Training Report

Uranium Corporation of India Limited, Jadugora

(A Government of India Enterprises)

Abhishek Kumar Azad

2011JE0552
Mineral Engineering with
MBA
Indian School of Mines
Ore processing sections refers to as the “Mill” of the plant.

Training Report
 ACKNOWLEDGEMENT

I would like to take this opportunity to thank Mr Ravindra Kumar, Chief

Supdt. (Mill) UCIL and Mr. Malay Mandal, Supdt.(Mill) for allowing me to
do the training from 13 May 2013 to 22 June 2013 in mill.

I would also like to thank Mr A.K. Roychowdhary Chief Supdt. (Mill),

Mr. Chandan Kumar Jha ( Assst. Supdt.) (mill), Mr Malay Mandal
Supdt.(mill), Mr A.K Roychowdhary Supdt.(mill) for giving me the
valuable time for proper understanding of the workings involved in the
mill.

22 June 2013 Abhishek Kumar Azad

2nd year Dual Degree

Mineral Engineering with MBA

Indian School of Mines

Dhanbad

2
 Index:
Sr. Contents Page No. Remarks
No.
1. Introduction 4

2. Chemical “A” 5-12

3. Dewatering Plant 12-17

4. Chemical “B” 18-25

5. Chemical “C” 26-36

6. Product Recovery 37-55

7. Tailings Disposal 56-61

8. Water Treatment 62-65

Plant
9. Effluent Treatment 66-69
Plant
10. Sewage Treatment 70-72
Plant

3
Introduction to the UCIL Jadugoda Process Plant
“Mill section”

The run-off ore from Jaduguda, Bhatin, Bagjata and Narwapahar Mine are
processed in the centralized processing plant (Mill) located close to Jaduguda
Mine. Uranium is extracted from ore in the Jaduguda Mill by hydro-
metallurgical process. After three stages of crushing, the crushed ore
undergoes two stages of wet grinding. The slurry thus obtained is pumped to
the leaching pachucas for dissolution of Uranium. The leached slurry is filtered
to obtain Uranium liquor.

The Uranium liquor is purified and concentrated by ion exchange method. The
Uranium is then precipitated from this concentrated liquor as magnesium Di-
Uranate, generally known as “YELLOW CAKE”. This is thickened, washed,
filtered and dried in the spray dryer and finally packed in drums and then sent
to Nuclear Fuel Complex at Hyderabad for further processing into UO2 pellets.

The plant has also undergone several modifications adopting technologies to

maximize the re-use of water, high recovery of the product and minimum
discharge of effluents. It has several automated process control mechanism
and online monitoring system.

This manual will give an overall idea about the Plant Operations of different
sections of the Mill. The entire mill in this plant is divided into 3 main sections
named as Chemical A, Chemical B, and Chemical C. These sections deal with
the different processes leading to the liberation of uranium from the run-of-
mines. All the relevant information related to the control parameters, normal
operations, shutdown procedures, safety measures are given in this report.

4
 Chemical “A”
The ore obtained is basically a mixture of the UO2 (uraninite) and UO3.
This mixture is called the pitch blende which also contains the mixture of
sulphate, silica, quartz, chloride, phosphorous pentoxide .Feed cut-off
grade is 0.07 and the feed rate supplied per day is 750 tonnes per
hour(tph).

Grizzlies

Conveyor
Belt

Scalper
Screen

Jaw Crusher

Ball mill and

Rod mill

5
Crushing Section:
 Grizzlies have square apertures of area 1 sqr feet and they have
3 bins beneath each of them with a capacity of 100 metric tons.
The particles with sizes less than 25mm the aperture size, fall in
the bins and from there they are transferred to the conveyer belts.
 Conveyer Belts : Troughing belt conveyor are mostly used in
the mills .They provide proper inclination to the belt and have high
capacities.
The major components of the Conveyors System are Belts,
Scrapper, Skirt plates, Tail and Head Pulleys, Idlers etc.

Brief specifications:
Equipments Belt width Speed(M/min)
Belt conveyer No. C1 600 70
Belt conveyer No. C2 750 60
Belt conveyer No. C3 1000 90
 Scalper Screen: It is a vibrating screen which allows the
materials of sizes greater than the 4 mm to pass through it into the
jaw crusher but the material of size lesser than 4 mm is sent to the
double decker screen. The material of the jaw crusher after being
crushed is sent back on to the double decker screen.
 Jaw Crusher: The standard parameters used to define the
functioning of jaw crusher is:
 Temperature is maintained from 45 degree Celsius to 65
degree Celsius. This machine is automated which implies
that it gets tripped at temp below 45 or above 65 so as to
prevent damage to its parts.
 The pressure is to be maintained between 5 to 11 PSI such
that it too gets tripped if pressure goes beyond its limits.
 The capacity of this crusher is 80 tph. The jaw crusher works in the
open circuit but the cone crusher is operated in the closed circuit.
The Cone Crusher is in close circuit with the double decker screen.
The final product obtained from this crushing section is U3
O8(90%), silica (4-5%) , 3% magnetite and 1% impurities. The

6
 capacity of the cone crusher is 273-350 tph. The jaw crusher
works for about 7- 8 hrs. The tailings constitute about 1% of the
feed grade. The electricity consumed in this section is about 1000
W.

Jaw Crusher:
The major components of the Jaw Crusher are Fixed Jaw, Swing
Jaw, Liners for both and Toggles.

Brief Specification:
Size 24’’ to 36’’
Duty 80TPH of 5’’- 12’’of the ore.
Nominal Product -4’’(100mm)
Nominal S 260 RPM
Motor Rating 750 RPM
Jaw Setting 4’’(100mm)
Approx. Jaw Movement 9/16’’

Cone Crusher:
The major component of the Cone Crusher are countershaft unit,
socket with lines, bowl assembly with liner, feed arrangement
along with other fittings.

Brief Specification
Size 4ft.
Duty 160 TPH
Nominal Product -25mm
Nominal Speed 485 RPM
Gap Setting 20-30 mm
Normal Operating Oil Pressure 5-11PSI
Gap Setting(hydrocone) short head 15-22 mm

7
Grinding Section:
This section consists of the rod mills, ball mills, disc filters and
thickeners. The Plant is wet – grinding based and operates continuously.
The old circuit consists of Rod Mill – Pebble Mill – Classifier. The Rod
Mill (Primary) operates in open circuit and the Pebble Mill (secondary) in
closed circuit with the Spiral Classifier. The new circuit consists Rod Mill
– Ball Mill – Hydro cyclones. The Rod Mill (Primary) operates in open
circuit and the Ball Mill (secondary) in closed circuit with the Hydro
cyclones. The uranium mineral concentrate (wet solids from copper
tailings benefication plants) is ground in a Ball Mill – Hydro cyclone
combination in closed circuit. The requirement of in all the three grinding
circuit is met by recycle of water from downstream dewatering step. The
material of size about 25mm is converted into 75 microns . The
reduction ratio of the grinding mills is 1000:3. The crushed ore (- 25 mm.
size) is ground to 60% – 200 mesh (75 micron) particle in two stage by
wet grinding.
 Rod mills: The rods used in the rod mill are made up of high
carbon steel . The chemical composition of the rods include carbon
(0.85 – 1%), manganese (0.9 – 1.3%) , silica ( 0.15- 0.25%) and
phosphorous and sulphur( 0.4%). The physical properties of these
rods includes hardness (275 BHN), tolerance ( 0- 10 mm) else it
gets struck. The dimensions of the rod is 4.4m length and 100mm
diameter

Brief Specifications:
Size 8ft(length) *12ft(diameter)
Speed 17 RPM
Input size 25mm
Output size 1mm
Rod Loading 30%
Circulating Load Ratio 400%

 Ball mills: The balls used in the ball mill are made up of
chrome steel . The chemical composition of the balls
includes steel (75 – 80%) ,carbon( 2-3%), manganese (1%),
8
 silica (1%), chromium( 16 to 18%) , phosphorous and silica
(0.067%). The hardness is 600 BHN.The ball mill is operated
at 60% of its critical speed. The capacity of the mills is 100
metric tonnes and it can be run 24 hrs at a stretch . The
capacity of the total combined mills used in the UCIL plant is
45tph. The rods are introduced manually into the mill but the
balls can be introduced in the running mill. The liners used in
the mills are shell liners and are fixed with the rubber
stoppers. The total power consumed in the mill section is 49
kwhr. The size of the balls used in the ball mill is 40mm.

Brief Specifications:
Size 9.5ft(length) * 15 ft(diameter).
Speed 22RPM
Input Size 1mm
Output Size 75micron
Ball Loading 32-40%
Circulating Load Ratio 250%

Hydrocyclone:
The major components are :
o Body with liner
o Vortex finder
o Apex valve

Major components of this section are listed as:

PUMPS :
The following types of pumps has been used in grinding section :
o “Denver Pump”, Horizontal Centrifugal.
o “VASA Pump”, Horizontal Centrifugal.
o “Water Pump”, Horizontal Centrifugal.
o “Sump Pump”, Vertical Centrifugal.

9
Major components of the pump are :
o Casing
o Impeller
o Shaft
o Shaft Sleeve
o Bearing Housing
o Drive(Motor)
Before starting the Mill, the following parameters are to be
checked :

- Industrial water is available in the overhead tank.

- Cooling water pump is “ON”.
- Thickener overflow water pump is “ON”.
- Fine Ore is available in Bins.
- Compressor is “ON” and compressed air is available.
- Classifier pool is filled with water.
- C.O.P. Pump/Hydro cyclone overflow pump is “ON” with water.

HYDROCYCLONE OVERFLOW :
The following parameters to be changed one by one to get the
best result, if required.
- Feed density.
- Size of the apex Valve.
- Size of the Vertex Finder.
- Inlet pressure of the entering Slurry.

SAMPLING :
Sampling of solid feed and pulp at selected points is essential for control
over grind size of the product.
The essential grinding circuit samples are :-
- Feed to primary mill.
- Primary mill discharge.
- Secondary mill discharge.
- Classifier returns.
- Classifier overflow.
- Hydrocyclone underflow.
- Hydrocyclone overflow.

10
ABNORMAL OPERATION & EMERGENCY ACTION:
Grinding Plant allows good visibility to operator which help them to react
sharply. Regular check on densities of various streams will indicate the
normal / abnormal operation to the operators. The following chart
indicates the remedies in the abnormal conditions:-

CLASSIFIER OVERFLOW :
Since optimum grinding is essential, periodic checking of classifier
overflow density gives operator running control. The effects of changes
in classifier overflow, mill discharge or classifier circulating load are
accompanied by possible associated changes, any one of which could
be responsible.
Thus:
Indication Possible Causes Remedies
a) Classifier Density 1. Mill discharge is finer. Increase water
Overflow Rising 2. Insufficient feed water. to mill and / or
3. Pool dilution low. classifier
b) Classifier Density 1. Mill discharge is coarser. Decrease
Overflow Falling 2. Feed going through too somewhat mill
quickly. and / or
3. Mill water is excessive.
classifier water.
4. Classifier water too high.

In general milling practice increasing water to classifier has the effect of

finer release mesh and greater circulating load, i.e. a greater tonnage of
classifier returns.
Therefore:

Possible Caused Remedies

a) Rising Classifier 1. Classifier pool too dilute. Cut new feed or
2. Mill overfed . reduce settling
Circulating Load.
3. New feed too coarse. pool water.
b) Falling Classifier 1. Classifier pool density too high. Increase classifier
2. New feed finer or slower. water or increase
Circulating
Load. new feed.

11
Similarly, if the Secondary Mill discharge shows a decreased solid/liquid
ratio, that is the pulp is too dilute, it could mean that classifier returns are
insufficient or mill feed water too high or the feed rate too low from the
Primary Mill. Likewise, with mill discharge solid/liquid ration increasing,
the causes may lie in too high rate of feed, insufficient feed water.The
mill may also get overloaded, this of course, will be shown by the mill
ammeter and checks have to be made then of any abnormalities in the
circuit.
The ore, after grinding , overflows from the classifier/ hydrocyclone as
40-44% slurry and comes as the feed to the neutral thickeners and high
rate thickeners. The high rate thickeners have lesser bottom floor area
and flocculant Flamine of 4953 grade is added. The slurry density
obtained from the HRT is 65- 75% The slurry is thickened to about 60%
in neutral thickeners .This output is then filtered in Disc filters. The water
is recycled to the mills. This dewatered cake is repulped with Secondary
Drum filter’s filtrate and then sent to the Leaching Pachukas for leaching.

DEWATERING PLANT
Classifier overflow is sent for recovery of by-products (Cu, Mo). The
slurry, after recovery of the by-products, is dewatered in a mechanical
continuous thickener (neutral thickener). The ground slurry from the ball
mill – hydrocyclone circuit (20 – 30 % solid) is sent directly to another
thickener. Hydrocyclone overflow from the new mill circuit is fed to 8 m
dia. high thickener. The thickened slurries from the thickeners are further
dewatered on rotary vacuum disc filters. Disc filter cake is repulped with
recycled secondary filtrate (after leaching – filtration steps) in
mechanical horizontal repulpers and the slurry flows to surge tanks.
From the surge tanks, the slurry is pumped to leaching circuit.
Maintain following conditions in the thickeners . disc filters / repulpers:-

- Maintain 80’ thickener rake load to normal ( 3 –4 amp.)

- Underflow thickener discharge density : 48 – 65% (w/w)
- Dilute flocculent addition to high rate thickener (Dose Rate : 4 l/m or 2
–4 Kg / shift of dry powder.
- Bed level of high rate thickener (HRT) : 0 – 10 %
12
- Bed mass of high rate thickener (HRT) : 50 – 70 %
- Vacuum in Disc Filter : 300 – 450 mm of Hg.
- Disc Filter repulper discharge density : 50 – 72 % (w/w)
- Disc Filter vat level to normal.

Major Equipments:

A. NEUTRAL THICKENER ( 80 ft. dia.)

This thickener takes the feed from the grinding circuit.

The major components are: -

- Tank
- Rake
- Rake Drive mechanism
- Rake overload mechanism
- Feed launder
- Feed Well
- Underflow slurry pumping system.

High RATE THICKENER (8 m dia.)

Instead of the conventional neutral thickeners, an improve version i.e. a
High Rate Thickener has been installed in the plant for better control on
dewatering system and needing less area requirement for installation.
The incoming pulp in the thickener is flocculated with polyelectrolytes or
Flamine of 4953 grade is used now-a-days as flocculant This flocculant
is used to about 24 tonnes per year. The overall area requirement for
sedimentation is much reduced because of big floc formation and rapid
settling. High degree of instrumentation has been provided such as bed
level detector / transmitter and automatic speed control of the underflow
pump by D.C. Thyristor. Automatic feeding of the flocculent by level
sensor depending upon the solid accumulation at the thickener has been
incorporated.

13
DISC FILTER:
The major components are:-
- Through Assembly
- Agitator Assembly
- Shaft Assembly
- Disc Assembly
- Valve Assembly
- Scrapper Assembly
- Disc Drive Assembly
- Vacuum Pump
- Air Blower.

START-UP PROCEDURE for the dewatering plant :

Before starting the Dewatering Plant, following are to be
checked :
- Thickener rake position is at ‘O’.
- Thickener overload indicator is at ‘O’.
- Dorrco Pump is under recirculation.
- Feed well is clean.
- Flocal pump is running OK.
- Bed mass level is 60-80 % and Bed level is 0- 10 %.
- Hose pump is under operation.
- All the Tank Agitators are running.
- All Lubrication points in the system to be checked.
- Vacuum pump is running.
- Blower is running.
- Filter cloth is OK.
- Scrapper is alright.

14
START-UP PROCEDURE OF NEUTRAL THICKENER & DISC
FILTER :
- Fill up water in thickener tank until it over flows.
- Open cone valve.
- Dorrco pump primed with water.
- Open suction valve.
- Start Dorrco pump & put in recirculation.
- Start Rake.
- Lower up to ‘O’ mark slowly.
- Take slurry from mill.
- Keep Dorrco in recirculation up to 55 % density.
- Check disc filters vat drain valve & close.
- Start repulper of D/F.
- Start vat agitator.
- Take slurry in D/F vat after closing recirculation launder of Dorrco.
- Start vacuum pump.
- Start blower.
- Start Disc Filter.
- Open vacuum valve.
- Open blower valve.
- Secondary filtrate valve in repulper opened as per requirement.
- Leaching pachuca has to be informed.
- Warman/Vacseal start for slurry supply to leaching pachuca.

START-UP PROCEDURE FOR High-RATE THICKENER :

- Fill up water in thickener till overflows.
- Start rake drive in clock wise direction (It rotate in anti clock wise
too).
NOTE : Rake rotation direction to be clockwise when viewed from
the top.
- Start hose pump in drain condition (Pump speed kept 70 RPM0.
- Lower Rake in fully lowered position(Indicate light glow).
- Open sperger water through Rota Meter (For dilution of Flocal).
- Take slurry from Mill in thickener.
15
- Water valve incoming slurry launder from Mill should be opened to
make low density of incoming slurry. It is necessary for efficiency of
thickener & auto water addition.
- When Bed Mass become 55-60 % drain valve of Hose Pump is
closed and slurry is taken in Disc Filter.
- Put Hose pump in auto speed (RPM) position.

NORMAL OPERATION :
During normal operation of the Dewatering Plant, observe the
following whether :
- Thickener underflow density is 48 – 65 %.
- Thickener (80’) rake load is 3-4 Amp.
- Thickener (50’) rake load is 2.8 – 3.0 Amp.
- Dilute flocal addition to High Rate Thickener is OK.
- Bed Level of Hi-rate thickener is 50-70 %.
- Vacuum in Disc Filter is 300-450 mm.
- Filtrate is clear.
- Disc Filter repulper discharge density is 50-72 %.
- Addition of Secondary Filterate is OK.
- Acid Slurry is being pumped to Leaching Pachucas.

Indication Possible Causes Remedies

- Rake Rises 1. No Pumping 1. Diaphragm/Valves
seats to be checked.
- 2. Cone Jamming. 2. Water & air may be
blown from the bottom.
- Cone may be drained.
- 3. Coarse particle. 3. Grinding Plant to
be instructed.

16
CONTROL OF FILTER CAPACITY :
The capacity of Disc Filter, expressed in tones of filter cake
discharge per hour depends upon the following :
- Characteristics of Filter Feed.
- Solid content of Filter Feed.
- Disc Speed.
- Vacuum in the pick up zone.
-
The filter station has no control over the first two factors as they depend
on process. The variations in the characteristics of settlings can be
countered by varying disc speed to operate the filter at optimum
capacity. The alteration in disc speed changes the surface area of the
disc per minute on which cake is forming and cake discharging is taking
place.
SAFETY :
 When cleaning compresserd air pipes, be sure that air valve is closed,
then remove the connection SLOWLY, because the line is still under
pressure.
 When repairing valves, check and make sure that the pump is
stopped and the line is drained.
 Take care when opening or closing a valve, be sure of your footing so
that you don’t falls.
 Know what to do in case of power failure or emergency.
 Wear protective clothing & equipment as necessary.
 Necessary walk under a load or move a load over the top of anyone.
 When entering closed vessels and empty tanks direct compressed air
into them for sufficient ventilation.

In leaching stage, the slurry is treated with 98% concentrated sulphuric acid
& pyrolusite (MnO2) slurry. A pH of 1.7 is maintained. Slurry, after leaching
is brought to the Filter House for solid – liquid separation. This separation is
again done in two stages by vacuum drum filters. The filtrate from the first
stage filtration which is called the Unclarified Pregnant Liquor (UPL) is
clarified in a vacuum drum precoat filter. The solid content in unclarified
pregnant liquor is around 200 ppm while in the clarified liquor it is around 8
ppm.The filtrate from the second stage of filtration is used to repulp disc
filter cake and the solid is repulped with water and sent to Tailings Plant.

17
 Chemical “B”
The slurry in Pachuca is treated with 98 % concentrated Sulphuric Acid
& Pyrolusite (MnO2) slurry. Pyrolusite acts as the oxidant and an e.m.f.
of about -490 mV is maintained. The Sulphuric Acid dissolves the
Uranium from the ore into the solution. A pH of 1.7 is maintained. Along
with Uranium, Iron, Manganese etc. is also dissolved to some extent.

Following equations are typical in the Leaching Section :

2Fe++ + MnO2 + 4H+ = 2Fe+++ + Mn++ + 2H2 O

UO2 + 2 Fe+++ = UO2 ++ + 2 Fe++

UO2 ++ + SO4- - = UO2SO4

UO2SO4 + SO4- - = [ UO2 (SO4)2]- -
[ UO2 (SO4)2]- - + SO4- - = [ UO2 (SO4)3]- 4

To accelarate the reactions, temperature around 400 C is

maintained in the Leaching Pachucas by injection of live steam.

Following conditions are maintained in Pachucas :

Density 50 – 72 % (w/w) / 45 –68 % ( w/w)

pH of slurry 1.5 – 2.0
Air Pressure 30 – 45 Psi ( about 2.2kg/cm2)
Temperatures 50-55 degree celsius
E.M.F. - 480 – -510 mV
Leaching duration = 08 – 12 Hrs.

18
LEACHING :
Leaching of the ground slurry is done in vertical cyclinderical vessels,
known as Pachucas. The Pachucas vessel is made of Mild Steel lined
with soft Rubber. Compressed air is supplied through S.S. pipes for
keeping the slurry in suspension. Steam is supplied at the centre for
attaining the desired temperature required for optimum leaching. Inlet &
outlet of slurry points has been provided in the Pachucas at the entry
and outlet of slurry points for minimising the short circuiting of the
reaching components. There are 2 sets of Pachucas, having 10 nos. in
each.

Instrumentation:

DCS based control system for the control and monitoring of the following
process parameters have been envisaged.

1. Automatic Control of pH and Temperature in Pachucas no. 1,2,3,4,

& 5.
2. Automatic Control of Oxidation Reduction Potential (ORP) in
Pachuca No. 2.
3. Manual Monitoring of pH and ORP (EMF) in remaining
Pachucas.
4. Monitoring and alarm for low and high air pressure.

The final input to the pachucas includes the mixture of lime, pyrolusite,
sulphuric acid, compressed air and steam in proportion so as to obtain
the desired output from the pachucas.

A. LIME SLURRY PREPARATION PLANT :

Neutralisation is carried out with slaked lime or carbide sludge.

Wet carbide sludge (50 % CaO & 40-45 % moisture content) is
received in trucks, unloaded into shallow rectangular pits, retrieved
from the pits by directing water jets into the pits, slurrying the
sludge (at 10-12 % solids) and finally the slurry is pumped via
surge tanks to various process steps.

19
B. PYROLUSITE SLURRY PREPARATION PLANT :

Pyrolusite Ore lumps of –50 mm. size are received in trucks and
unloaded in an open yard. After screening in a grizzly-hopper, the
lumps are fed to a Blake Jaw Crusher in open circuit to reduce the
size to –12 mm. The product is wet ground to –200 mesh size in a
Conical Ball Mill. The ground slurry (20-25 % solids) is stored in an
agitated surge tank. It is then pumped to the leaching pachucas as
required.

C. SULPHURIC ACID HANDLING & STORAGE :

There are 8 nos. of Acid Storage Tanks, 6 nos. of 250 M.T.

capacity each and 2 nos. of 100 M.T. capacity each. However, the
filling capacity is 1400 M.T., as one tank is kept empty to take care
of eventuality of leakage from other tanks. Acid is received from
outside b tankers and stored in these tanks. Pumps are used to
unload acid from tankers into the storage tanks and also to pump
the acid from the storage tanks to the leaching pachucas and
elsewhere as required.

D. COMPRESSED AIR :

A total of 4 nos. of Air Compressors of 42 M3/min. capacity each

are installed. Two or three compressors are required to meet the
compressed air requirement.

E. STEAM :
The steam Generation System consists of Three Package Boiler
(one is a stand by) of 4 tonne/hr. and 5 tonne/hr. capacity at
10kg/cm2 pressure, furnace oil and storage and handling system
and water softening plant. The steam is supplied to user points
through insulated piping with suitable valves, safety valves steam
traps etc.

20
 Pyrolusite lumps, less than 65 mm are stored in open stock pile. A
ground hopper (capacity 5.0 MT) is charged with the ore by a pay-
loader as and when required. A dust suppression system
consisting of sprinklers is installed to suppress the dust produced
during the charging of ore into the hopper. Water at 1.5 – 3.0
Kg/cm2 pressure supplied to spray nozzles while dumping the ore
by the pay-loader. Sprayed water suppresses the flying dust
particles.

Ore from the ground hopper is fed to a duplex chain bucket

elevator at controlled feed rate by a vibratory feeder. Discharge of
the duplex chain bucket elevator flows to a double toggles Jaw
Crusher. Crushed ore (size 15 – 20 mm) is directly fed to a double
roll crusher. The product size from double roll crusher is - 8mm.
This crushed product is fed to a belt bucket elevator and is
discharged to the surge bin of 10 tons storage capacity.

Fine ore from the surge bin is fed to a conical ball mill by a belt
feeder. Controlled quantity of water is added to grinding mill for
maintaining the required pulp density. The ground material from
the grinding mill is discharged to a sump and pumped to another
day tank located below the leaching pachucas for supply to the
leaching plant.

Maintain the following conditions:-

Pyrolusite pulp density : 10 % (solid)

Particle size : 48 mesh 2 % minimum

- 325 mesh 60%

21
 START-UP PROCEDURE :
The following points are to be taken care before taking the
Pachucas in line :

i) - Air Compressor should be in running condition.

- Air is to be provided in the bottom.

- Before taking slurry in Pachuca, side air valve and centre air
valve is to be opened.

- Ensure that day tanks of Sulphuric Acid and Pyrolusite is filled.

ii) - Ask Disc Filter Operator to supply slurry.

- Open Air Valves & Steam Valves (if required).

- Pump Pyrolusite slurry in Pachuca No. 2.

- Pump Sulphuric Acid in other Pachuca.

NORMAL OPERATION :
During normal operation of the Leaching Pachuca, observe the
following, whether :

 Incoming/Outgoing slurry is 50-72 % density / 45-68 % w/w.

 pH of outgoing slurry is of 1.50-2.00.
 Air Pressure is 30-45 PsiG.
 Temperature is 40-600C.
 Emf is –480 mV to –510 mV.
 Leaching duration is 8-12 hrs.
 Agitation is ok.

22
 ABNORMAL OPERATION & EMERGENCY ACTION :
Indicatio Possible Causes Remedies
n
Low pH 1. Acid pump not 1. Check the pump/line and
functioning Valves.
properly.
2. Acid day tank is 2. Check the day tank.
empty.
High pH Acid pump has not Stop the acid addition and
been bring the pH down to normal
stopped in time. position.

Low Emf. 1. Pyrolusite Pump is 1. Check the pump/line and

not Valves.
Functioning
properly. 2. Check the day tank.
2. Pyrolusite day tank
is
empty.

High Emf. Pyrolusite Pump has Stop the Pyrolusite

not Addition.
Been stopped in
time.

Low Temp. Insufficient supply Check the Boiler.

Of Steam.

Low Air Insufficient supply of Check the compressor.

Pressure. air.

SHUTDOWN PROCEDURES :
The following steps is to be taken for shutting off the Pachucas :

- Stop Acid addition.

- Cut off slurry supply.
- Stop Pyrolusite addition.
- Open the drain valve.
- When the vessel is empty, stop the air supply.
- Wash out the slurry.

23
 SAFETY :
- When cleaning compressed air pipes, be sure, the air valve is
closed.. Then remove the connection SLOWLY, because the line
is still under pressure.
- Take care when opening or closing a valve, be sure of your footing
so you won’t fall.
- Always replace man0-hole covers of the pachucas.
- Know what to do in case of power failure or emergency.
- Wear protective clothing as necessary.
- Watch your footing around areas that are slippery.
- When entering closed vessels and empty tanks direct compressed
air into them for sufficient ventilation.
- Securely clamp all hoses to nozzles. Remember hose under
pressure slipping from a nozzle can hurt a man.
- Pyrolusite dust if inhaled or swallowed, effects the central nervous
system. Hence use of personnel protective equipment such as
respirators, hand gloves and gumboots is essential.
- While handling pyrolusite ore, sprinkle water to suppress the dust.
- Wash your hands and face with soap before taking meal.
- Avoid naked light, fire or spark near sulphur.
- Acid will cause serious burns. Be alert to the possible leaks or
splashes from equipment and pipelines containing sulphuric acid.
- In case of acid burn rush up immediately to the safety shower and
use full flow of water to wash part of the body affected for atleast
30 minutes. Remove all contaminated clothing.
- In case of acid splash in eyes, flush thoroughly with cold water for
atleast 15 minutes and then report to first aid at once.
- Do not use alkaline neutralising agents for acid burns.
- All persons operating in the plant should wear goggles when
working near acid pump, valves, pipelines, while handling acid and
where there are chances of acid splash.
- Use protective equipment as required. These include safety
helmets, rubber gloves, rubber boots, rubber suit, safety goggles,
gas masks, breathing apparatus etc.
- Do not leave spilled acid unattended. All spillages should be
removed by immediate flushing with water and covering with
hydrated lime.
- Under no circumstances should water or other liquid be introduced
into loaded or unloaded tank-cars, tanks and drums. Remember
dilute acid attacks iron very rapidly.

24
- Do not smoke in Sulphuric acid plant area including pump house
and storage tank area. Hydrogen generated inside metal
containers may cause explosion.
- Isolate acid from comestible and organic materials and such
products as nitrates and metallic powder as acid may cause fire
and explosion by contact with these materials.
- Tanker unloading should be conducted by carefully instructed
reliable employees under adequate supervision.
- Before starting tanker unloading check shower system to make
sure that it is operating. In addition a running water hose must be
available.
- Drain pipeline or equipment thoroughly before handling over for
repair, caution repairmen about possible hazards.
- Do not enter an empty storage tank or tanker for any purpose
what-so-ever without due certification by an Engineer.
- Compressed air, if used in acid lines must be as free as possible
from oil, water and foreign matters.

25
 Chemical “C”
There are total 8 sections that work together to obtain the useful uranium
from the slurry and dispose off the waste from it.

 Drum filter
 Precoat( clarification)
 Ion exchange
 P P N (precipitation)
 Drying unit
 Peroxide unit
 Tailings
 Magnetite unit

The slurry, after leaching is brought to the Filter House for solid-liquid
separation. This separation is again done in two stages by Vacuum
Drum Filters.

The Filtrate (UPL) from the String Discharge Vacuum Filter is

clarified in 8’ dia x 8’ LG Precoat Vacuum Filter.The clarified liquor
is called C.P.L. The main components of the filter are as follows :

1. Vat/Tank.

2. Drum Assemble.
3. Agitator Assemble.
4. Valve Assemble (Consisting of valve body, bridge plate, bridges
and wear plate)
5. Cake cutting mechanism.
6. Vacuum Receiver.
7. Moisture Trap.
8. Drum Drive Assemble.
9. Trunion Bearings
10. Polypropylene Grids.

26
Other ancillaries required for filter operation are :

 Vacuum Pump
 Filtrate Pump Precoating material.
 Precoat material slurry pump.
 Barometric leg.
 Instruments (Mainly Ultrasonic type level transmitters,
enunciator, DPMS, pH meter, indication lamps).
 Acidified water.
The Filtrate in the first filtration stage called Pregnant Liquor
Contains about 0.5 gm/litre of Uranium and is further clarified in
Precoat Filters to bring down the solid content to below 2 to 3
ppm. The Filtrate from the second stage of filtration is used to
repulp Disc Filter Cake. The clarified pregnant liquor is then
taken for purification and concentration in the Ion-Exchange
Columns. The cake from the secondary filters is repulped with
water and sent to the Tailings Treatment and disposal plant.

No Chemical reaction is involved in the solid-liquid separation and

clarification stages. Flocculent is used as coagulating agent for better
filtration.
In Ion-Exchange columns, purification and concentration of
clarified pregnant liquor (CPL) is done here for final precipitation of
Uranium as solid. The major equipments in this area are as
follows:

 Compressor.
 Ion-Exchange columns.
 Control Valves.
 Spring loaded sounders valves.
 Pumps.
 Tanks for various streams.
 Automatic Analyser.
 Control Desk.
 Instrument.

27
 The Ion-Exchange columns are partially packed with anionic
organic resin. The negative ions of Uranium and Iron displace the
Chloride ions in the resin, when the clarified pregnant liquor is passed
through the resin bed. This is done till the resin is saturated with U ions.
Next, acidified brine solution is passed through the resin bed when again
the anions are exchanged, U --- F +++ ions are released into the solution
and the Cl- ions are back into the resin matrix. This solution, called
strong Eluate, containing about 5.0 gm/ltr. Of U3 O8 is sent to the
Precipitation Section.
The liquor coming out of the Ion-Exchange columns after
adsorption of U is called Barren Liquor. It is sent to the Tailings
Treatment Plant, treated with lime solution to raise the pH to 10.5 – 11.5
. It is next mixed with the Secondary Drum Filters, repulped cake. Final
pH is about 9.0 to 10.
Maintain the following condition with two/three ion exchange columns in
series :

Flow rate of liquor = 400 – 800 lpm.

Instrument Air Pressure Cooling = 4 – 7 kg./cm2

Water Flow to analyser

U3 O8 in barren liquor = < 0.01g/l
Column Press = less than 4.5 kg/cm2
After saturation of leading column (when barren value is more than
0.004 gms/l., switch it over to elution & run the trailing one or two column
of adsorption with standby column in series as the last column on
adsorption.

During elution maintain the following condition :

i) Flow of back wash liquor = 400 – 800 lpm.

ii) Flow of elution liquor = 250 – 285 lpm.

28
iii) Constituent of 2nd eluent = Chloride : 33 – 38 gm/l.
SO4 : 20 – 35 gm/l.
Acidity : 0.1 – 0.15 N.
iv) Time duration mentioned earlier of each stages of elution
namely:

 Flush.
 Early Back Wash.
 First eluent liquor to pregnant circuit.
 1st eluent to precipitation circuit.
 2nd eluent liquor to precipitation circuit.
 2nd eluent liquor to 1st eluent tank.
 Rinse to 1st eluent tank.

From this slurry, sand-slime separation is done in 2 stage

Hydrocyclones – sand goes to the Mines for backfilling and the
slimes are pumped to the slimes dam for containment. A typical
reaction between the mobile ion adsorbed on the resin, chloride
ion in this case, and the Uranium ions in solution (‘R’ designating
the fixed ion group and ‘X’ the mobile ion), will proceed as follows
in the Ion-Exchange Columns :-

Adsorption Reaction :
4R+ X- + UO2 (SO4 )3 -4
= (R 4 + ) UO2 (SO 4) 3 -4
+ 4X

Elution Reaction :
R4 (UO 2) (SO4 )3 + 4X- = 4RX + UO2 (SO4 )3

The strong eluate, from the Ion-Exchange columns, containing iron

( 1 to 1.3 gm/ltr.) & Uranium ( 5.0 gm/ltr.), is pumped to the
precipitation section. By neutralisation, iron and uranium are
precipitated out separately in two stages. First, the strong eluate is
29
 treated with lime solution and the pH is brought up to 3.5 to 3.8 . At
this pH, iron precipitates out and is separated in a thickener as
iron-gypsum cake. Along with iron some complex of Uranium also
gets precipitated.Separation of Iron and Sulphate and precipitation
of uranium as product concentrate takes place here. The following
main equipments are used here :
- Agitated tanks.

- Thickeners
- I.C.C. Filter
- Pumps

- Instruments.
This cake is recycled to the uranium leaching circuit. Clear overflow from
this thickener is further treated with Magnesia to bring up the pH to
about 6.5 to 7, when the uranium precipitates out as Magnesium-di-
uranate(MDU). This MDU is separated out in another thickener,
washed, filtered in a Belt Filter and dried in spray dryer and then
automatically packed in drums lined with polythene bag.

pH is measured in the 1st and 5th tanks using a dip type electrode well
insulated against effects of the slurry. The output from the sensor is fed
to the input of a pH transmitter which provides local indication while
transmitting the current signal to the RTU.

This value from RTU is compared with a set point and a resultant digital
output operates a 3-way solenoid valve which in turn operates an air
cylinder. This make or breaks the supply of lime into 1st tanks.

MDU / ADU Precipitation :

a) Addition of Magnesia slurry is done like lime addition or

b) Liquid ammonia is the additive that controls the pH value of the

slurry.

30
Liquid Ammonia from the first service tank is pumped into the second
service tank. The level of liquid ammonia is monitored using liquid level
indicators of 2m. & 1m. respectively in the first and second service
tanks.

Slurry of Magnesia powder (2 bags) is made in tank by hosing it through

a 100 mesh screen into tank. PH value of the slurry in the precipitation
tank is measured using a combination of dip type sensor and a
transmitter with local indication. The current output from the transmitter
is wired through and indicating meter to the RTU in the control panel.
The resulting current output operates an I/P converter whose air output
regulates the flow of magnesia/ammonia from the tank/service tank into
the precipitation tank through a ½” control valve/pneumatically operated
cylinder, solenoid valve.

Annunciator for Low/High pH has been installed.

INSTRUMENTS & CONTROL SYSTEM :

In this section major instrument provided for process control are

listed below :

ULTRASONIC LEVEL TRANSMITTERS :

Leach Pulp Surge Tank (3 nos.)
Primary Pulp Tank (3 nos.)
Secondary Pulp Tank (2 nos.)
Acidified Water Tank (3 nos.)
Wash & Filterate Tank (2 nos.)
Measuring Range : 0.3 mtr. To 10.00 mtr.
Output : 0.4 to 20 mtr.

31
START-UP PROCEDURE :
Before starting up the filter, following to be checked :

- Check that there are no hole in the filter cloth. Holes to be patched
before starting the drum.

- Vacuum pumps are on and sufficient vacuum is available near the

filter.

- Flocculent is ready and its pump is on.

- Wash liquor is available in the wash heard.

- Strings are at place.

- Agitators is on & vat drain is closed.

- Repulper is on.

- Filtrate pump to be started as soon as vacuum is applied to the

filter.

B) The following steps should be used as a guide in starting the filter :

- Start drum drive at slowest speed and increase speed to suit

desired capacity and discharge cake moisture.

- Open slurry feed and to be sure check whether feed is flowing into
filter tank. Allow tank to fill, and adjust fed rate until slurry just
barely goes over overflow weir. Feed rate can be changed later to
suit final operating conditions.

- Open filtrate zone vacuum valve first & then wash zone vacuum
valve.

- Start Filtrate pumps.

- Turn on wash liquid.

32
 Observe operation & make adjustments to provide :

 Best cake thickness based on required plant capacity.

 Adjust wash flow to provide best wash efficiency with minimum
drip or dilution into filter tank.

Maintain the following during normal operation :-

i) Vacuum in main= minimum 500 mm.Hg.

ii) pH of acidified water = 1.5 to 2.0
iii) Addition of dilute flocculent to primary filters 60 – 100
l/min. & secondary filter 30 – 70 l/min.
iv) Repulper discharge density of primary filters 55 – 70 % w/w.
v) Repulper discharge density of secondary filters 40 – 60 %
w/w/.

NORMAL OPERATION :
During normal operation of the filter, the following to be
checked/adjusted :

 Adjust the slurry feed, wash water flow and drum speed for the best cake
thickness.
 See that line vacuum is minimum 500 mm.
 See that acidified water is OK.
 See that back wash out is OK.
 Addition of flocculants is OK.
 Cake discharge is OK.
 Repulper discharge density of the Primary Filter is 55 – 70 % and that of
Secondary is 40 – 60 %.
 See that there is no carry over.

ABNORMAL OPERATION AND EMERGENCY ACTION :

The Drum Filter allows very good operator visibility and it should
be possible to detect, identify and correct any problems without
any disruption to the overall operation to the plant. However, this is

33
 dependent on plant operators reacting to their visual observation
and taking the appropriate action.

The main source of problems and their solutions are outlined below
under distinct headings.

LOSS OF VACUUM :
Observation will show no cake formed. Check the
following :

- Vacuum pump running at correct speed and supplied with clean seal water
at the correct pressure and flow.

- Check all flanges and joints in vacuum manifolds and receivers.

- Check the filtrate is being removed satisfactorily by the filtrate pumps.

- Check if there is sufficient slurry in vat.

- Check that there is sufficient wash water on filter.

POOR CAKE DISCHARGE :

In such situations , the following parameters can be checked :

- Using correct filter cloth.

- Thickness of cake.

- Dryness of Cake.

- Amount of product wash liquor added in washing zone.

- Drum Speed.

TEARING OF CLOTH :
In the event of the cloth tearing : Repair or replace cloth.
34
SHUTDOWN PROCEDURE :
- Close filter feed valve/plug.

- Continue operation until the slurry in the tank is below the drum.

- Drain, tank completely back to the slurry fed tank.

NOTE :

If shutdown is to be of a short duration, it is not necessary to drain

the slurry back to the fed tank. However, when this is done, the
filter agitator should be left running to prevent the solids from
settling out and freezing the agitator.

- Shutdown vacuum pump motor.

- Shutdown drum drive motor.
- Close wash spray valves.
- Shutdown filtrate pump.

If shutdown is for longer period, rotate drum and hose-down

completely the filter drum and tank and clean up around the unit.
Remember it is easier to keep the equipment clean than to have to
clean it after solids have been allowed to harden on the various
parts.

- Shutdown drum and agitator.

CAUTION :
Most slurries have a tendency to settle out and harden. For this
reason the agitator should be kept running as long as there is any
slurry in the tank.
- All filter accessories such as repulpers, etc. should be
cleaned up and shutdown in like manner.

35
SAFETY :
1. Grids are flammable and will support combustion.
Keep all flame work away from them, such as would be provided
by blow torches and acetylene torches when burning metal, arc welding
or any such fire producing operation in the vicinity of the filter from, be
sure to cover the whole drum with a canvas tarp or the like to prevent
sparks and / or flame from coming in contact with the grids.

2. If the grids are stored in a place where the temperature is below

room standards bring grids temperature to 700 before handling
them whether to install or to remove.

3. Do not allow workmen to walk on the grids since they are not
designed to stand such misuse.

4. Flocculants used in the plant are of two types i.e. Gum

Product(Flocal) and Synthetic Chemical (Magnafloc etc.).
Flocculants when comes in contact with water, it forms gel which is
slippery in nature. Hence more carefully in the flocculants
preparation area.

5. Avoid spillage of flocculent on floors.

6. Synthetic flocculants is toxic in nature, injection of it is harmful.

7. Keep flocculants preparation area always clean.

8. Avoid inhalation of flocal powder as it cause irritation in your

vessels & throats.

36
PRODUCT RECOVERY

In this area, filtration, drying and packing of MDU/ADU takes place.

The major equipments are as follows.

- Agitated tanks.

- Horizontal Belt Filter-5M2 filtration area.

- Spray Dryer.

- Bag Filters.

- Weighing and Bagging System.

- High Rate Thickener.

- Pumps.

- Fans.

- Absolute Filters.

- Compressors.

- Vacuum Pumps.

- Control Desk.

- Instruments.

HORIZONTAL BELT FILTER :

Delkor horizontal vacuum belt filter model no. 12 B / 02 – 25 V,
designed for dewatering and washing of M.D.U. / A.D.U. Slurry
has been put to use. The major components of the Belt Filter are
as follows :

- Head and Tail pulleys.

- Belt return and cloth rollers.

37
- Transporter Belt.

- Delflex curb.

- Vacuum box, water injection and seal.

- Belt support.

- Cloth tracking.

- Slurry feeder.

- Cake wash distributor.

INSTRUMENT AND CONTROL SYSTEM :

The filter has the following instrumentation included :

a) SEAL WATER FLOW SWITCH/INDICATORS :

A switch is supplied with the seal water flow meter to give a low flow

signal. This should be wired to give an alarm followed, after a short

delay, by a filter shutdown.

b) CLOTH TRACKING :

The filter cloth is guided using a tracking system.

The cloth tracking system consists of a standard cloth return roller

set a position where the cloth changes direction through
approximately 1350 . This roller is moved backwards and forwards

38
 when activated by a pneumatic sensor and Deltracker proportional
pneumatic tracking unit.

c) CLOTH SIDE TRAVEL SWITCHES :

Two cloth side travel switches are mounted at the feed end of the
filter.

d) BELT SIDE TRAVEL SWITCHES :

Two belt side travel switches are mounted at the feed end of the
filter.

e) SAFETY TRIP WIRE ASSEMBLIES :

Two safety trip wires are mounted along the sides of the filter.

START-UP PROCEDURE :

a) Check that the pressure and flow of the vacuum box seal water is
correct and that the flow switch function correctly.

b) Wash the underside of the belt to removal all dirt and foreign
matter.

c) Check that the compressed air line is open and that the filter
regulator is not blocked and that the lubricator is filled with the
correct oil. The cloth tracking device should be checked manually
for operation.
39
d) The filter drive should be started and adjusted to obtain a slow belt
speed.

e) At this point the four limit switches (two transporter belt and two
cloth tracking), should be checked in turn for correct operation.

f) The belt speed should be increased slowly and if it is running

satisfactory, it should be set to normal operating speed
(approximately at mid point 0.5 m/min.).

g) Check that the tension of the belt is such that slip does not occur
on the drive pulley and that a catenary exists between the belt
return roller. Increase the belt speed gradually to full speed of 0.9
m/min. once the belt is tracking satisfactorily.

h) Feed water to the cloth wash sprays and check that all spray jets
appear the same and are not blocked.

i) Check the spray pressure which should be at 3 bar gauge for the
correct washing pattern.

j) Check that the slurry feeders, wash distributors and dams are
correctly positioned and are cleared of debris.

k) Check that there are no holes in the filter cloth. Holes can be
patched by gluing on cloth patches or by sewing or patches.

l) Start vacuum pump.

40
NORMAL OPERATION :

a) Start slurry feed onto the filter.

b) Check that all sprays are open and covering the full width of the
cloth and that the cloth is being cleaned completely on both sides.
Clean any sprays if they are blocked.

c) Ensure that a good cake discharge prevails by adjusting slurry rate

and belt speed to design limits

d) Feed cake wash liquors to cake at designed rate.

e) Ensure that vacuum box seal water and cloth sprays and cloth
tracing compressed air are on.
f) Adjust the slurry feed, wash water flows and belt speed to optimise
the filter capacity and to obtain the most economic cake thickness.

ABNORMAL OPERATION AND EMERGENCY ACTION :

The horizontal belt filter allows very good operator visibility and it
should be possible to detect, identify and correct any problems
without any disruption to the overall operation to the plant.
However, this is dependent on plant operators reacting to their
visual observations & taking the appropriate action.

The main source of problems and their solutions are outlined

below under distinct headings. These are not intended to be a
complete list of all possible faults, but those most likely to occur,
are covered.

41
a) LOSS OF VACUUM :

Observations will show gradual increasing size of dewatering

zones or no cake formed (i.e. feed slurry discharging off end).
Check the following :

- Vacuum pump running at correct speed and supplied with clean

seal water at the correct pressure and flow.

- Check all flanges and joints in vacuum manifolds & receivers.

- Check the filtrate is being removed satisfactorily by the filtrate

pumps.

- Check wear belts for possible damage and seal water flow rates.

- Check all joints and end brackets of vacuum box.

- Check if there is sufficient slurry/cake on filter.

- Check that there is sufficient wash water on filter.

- Check that main transporters belt is tracing straight.

b) POOR CAKE DISCHARGE :

Check the following :

42
 - Using correct filter cloth.

- Thickness of cake.

- Dryness of cake.

- Amount of product wash liquor added in washing zone.

- Belt speed.

- Cloth tension.

c) BELT TRACKING :

Adjust head and / or tail pulleys and / or belt return roller.

d) POWER FAILURE :

In the event of power failure :

Ensure that feed will shutdown immediately.

e) INSTRUMENT AIR FAILURE :

In the event of instrument air failure :

43
i) Stop Feed.

ii) Stop filter drive.

iii) Stop all pumps.

f) TEARING OF CLOTH :

In the event of the cloth tearing :

Repair or replace cloth.

SHUTDOWN PROCEDURES :

The following procedures should be followed for shutdown :

- Shut slurry feed valve, cake wash water valves and feed pumps.

- Allow the wet cake sufficient time to dewater and dry as much as
possible and discharge all the cake.

- Stop vacuum pump.

- Close valves in vacuum circuit i.e. vacuum pump, vacuum seal

water. Ensure that cloth and belt sprays are on.

- Stop filtrate pumps (including gland water feed valves).

44
- Allow filter to continue running in order to rotate cloth 2-3
revolutions to ensure that both cloth and belt are fully discharged
and clean.

- Stop drive.

- Close seal water valves.

- Close valves for instrument air supplies.

- Shutdown cloth spray water and slurry pumping system.

SAFETY :

1. Ensure that the filter is properly guarded the thickener hand railing
is in place and maintain in a satisfactory order and plant personnel
are fully conversant with method of operation.

2. Test all emergency stop systems (i.e. cloth/belt tracking limit

switches, emergency pull wires and stop) for effectiveness before
leaving the equipment to run unattended.

3. Always isolate the plant before carrying out any work on the filter.

4. Observe local safety regulations.

45
SPRAY DRYING PLANT :

The discharge cake of the Belt Filter is repulped with water to 30 –

35 % solid and this slurry is dried in a spray drying unit. The major
components of this unit are as follows :

- Spray Dryer, consisting of a) High speed centrifugal atomizer.

b) Drying chamber.
- Pumps.

- Fans.

- Air Filter and absolute Filters.

- Air heater.

- Bag Filter.

- Rotary Valve.

INSTRUMENT AND CONTROL SYSTEM :

In this section major instrument provided for process control are

listed below :

a) PID Controllers for Inlet & Outlet Temperature control of Electric

Heater and Drying chamber.

46
b) Safety interlocks are as follows :

- Air supply fan and ADU feed pump must be running before starting
of electric heater.

- In case of very high inlet temperature of electric heater & very high
outlet temperature of drying chamber, mains supply to electric
heater gets cut.

- In case of very high outlet temperature of the drying chamber,

safety water starts pouring in and false air damper also get
opened.

c) Control Desk :

Temperature Recorder, Controllers, Status Indications and

Annunciators are provided in the Control Desk :

- Temperature Recorder for Inlet/Outlet temperature of Drying

Chamber.

- Controllers for Inlet/Outlet temperature control of Drying Chamber.

- Status indication for Air Supply Fan, Feed Pump, Rotary Valve,
Exhaust Fan, Atomiser, Cooling Fan and Electric Air Heater.

- Annunciation for Exhaust fan stop, supply fan stop, cooling fan
stop, inlet air temperature high, outlet temperature high, rotary
valve stop, fed pump stop, chamber vacuum high, atomiser oil flow
low, Atomiser stop, Bag filter Diff. Pr. High/low.

47
START-UP PROCEDURE :

1. Please ensure that all the openings such as chamber door, sight
glass cover etc. are tightly closed.

2. Star “Rotary Valve”.

3. Put “Exhaust Fan Bypass” switch on ICP in “Bypass” position.

4. Start “Exhaust Fan.”

5. Start “Supply Fan” immediately.

6. Put “Exhaust Fan Bypass” switch on ICP in ‘ON’ position.

7. Start cooling Fan”.

8. Start “ Rotary Atomiser”.

9. Put ‘OUT’ = 0.0 in “ TIC – 02 “ on ICP.

10. Ensure water is available continuously in pump suction flushing

line.

48
NORMAL OPERATION :

1. Start “Feed Pump” (Since ‘Out = 0.0 in TIC – 02, Power goes to
pump motor, however it does not pump water).

2. Start “Electric Air Heater” Inlet/outlet temperature will start

increasing.

3. Monitor & control “Outlet Temperature” at about 85 – 950C by

increasing “Out = 0.0 upward (i.e. by increasing output of feed, it is
possible to control outlet temperature). General feed )Water)
should start entering in “Atomiser” when outlet temperature is @
60 – 70 0C.

4. Change over to ‘Slurry’ with the help of valve and again control
outlet temperature at 85 = 95 0C once the inlet temperature is
stabilised at desired temperature (say 350C or 45 0C etc/)

49
ABNORMAL OPERATION AND EMERGENCY ACTION:
The following are the main problems during Drying Plant
Operation:

Indication Possible cause Remedies

1. Feed is blocked. Clean the
strainer/check the
Chamber
pump/line &
Temperature High.
valves.

2. Feed is dilute Check the density.

3. Inlet temperature Check the inlet

is temperature.

High

1. Bottom of the Check the

drying chamber.
Chamber Pressure.
chamber and the
bag.

2. Line between Check the line.

drying

chamber and the

bag

filter is choke

Differential pressure 1. Bags are choked. Bags to be

across the bag filter cleaned/changed.
is high
2. Absolute filter is

choked.

50
SHUTDOWN PROCEDURES :
1. Change over to “Water” from “Slurry” & control outlet
temperature.

2. Stop “ Electric Air Heater ”.

3. Water quantity to be reduced gradually since inlet temperature is

reducing. Keep controlling outlet temperature.

4. Once the inlet temperature about 150 –1600C & outlet temperature
starts falling below 900C, stop the feed pump.

5. After @ 2-3 minutes, stop “ Rotary Atomiser ”.

6. Stop “ Slurry & Exhaust ” fan once the inlet/outlet temperature is

less than @ 900C.

7. Stop cooling fan after @ 10 minutes and then “ Rotary Valve ”.

SAFETY :
1. A.D.U./M.D.U.is a radioactive material, inhalation, injection is
harmful to health.

2. Use respirators, gumboots, protective clothing, while working in

M.D.U. / A.D.U. drying & packing area.

3. Use of Film Badges is mandatory.

51
4. Do not take your contaminated clothing to your house for washing.

5. After finishing work, take bath, change dress & then go out of work
place.

WEIGHING AND BAGGING SYSTEM :

Once the ADU/MDU bin is filled, with material, weighing and bagging

operation starts. This unit consist of the following major equipment :

- Double Screw Feeder.

- Weigher.
- Microprocessor based electronic controller.
- Discharge chute.
- Drum holding mechanism.
- Dust extraction system which includes fans, bag filter, absolute
filter, ducts etc.
- Roller conveyor.
- Management data printer.

INSTRUMENT AND CONTROL SYSTEM IN ADU BAGGING

PLANT :

In this plant a semi automatic Microprocessor based Bagging

System has been provided to control the following operation :

52
- Placing the drum at the filling point.
- Covering the drum by bellows before stating filling cycle.
- Automatic weighment during filling cycle.
- Stopping the feeder after the drum is filled with the present weight.
- Transporting the drum from the filling point to discharge point.

To control all these operation, a Control Desk is provided which

contains the following :

- SPEED AC-7 Controller with Display.

- Electric Contactors.
- Push buttons for operation and programming of the Micro
Processor.
- Printer.

START-UP PROCEDURE :

Before starting the weighing and bagging system, the following are
to be checked:

- Empty Drum with Polythene bag inside is ready.

- Sample collecting bottle is placed properly.
- Dust Extraction System is on.

NORMAL OPERATION :

- Keep main isolator ‘ON’.

- Keep CVT ‘ON’.
- Press Control ‘ON’ push button in main panel.

53
- Select the present weight in key board.
- Press ‘RUN’ key board, then place the drum, indication will come,
locking device will lock the Craddle, Craddle Conveyor starts
running, Drum stopper will operate.
- Place the drum on Inward Conveyor and press Inward Conveyor.
- Drum will touch to the limit switch on Craddle Conveyor & Craddle
Conveyor stops.
- Press the spout down push button and check whether it is properly
placed on the drum or not.
- Press weighment start push button. Drum spout will cover the
drum, immediately locking device & drum stopper de-energies,
catch gate opens, full feed, fine feed screws starts running
simultaneously till full feed weigh and remaining weighment will be
completed in fine feed.
- After completion of weighment immediately catch gate will close. If
any alarms comes accept it, weighment indication comes, again
locking device will lock the cradle and starts out ward conveyor
alongwith cradle conveyor automatically after time out.
- While Drum Travelling on outward conveyor drum touches to OK.
To release limit switch, then place drum indication will come
immediately outward conveyor stops.
- Repeat the procedure from step no. 6 for next weighment.
- Take the print out after the completion of each lot.

ABNORMAL OPERATION & EMERGENCY ACTION :

Indication Possible Cause Remedies

1. Bin is empty. Check the bin.
Taking too

54
 much time 2. Screw feeder is not
in filling working
the drum. properly.
3. Set point is not being
assessed
by the instrument
Check the feeder.
Call the Instrument
mechanic and get it
checked.

4. Compressed air not Check the compressor

available. and dry air chamber
pressure.

SHUTDOWN PROCEDURE :

- After the 10th step of the normal operation, do not place any drum
on the inward conveyor.
- Empty out outward conveyor.
- Bring the main isolator on ‘OFF’ position
- Stop the Dust Extraction System.
- Stop the Compressor.

SAFETY :
1. ADU / MDU is a radioactive material, inhalation, injection is
harmful to health.
2. Use respirators, gumboots, protective clothing, while working in
MDU / ADU drying & packing area.
3. Use of Film Badges is mandatory.
4. Do not take your contaminated clothing to your house for washing.
5. After finishing work take bath, change dress & then go out of the
work place.

55
TAILINGS DISPOSAL
Before disposing the tailings i.e. combination of Secondary Drum Filter
Cake and Ion-Exchange barren liquor, these are neutralised. After
neutralisation these are passed through Hydrocyclone to separate sand
and slimes fraction. Sand is sent to mines for Mine Back filling and
slimes are pumped to slimes dam. The tailing section receives its waste
material from the secondary drum filter and from the barren left after the
entire process of adsorption and elution. It is sent to the neutralising
pachukas where lime is added to neutralise the entire waste material .
the pH is maintained at 9.5 so as to liberate Mn which liberates at this
pH. This material is then eliminated into the nature.

The major equipment in this area are :

- Neutralising Pachucas.

- Agitated Tank.

- Auto Sampler.

- Pumps.

- Instruments.

START-UP PROCEDURE :
A) Before starting the Plant, the following to be checked :

- Air pressure.

- Day tank of lime stone slurry.

- Day tank of lime slurry.

- Thickener water overflow pump

- Discharge pipes (Cloth) of the hydro cyclones.

- Bench pH meter.

- All other pumps.

56
B) Keep the air pressure for Pachucas agitation at more than 1.0
kg/cm2.

- Feed Barren Liquor to Neutralising Pachucas No. 1

- Add Lime Stone Slurry (5-20 % solid w/w) to Pachucas No. 1 and
maintain the pH of outgoing slurry of Pachucas No. 3 between 3.7
to 4.2.

- Add Lime Stone Slurry( 5-20 % solid w/w) in Pachucas No. 3 and
control the addition such that the pH of outgoing slurry of
Pachucas No. 6 is kept > 9.5

- Mix neutralise barren liquor and return secondary pulp slurry of

magnetite plant in Neutralise Repulper Tank & maintain the pH of
outgoing slurry of N.R. Tank more than 8.5.

- Feed the discharge slurry of N.R. Tank to Primary Hydro cyclones.

- Maintain Primary Hydrocyclone underflow slurry density to around

50 – 65 % solid w/w and pump this underflow to mines for backfill.
Percolation rate of this slurry should be 400 – 500 cc/hr.

- Primary Hydrocyclone overflow slurry through pump to

secondary stage hydro cyclones and maintain underflow slurry
density around 50 – 65 % solid (w/w). Pump this underflow to
mines paddock/underground. Percolation rate of this slurry should
be 300 – 370 cc/hr.
- Pump out secondary hydrocyclone overflow slurry to tailings pond
for impounding of solid waste.

NORMAL OPERATION :
During normal operation of the Tailings Disposal Plant, the followings to
be adjusted/checked:

- See that air pressure in the line near neutralising pachucas is 1.0
to 2.5 kg/cm2 and agitation in pachucas is good.

- Barren is flowing.

- Lime slurry is being added.

57
- See that pH of the outgoing slurry of the pachucas is 10.5 – 11.0

- See that slurry is coming to N.R. Tank.

- See that the pH in N.R. Tank is around 9.0 to 9.5.

- See that auto sampler is working.

- All the agitators of the tanks are running.

- Sand classification system is OK.

- Check the percolation rate of the primary & secondary sand.

- See that all the tailings disposal pump are OK.

ABNORMAL OPERATION AND EMERGENCY ACTION :

Indication Possible Cause Remedies

1. Lime pump is not Check the
pumping pump/line/valve etc.

properly
PH low
2. Lime tanks may be Check the tank.
empty

3. Field instrument may be Check the slurry in

faulty. bench pH meter/call the
instrument mechanic.

1. Fine grinding Get the particle size

analysed.
Percolation rate
low 2. Improper functioning of Check the Hydro
cyclones. Specially
Hydro cyclones.
vortex finder, Apex
Valve and Inlet pressure.

58
SHUTDOWN PROCEDURE :
- Ensure that Barren Liquor and the Secondary Filter Pulp is not
coming to the Tailings Plant.

- Stop lime pumps.

- Wash/clean the auto sampler.

- Stop the slurry pumps after complete flushing.

- Stop the water pumps.

SAFETY :
1. Wear safety goggles, cap, rubber boots and rubber gloves.

2. If lime is pilled or splashed on your skin, wash it off with plenty of

water.

3. If lime splashes on your eyes flush immediately with clean water.

Barrage:
1. To meet the water requirement, both industrial and Potable,
a barrage has been built on Gara Nala, which is 3 Km. Away from
the Main Plant .The details are as follows :
(1) Catchment Area of Barrage : 2.55 sq. Miles.
(2)
a Capacity of Barrage : 300 Million
gallons.
b. Max. water level of the Barrage : 335.00 ft. from sea level
c. Length of Barrage : 339 ft.
d. Bed level of the barrage near gates : 300 ft.
e. Under sluice weir crast : 310 ft.
f. Other gates weir creast : 315 ft.
g. H.F.L. of Barrage (designed) : 328 ft.
h. Maximum Discharge : 1,02,000
cft./sec.

59
 MAJOR EQUIPMENTS :

BARRAGE GATES & MACHINERY

1. GATES:
5 gates (4 gates are ordinary and one gate is under sluice
which controls the water level in normal season). Normally all the
gates are closed.

(a) Size of under sluice Gate :

1 x 60’-0” x 26’-0”
Other gates size : 4 x 60’ –0” x 21-0”
Top levels of the gates are same : 336’-0” (R.L.)
The sill of the under sluice is 5 ft below the others.

(b) Each gates are having counter weigh box.

Weight of the under sluice counter weight : 42.2 tonnes.
Weight of the other gates counter weight : 31.2 tonnes.

2. Lifting arrangement of the gates are through the gear box

fitting with reverse and forward operation with motors.

(a) H.P for under sluice gate operating motor : 3 H.P.

(b) H.P for other gates operating motor : 3 H.P.
(c) 2”Ф steel wir4e ropes are fitted on either sides which are
connected is rotating drums. The drums are connected with shaft
and the gear box is connected with motor. Arrangement is also
provided for hand operation with the hand brake etc.
(d) Pumps.

START-UP PROCEDURE :

Before opening the gates, the following to be checked :

- Water level in the barrage. It should be over flowing

condition.
- sounding siren for at least 15 mtrs. , so that the persons in
the down stream could take care of.

60
 - Opening the gates as per the inflow of water.
- Start the pump on request of W.T.P.

NORMAL OPERATION :
During normal operation, the following to be checked :

- See that the water level does not go 3 to 4 ft. lower than the
over flow point.
- During rainy season, inflow water should be continuously
monitored.

ABNORMAL OPERATION & EMERGENCY

ACTION :

The following abnormality may come which should be

rectified.

(a) Water over flowing the gates :

Gates to be opened.

SHUTDOWN PROCEDURE :

The following steps to be adopted for shutting down the gates :

(a) When the water level goes down to 3 – 4’ below the gate top,
it should be closed slowly.
(b) Stop the water pump, if requested by W.T.P.

SAFETY :
- All the electrical accessories should be checked periodically
which are necessary for gate operation.
- Lubrication of gear boxes is to be done periodically.
- Counter weight ropes to be checked thoroughly.
- Do not take bath in the barrage.
- Do not allow any kind of boating in the barrage.

61
 WATER TREATMENT PLANT

PROCESS:

At present, 12000 m3/day raw water is pumped from Barrage to

Water Treatment Plant. The raw water comes from Barrage
through 16 inch dia C.I. pipe to Aeration chamber for mixing the air
with water to remove the Carbon dioxide and improves the quality
of oxygen in water. It also removes the iron, magnesium, odour
and taste etc. From chemical house, Alum solution is dosed as
coagulant for floc formation. Bleaching powder solution is dosed
for chlorination of water. Alum and Bleaching powder solution is
prepared in a Agitator fitted tank in Chemical House and is be4ing
dosed from Chemical House to the launder by gravity through PVC
pipe. Pre chlorination is being done by Bleaching powder solution
and chlorine concentration is maintained 0.3 to 0.5 ppm in the
water of clari-flocculator. After aeration chamber, water passes
through ventury channel for measuring the quantity of raw water.
One no. Electronic digital open channel Flow meter has been
installed at venturi channel to measure the flow of water from
Barrage. From venturi channel water passes through Flash Mixer
where all chemical dosage are mixed by means of mechanical
device. From Flash mixer, the water goes to clari-flocculation. This
is a settling tank in designed for settling the suspended matter.
Sludge is removed from the bottom of clari-flocculator. The
retention period is 3 hours.

From clari-flocculator, water flows to Industrial water reservoir and

rapid sand gravity Bed filter house (Three nos.).

After filtration, water goes to bottom sump of the filter house. There
are total six nos. Beds for Filtration. Each bed output is 75 to 80
m3/fr. Post-chlorination is being done by dosing Bleaching powder
solution from Chemical House to filter house sump by gravity
through PVC pipe. Chlorine concentration is maintained 0.3 ppm is

62
 sump of the Filter. From Filter house the Filtered water comes to
common sump.

There is pump house where pumps are provided for different units
for different places like colony, Mill, Mines Narwapahar and
surrounding areas of WTP of Jadugoda. There are two wings, one
side potable water pumps sets & other side industrial water pump
sets.

The following parameters are maintained :

a) Chlorine content= 0.2 – 0.3 mg/lit.

b) Clarity of water = 0 – 3 jtu.

MAJOR EQUIPMENTS :
The major equipments are :

i) Clariflocculator : Diameter = 21 M

ii) Rapid Sand Filter : Capacity = 75 M3/hr.,

Inlet turbidity = 0-10 mg/lit

outlet turbidity =0

iii) Reservoirs

iv) Pumps

v) Over Head Tank : Capacity(industrial) = 50,000 gallons

(Potable ) = 50,000 gallons.

63
INSTRUMENTS AND CONTROL SYSTEM :

Flow meter : Electronic digital open channel. Flow meter has been
installed at ventury channel to quantify the raw water coming from
the barrage.

START UP PROCEDURE :

(A) Before staring up the plant, the following to be checked :

- Solution of alum, bleaching powder and lime is ready.
- Sand filter beds is choked or not.
- Over head tanks levels, Reservoir levels to be checked.
- Clari-flocculator to be checked.
- Sump level to be seen.

(B) SEQUENTIAL OPERATION :

- Start flash mixture and clariflocculator.

- Start Barrage Pump.
- Start addition of reagents.
- Maintain the water levels in the sump.
- Start the Pumps of various areas.

. NORMAL OPERATION :

During normal operation, the following to be checked :

- Rate of flow of raw water from barrage.

- Rate of reagent addition.
Alum - As per requirement.
Bleaching powder - 0.3 mg/lit.
Lime - 40 mg/lit (only during rainy season).
Over flow water of the clari-flocculator. It should be clear and its
turbidity should be
0-10 mg/lit.
- Filter bed requires back washing or not.
- Water levels in over head tank sump and Reservoirs.

64
 ABNORMAL OPERATION AND EMERGENCY
ACTION :
The abnormality observed during operation is described below
along with the actions to be taken to do away with it.
(a) Chlorine content in water is low / high :

- Addition of bleaching powder to be checked.

(b) Water is turbid (Raw & clarified water) :

- Addition of Alum is to be checked.

(c) Filter outflow is less :

- Back washing is required.

- Rate of pumping to be checked.

SHUT-DOWN PROCESS :

The following steps are to be followed for sequential shut down of

the plant :
- Stop Barrage Pump.
- Stop reagent addition.
- Bring the level to minimum position.
- Stop the Pump

SAFETY :

- Use Personal Protective appliances such as hand gloves, gumboots,

etc. during handling of bleaching powder, Alum.
- Do not move on the walls of reservoirs.

65
EFFLUENT TREATMENT PLANT

The Effluent Treatment Plant has been installed for reclamation and re-
treatment of effluent to remove excess Ra and Mn before discharging
the same to environment.

The Plant tailings after neutralisation, containing ore waste and effluent
is pumped to the Tailings Pond for settlement of solids. The decanted
clear overflow water through a brick masonry drain is taken by gravity to
a sump in effluent treatment plant.

The effluent from sump is pumped to a flash mixer where flocculant

solution is dosed. The overflow from the flash mixer flows into the
Primary Thickener having about 4 hours retention time, where
suspended solid are allowed to settle down. The underflow from the
Thickener containing 10 – 30 % solids is withdrawn by suction pump &
then pumped to the Tailings Pond for settlement and deposition. The
overflow water from the Thickener is collected in a clarified water
intermediate reservoir of 400 cu.m capacity. A part of the clarified water
is recycled to the process plant fro reused, such as Sec. Cake repulper
tailings dilution etc. Balance water from the intermediate reservoir is
pumped to the flash mixer, where barium chloride solution ( 2% strength)
is dosed from where it goes to RaBa sulphate precipitation tank.

According to the following chemical reaction, barium radium sulphate co-

precipitates, thereby removing almost 99 % of the dissolved radium present in
the effluent.

BaCl2 + RaSO4 = (BaRa) SO4 = 2 Cl-

5 nos. tanks operating in series are provided for Ra and Mn

precipitation. In first two tanks Ra precipitates. In third tank lime solution
is added to increase the pH to 10.

The lime treated effluent from the last tank by gravity goes to a flash-
mixer where polyelectrolyte type flocculant is added to facilitate floc
formation and settling and settling before the effluent is passed to the
secondary Thickener for sedimentation and clarification.

The secondary thickener is having a retention time of 8 hours, where

precipitated floc settles and withdrawn from the bottom of the thickener
as sludge. Because of high radioactive nature, the sludge is pumped to
66
 the tailings plant where it is mixed with the neutralised plant tailings and
sent to the Tailings Pond for deposition and retention, thereby effectively
controlling re-escape of the precipitated solids into the environment.

The overflow from the secondary thickener is collected in a tank and

drained to the environment as per excess quantity.

The plant’s designed capacity is to treat 180 cu.m/hr of tailings pond

effluent along with Narwa Mine water.

MAJOR EQUIPMENTS :

- Thickeners.
- Flash mixtures.
- Agitated reaction tanks.
- Pumps.
- Reservoir.

INSTRUMENT AND CONTROL SYSTEM :

In this section major instrument provided for process control are
listed below :
- pH Meter for outgoing effluent steam.
- Automatic Motorised Lime Addition system.
- Recorder for pH and effluent flow.

START-UP PROCEDURE :

Before starting the plant, the following to be checked :

(A) Reagent solutions such as BaCl2 solution, lime solution, flocculant are
ready.

- All the reaction tanks agitator is running.

- Thickener racks are running.
- Thickener rake position.
- Availability of effluent.
- Agitators of flash mixtures are running.

67
(B) SEQUENTIAL START – UP :

- Start Raw effluent pump.

- Start recycling pumps.
- Start dosing Barrium chloride, solution in tank no. 1 and 2.
- Start dosing lime solution in tank no. 3.
- Start dosing flocculants before the secondary thickener.
- Start various sludge pumps.

NORMAL OPERATION :
During normal operation, the following to be observed :

- pH to be checked in all the reaction tanks.

- pH of the treated effluent, going up to the environment to be checked.
- Flow of the Raw effluent for treatment to be checked.
- Collected Raw/Treated effluent samples.

ABNORMAL OPERATION & EMERGENCY

ACTION

The following is the abnormality during the operation which should be

rectified as follows :

a) pH low :

- Check the lime addition.

b) Treated effluent is turbid :

- Check the flocculant addition.

- Check the sludge pump.

c) Raw effluent flow is low :

- Check the Raw effluent supply.

- Check the Raw effluent pump.

68
 SHUTDOWN PROCESS :

The following steps to be adopted to shut down the plant :

- Stop the raw effluent pump.

- Stop Barium Chloride solution addition.
- Stop lime solution addition.
- Stop flocculant dosing.
- Stop flash mixtures.
- Stop the agitators of the reaction tanks

SAFETY
- Wear Safety goggles, cap, rubber boots and rubber gloves respirator
and keep them in good repair, while handling lime, flocal powder etc.
- If lime splashes on your eyes or skin flush immediately with clean
running water on the affected parts and then report to first-aid.
- Avoid inhalation of flocal poser as it caused irrection in nossels and
throats.
- Avoid spillage of flocal powder on floors as it form gel with water, which
si slippery in nature.
- While handling Barrium Chloride, do not inhale it.

69
SEWAGE TREATMENT PLANT

PROCESS:

The Sewage Treatment Plant is capable of handling 0.9 MED containing

approx. 3 % solids. Raw Sewage comes from colony through hume pipe
by gravity to Raw Sewage pumping station. From RSP, the raw sewage
is pumped to grit chamber through inclined bar screen, to remove the
undesired elements in the sewage. From grit chamber, the sewage flows
to Aeration chamber (four large separate compartments fitted with
Aerators in each). The purpose of Aeration chambers to reduce the BOD
level of sewage. The maximum BOD level comes down here at Aeration
chamber. From Aeration chamber, water flows to clarifier. The overflow
of the clarifier flows to tank where chlorination is being done before
discharge to environment. The underflow (sludge) of clarifier is partly
recycled to Aeration chamber and the rest part of the sludge is sent to
sand filter beds. The Filtrate from Filter Bed is recycled to Aeration
chamber. The manure is periodically removed from the top of the sand
Filter Beds.

The following is to be maintained :

B.O.D. : < 20 mg/lit.

Suspended solid : 15 mg/lit.

MAJOR EQUIPMENTS :

The major equipments in this plant are as follows :

- Pumps.
- Grit Chamber
- Aeration Chamber with aerators.
- Clarifier 20 M dia.
- Chlorination tank.
- Sand Filter Bed.

70
INSTRUMENT AND CONTROL SYSTEM :

Open Channel flow meter :

This has been provided to ascertain the quantity of Raw sand sewage
flow. One recorder has also been provided in the control room.

START-UP PROCEDURE :
(A) The following to be checked before starting the plant :

- Grit chamber screen to be checked.

- Clarifier should be in running condition.
- Chlorine solution should be ready

(B) SEQUENTIAL OPERATION :

- Start Raw Sewage pump.

- Remove the foreign materials, if any, on the screen of grit chambers.
- Start the aerators when the water level submerges the aerator blades.
- Start chlorination.
- Start the sludge pump of the clarifier.
- Start Under flow pump of the sand filter bed, if required.

NORMAL OPERATION :
During normal operation, the following is to be checked :

- Raw sewage is continuous or intermittent.

- Grit chamber to be kept clean.
- Scum chamber of the clarifier scrapper is to be kept clean.
- Addition of chlorine at the rate of 0.5 mg/lit.
- To collect sample from chlorination chamber for the check of B.O.D. and
suspended solids.

71
 ABNORMAL OPERATION AND EMERGENCY
ACTION :

The following abnormality may occur which is to be rectified :

a) B.O.D. High :

- Check the aeration system.

- Check the chlorine addition.

b) Suspended Particle Concentration in the Treated Sewage is high :

- Check the aeration chamber.

- Check the clarifier.

c) Chlorine content in the treated sewage is less :

Check the chlorine addition.

1. SHUTDOWN PROCEDURES :

The following steps should be taken to stop the plant sequentially :

- Stop Raw Sewage Pump.

- Stop the aerators if required.
- Stop the clarifier if required.
- Stop the sludge pump and filtrate pump.
- Stop addition of chlorine.

72