and they have a problem to limitation to extraction of material
in limited 30 meters. But the material is deposited in 80 meters. So they have
a limitation to working in limited depth.

18.  Not only do cement producers need easy access to large quantities of raw
materials, fuel and cheap labor and local transportation. They also, of course,
require profitable markets.
 Total production figure and requirement of each raw metal, coal or other
mineral country wise as well as in global perspective has to be found out.
 For ore and other mineral “grade of ore” is very important.
 Like in Sanghi Cement Industries Ltd. about 250 hector area mining done. So
in that area grade of ore is not same because of the grade change with the area
and geological components and geological properties, and also in limestone
mixed with different impurities that’s the reason material value changes with
different area and impurities in materials

19.  During working process of surface miner in limestone mines it causes many problem in
surface mine machine or equipment, due to the fault problem it causes the ground surface
very hard thus these leads to broken of cutting bits.
 In the same manner some other parts of the surface miner get damages due to the
warmness or due to the high load bearing capacity of miners.
 When one cycle is completed of cutting ground or surface deposited with limestone it
takes more time in turn of machine thus this leads to the extra consumption of high fuel
and creates environment pollution.
 In case of wet land, cutting process of limestone become comparatively slower than as
usual, and wet fragment of limestone sticks with surface miner’s cutter peaks. Thus there
will increment in time factor.
 Surface miners are generally works on Diesel and Electric power, surface miners which
works with electric power gives high efficiency compare to diesel, Thus power availability
Factor plays an Important role.

20.  For the purpose of selective mining and continuity of operation with the continuous
surface miner required large area and straight surface without any disturbances. That’s the
small area so surface miner not working properly and consume more fuel and less
production.
 When using of the surface minor at the cement plant the surface miner wants the large
area to cut the limestone. Because the surface mine takes diesel in high quantity about 150
litters in one hours so this reason the constant and straight cutting work is continue so this
reason the large or long area to make possible to decreased the cost.
 In Sanghi Cement Industries Ltd. required continuous and more output they manage to
maintenance Continuous surface miner one shift complete in every day.
And they attached with continuous surface miner moving conveyor units with side boom,
so in this process surface miner extraction of material and moving conveyor transport
material with help of side boom in the truck. In this process truck moving slowly with the
conveyor so more time and diesel waste in this attachment and less output is possible.

21. There may occur Geological discontinuities in land surface while using Surface
Miner in limestone mines, due to which surface miner’s cutter peaks cuts
boulders in large dimension. To overcome from these secondary Breaking can use
in work.
 Sprinkles Equipment shall apply to reduce Dust effect in mine environment.
 There should be provision to work in two or more faces due to weathering
problem.
In case of use of Surface miner in limestone mine, working row should as long
as possible and parallel to each other
There shall regular maintenance of Surface miner to keep its Efficiency constant
 There shall provision to keep reserve of raw material (limestone) supply to
cement plant.