HINDUSTAN COPPER LIMITED

INDIAN COPPER COMPLEX

SURDA MINES

VOCATIONAL TRAINING REPORT

PREPARED BY STUDENTS OF MINING ENGINEERING, B.I.T.

SINDRI , JHARKHAND:-

1. SANTOSH KUMAR (1308031)

2. VIKRANT VISHAL (1308037)
3. VIVEK KUMAR OJHA (1308039)
4. MAHESH JI PANDEY (1308019)
5. SUJIT KUMAR (1308036)
6. MRINMOY GHOSH (1308046)
7. RAJAN KUMAR (1308027)
8. ADARSH SAHAY (1308047)
9. MONU KUMAR (1308041)
10. AMIT KUMAR (1308005)
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 CONTENTS
ACKNOWLEDGEMENT
INTRODUCTION OF THE MINE
LOCATION, HISTORY,DETAILS AND GEOLOGY OF
THE MINE
SURVEYING
VENTILATION
METHOD OF WORKING
DRILLING
BLASTING
TRANSPORTATION
SAFETY ASPECTS
CONCLUSION

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 ACKNOWLEDGEMENT
We, the students of BIT SINDRI, Mining Engineering, have put a great
effort in completing this project but this would have not been
possible without the guidelines and help of the HCL EMPLOYEES.

We owe a great thanks to Mr. Ravi Singh Choudhary, Senior Manager

(Human Resource), who arranged a practical training for us at the
Surda Mines of HCL/ICC ,Ghatsila.

We like to express our profound gratitude and indebtedness to

Mr.D.K.Choudhary (Agent), Mr.Parwez Alam (Mines Manager),
Mr.Biswanath Oraon (Deputy Manager), Mr.M.C.Katare (AGM
Mines), Mr.Satyendra Kumar (Safety Officer), Mr.S.K.Patnayak
(Sr.Manager,Surveying), Mr.D.K.Sarkar (Sr.Manager Mechanical),
Mr.Ranjit Majhi (Ventilation Officer), Mr.Amit Degvakar (Geologist),
Sampath Kr Sangi (Training Officer), Mr.Mahesh Kr Yadav (Asst.
Manager), Mr.Vinay Kumar (Asst. Manager) for their continuous
support and suggestions during our training period.

Lastly we like to accord our sincere thanks to all the IRL EMPLOYEES ,
especially Mr. Anirudh Sharma, Mr. Mohammad Kaif, Mr. Deepak
Kumar, Mr. Jainath Kumar, for their co-operation and needful
advices during our training period.

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INTRODUCTION OF THE MINE
SURDA MINE operated between 1930 to 3rd January 2003 .The mine
is 2200m in strike in north-south direction and is accessed by 3
openings namely No. 3 Shaft (#),4 shaft and Adit

No. 3 # is in north Surda and is vertical to level 5 , from where a Sub-

Incline goes down upto the deepest (13th level) level, which is at a
depth of about 475 m from the surface.

No. 4 # is in South Surda and is inclined from surface to level 10 .It

gives more site production than No. 3#

The Adit is located near the No. 3 # and has a horizontal length of
115.8 m.

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LOCATION OF THE MINE
1. Indian Copper Complex, Ghatsila has the following operations
such as Ore mining, Beneficiation, Smelting, Electrolytic refining and
has a precious metal recovery plant (Gold, Silver, Selenium etc).

2. Khetri Copper Complex, Rajasthan, has the same operation as ICC

Ghatsila.

3. Malanjkhand Copper Project, M.P. has operations of ore mining

and beneficiation.The concentrate is sent for further processing to
KCC and ICC and excess quantity is sent abroad for toll smelting.

4. Taloja Copper Project, Maharashtra has C.C. rod facility

Indian Copper Corporation Ltd was established by a

British company in 1930 at Ghatsila consisting of a
cluster of underground copper mines, concentrator
plants and smelter On 25.09.1972. The Govt. of India
nationalized the company under provisions of the
Indian Copper Corporation (Acquisition of Undertaking
Act) and merged the same with HCL. Today it falls
under the state of Jharkhand , under the jurisdiction of
East Singhbhum.

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HISTORY OF THE MINE

Surda Mine is a part of Indian Copper Complex , a

group of six mines(Mosabani, Chapri, Pathagora,
Kendadih, Rakha and Surda) owned by Hindustan
Copper Limited, that was operated between 1928 and
2003.Surda mine was started in 1930 at a very small
scale and it was fully developed in 1956.The mine was
developed upto an extension of 2.2 km ,in the strike
direction (N200SE).HINDUSTAN Copper Limited (HCL),
Indias only integrated producer of refined copper
including mining, production of concentrate, smelting,
and refining. Hindustan Copper Limited (HCL) was set
up in 1967 for production of primary copper in the
public sector.

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DETAILS OF THE MINE
Shaft Inclination Dimension Depth From level To level

No.3 Vertical 4.5*2.5m 160m Surface 5th

No.4 400 4.40*2.6m 576m(Inc) Surface 10th

Sub-Incilne 320 4.40*1.7m 674m(Inc) 4th 13th

WINZES
1. 1065 S winze 5 level to 8 level incline depth-162m(3*1.6)m
2. 1200 S winze 8 level to 12 level incline depth 380(3*1.6)m
3. 25m S winze 10 level to 13 level incline depth-380(3*1.6)m

The mine is running approximately at 1000 tonnes per

day,designed to produce 1200 tonnes per day and is to be
upgraded to the capacity of 1500 tonnes per day.
The difference between the two consecutive levels is 37.5 m

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GEOLOGY OF THE MINE
Indian Copper Complex (ICC) at Ghatsila, Jharkhand
Singhbhum Copper Belt comprises of a Proterozoic volcano-
sedimentary rock that creates a shear zone known as
Singhbhum shear zone. Copper mineralization in SCB is
localized along this shear zone. Prominent deposits of the belt
are Surda, Chapri, Rakha, Kendadih, Pathagora and Dhobani.
Other deposits are:- Turamdih, Ramchandrapahar, Nandup,
Bayanbil, and Dhadkidih (Singhbhum,Jharkhand).Surda is one
of a number of mines of the Singhbhum Copper Belt which
wrap around the margin of the Singhbhum Granite.The mines
are hosted in shear zones which thrust Proterozoic
metamorphic rocks to the west. Rock types are quite varied
from quartzite through quartz-biotite schists to chloritic
,sericitic , micaceous and even talcose schists. Indicators of
proximity to mineralization are quartz,chlorite and K feldspar
.The ore is hosted in a mylonite schist.

Mineralization is in the form of disseminated and stringer

veins of chalcopyrite as well as minor quartz-chalcopyrite
veins. Pyrite is also common. Two and sometimes three main
lodes have been interpreted on cross and long sections.
Detailed rill sections, however, often show many more
lodes than the 3 interpreted. There is a high degree of
continuity over 50-100m,but lodes bifurcate,pinch,swell,end

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and get going again. This is generally not picked up on
sections. Neverthless, at least one of the lodes on each
section appears to be continuous over several levels(100m+).
On the sections viewed, the deepest holes appeared to show
grade, but in general, mineralization is probably continuous
to depth, and will continue to exhibit variability and a lack of
continuity in detail. Mosabani mine to the southeast was
worked from 1924-1998, reaching a depth of 1280m,
producing 2,000 tpd. Lode widths vary between about 1m to
8m. In a stope accesed from the 9 level(no 4 shaft), the 16m
apparent width hanging wall lode was separated from the
12m apparent width footwall lode by a waste pillar of
about 6m apparent width. Calculating for the fairly constant
300 dip, these true widths are 8,6 and 3m. The mineralization
has been regarded as a VMS type- there are metabasite (ex-
volcanic) rocks in close proximity. However, in the absence of
significant zinc, any evidence of metal zonation, or a footwall
stringer zone,this interpretation is highly questionable.

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METHODS OF WORKING
Depending upon the nature of ore body,
nature of rocks and considering the other
geological conditions, basically three methods
of stopping are applied for extraction of ore in
the Surda Mines:
(1)ROOM AND PILLAR METHOD
(2) HORIZONTAL CUT AND FILL METHOD
(3) POST PILLAR METHOD
MAJOR DECIDING FACTORS:
DEPTH OF LODE
WIDTH OF LODE
NATURE OF ADJOINING STRATA
AVAILABLITY OF TECHNOLOGY
GEOLOGICAL DISTURBANCES
STRENGTH OF LODE
STRENGTH OF HANGING AND FOOT
WALL

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Being all condition almost same, the width of
the lode is the main deciding factor here. Let
us have a brief view of the methods used:

ROOM AND PILLAR STOPING

METHOD:
This method is used where the width of the ore
body is between 1.5 m to 4m. A pilot raise is put
along the hangwall contact from the lower level to
upper level. A wooden chute is installed at the
lower level , together with an electric scraper
engine. A pillar of 5 m above the lower level and
crown pillar of 5 m below the upper level are left as
support.
In this method both faces of central raise are
advanced to a span of 10 to 15 m, with a systematic
bolting of the roof at the spacing of 1.2 m to 1.5 m
long, the dia is 20mm. Top -steel grouted rock bolts are
used as conventional supports in the place of timbers.
1.8 or 2.4 m long bolts are also occasionally used for
roof support in geological disturbed areas . A 3-4 m
wide rib pillar is left between two stopes.

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 Floor stripping is undertaken where the width
of ore body exceeds from 2.5 m. Once the mining is
completed to the extremities of the stop, backfilling of
the excavated areas is done and adjoining blocks are
mined. This method was practiced until early 1970.

HORIZONTAL CUT AND FILL METHOD:

This method is used where the width of the ore
body is 4-6 m . The stoping is started by driving a
sill level of 8m above the driving and the full width
of the ore body is exposed for a maximum vertical
height of 4.8 m. The hanging wall is supported by
rock bolt systematically at 1.5 m pattern. A
footwall haulage is driven on the footwall side of
ore drive and ore passes are excavated there from
in waste rock to hole into the stope at interval of
60 m along the strike. 1.5 m diameter ore pass
rings made out of 10 mm thick steel plates are
welded inside the stope to serve as manway and
orepass through the back fill. Cavo 310 or 0.76 cum
electric LHDs are used to load and haul broken ore
into the operations. Two panels are generally
prepared, one for the production and other for the
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 filling operation. Back strippings are carried out in
panels with 2.5m vertical cut at a time.

POST PILLAR STOPING METHOD:

This method is generally adopted in the ore bodies
exceeding 8 m width and minimum strike length of
80 m. Basically, it is identical to the horizontal cut
and fill mining except for the formation of 4m4m
in-situ vertical posts to give additional stability to
the roof by breaking long spans excavated. In
addition to the rock bolting of the bolt, the back of
each cut in ore is also rock bolted using 1.5m1.5m
pattern. The post pillars are spaced at
intervals of 13 m along the strike and 9 m along
dip. Generally, 2.2m high cut are taken by drilling
2.23m long upper at 70m to horizontal using two
boom stope wagons/ stope air longs. Maximum
height of excavation is limited to 4.8 m above the
backfill. 0.76/1.5 cum electric LHDs transfer the
broken ore into ore passes from where it is hauled
in larger mine cars by locomotives on to the grizzly.
In case if fractured conditions of hanging wall are
encountered cable bolting using cables up to 2m
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long is also employed to supplement roof bolting.
57 mm dia holes, 10m to 20m long are drilled into
hanging and back of stope at 1.9 to 2m interval.
Two 16mm dia tensile steel cables are inserted
together with a plastic grouting tube of small dia.
breathing tube. LHDs of capacity 1.68m3 are in use.

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DRILLING
Drilling is a prime operation in the excavation
technology without which exploration, development,
exploitation and liquidation of the mineral deposit
could not succeed.
In Surda mine percussive,rotary and rotary-percussive
drilling methods are used. As drilling techniques
Diamond drill bits and cemented tungsten carbide
integrated drill steels are used .Drilling is used for
various purposes in the mine.

1.For exploration: Diamond core drilling process is applied, commonly

NX-size core drill is used, representing a hole diameter of 76mm(3)
and core diameter of 54 mm(2 1/8).

2.For development and stoping: In Surda mine pneumatic tungsten

carbide drill bit, rotary-percussive drilling is used. For development
and stoping drilling is done to insert explosives for blasting. There are
generally 36 holes in case of driving and 30 holes in case of raising.

DRILL MACHINE

Jackhammer is common appearance for drilling.The model used in

Silver 3 Model and manufactured by Holman Climax Company.

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It is compressed air operated with size of 2ft.

Drilling rod used are of three sizes.viz 4ft,5ft &6ft of 32 mm diameter

having tungsten carbide drill heads.There are 48 jack hammer drill

operating in no. 3 shaft and 29 jack hammer drill operating in no.4
shaft. For blasting reamer hole bit dia. Is 57mm.

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PUMPING ARRANGEMENTS
The pumping arrangement of the mine is divided into
two parts viz 3# and 4# pumping arrangement.

In No.3# pumping system there are three sumps at

level 13th , 10th and 5th.
Water is collected at sump of 13th level from
11th and 12th level and pumped to the sump of 10th
level, while the water of 6th to 10th level is collected in
the sump of 10th level from where it is pumped to sump
of 5th level and the from 1st to 5th level water is
collected in the sump of 5th level and From 5th level the
water is finally pumped to the surface.

In No.4# shaft pumping system there are two

sumps at level 8th and 5th.Water is collected at sump of
8th level from where it is pumped to sump of 5th level.
From 5th level water is finally pumped to the surface.
The Ph value of water is 1.3 and hence is acidic in
nature . Therefore high density polythene pipe is used.

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DEWATERING
Dewatering is done by hydraulic, pneumatic
and electrical centrifugal pumps.
First of all ,the water from stopes , seepage
and tailings are collected in the sumps and
finally pumped to the surface and the water
collected at the surface is again recycled for
diluting the tailings.

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BACKFILLING
Backfilling is done by 4 inch dia tailing pipes having capacity
of 1060tons/day at Surda Project. Ore passes have been
refurbished with rings, being redesigned for better
performance. The focus has primarily been on preparation
work in conjunction with improvements in water handling.

1. NS Bunker
2. N1 Bunker
3. N2 Bunker
4. Magazine Bunker
These pumps efficiently transfer high density slimes or
classified tailings from the processing plant to underground
mining stopes. Present backfilling capacity is 40000 ton per
month taking all constraints (water,pipe-jam). Crushed mill
tailings from concentration plant are used as backfilling
material.

It is believed and practiced that through better back-filling

the company can achieve potential benefits in terms of
reduced subsidence, improved support for mining excavation,
increased underground extraction, reduced tailings on the
surface and reduced rock burst leading to enhance worker
safety.

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VENTILATION FAN
2Nos. [Axial Flow, Exhaust type]

North Fan
South Fan

NORTH FAN:
Make - Eswaran & Sons Engineers Ltd., Madras

Exhaust type, Axial Flow

Rating 160Hp @ 750 r.p.m.

Operates at 440 V , 50Hz

Motor type Synchronous Induction motor,3 phase Motor

manufactured by English Electric Company Ltd London

Water gauge developed- 55 mm

Voltage between slipping and start - 871 V

Excitation -23 V, 176 A

Insulation Class A

Star Connection

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MINING MACHINERIES
MACHINES USED IN MINE WINDER
No. 3#
Manufactured by M.B. Wild B.Co., England

Depth of Wind-169m

HP Motor - 100HP , operates @ 440 V

Dia. Of Drum-2.57 m

Dia of Sheave Wheel -2.57m

Dia of rope 26mm

Rope type Flattened Stranded, Langslay

Double Clutch Double Drum

Factor of Safety with Man 14.1

Factor of Safety with Ore 10.34

No. of Man round per trip 15

Total suspended load with Men 2834 Kg

Total suspended load with Ore 3885 Kg

Maximum speed of wind with Men 2.5 m/s

Maximum speed of wind with Ore 3.5 m/s

Inclination 900 (Vertical)

Date of Installation - 1966

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#SUB INCLINE SHAFT
Operates @ 3.3KV

Hp motor - 175HP

Dia. Of Drum - 2.29m

Dia. Of Sheave Wheel - 2.28m

Dia of Rope - 22mm

Length of Rope - 900m(Ungalvanised Rope)

Double Clutch Double Drum

No. 4#
Manufactured by Kopex Poland

Date of Installation - 1974

Operates at - 6.6KV

Hp motor 0.536 Hp (400KW)

Dia. Of Drum - 3.00m

Dia. Of Sheave Wheel - 3.00m

Dia of Rope - 30mm

Single Clutch Double Drum

Factor of Safety with Man 14.1

Factor of Safety with Ore 11.3

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TRANSPORTATION
In Surda Mine, by the mean of transportation, the ore from the face
to the surface is hoisted systematically. After blasting, dressing and
roof bolting the ore is loaded by LHD/Cavo Loader and dumped into
the ore Pass, in the bottom of the ore pass it has a special type of
opening Ore Chute in the level, through which it is loaded on Loco (a
80V battery operated locomotive engine and attached to 8-10 tubs)
and transported to Ore Transfer called tramming and dumped which
is collected at Ore Bin which is loaded on the Tub/Skip and hoisted to
the surface. Finally transported to the concentration plant on
dumpers or trucks.

LOAD HAUL DUMPER (LHD)

Operates at 440 V
Capacity 1.1 ton
Hp motor 40 Hp
Hydraulically loaded
Electrically operated
Contains 100 m cable wire(Copper + Platinum)
Costs about 80 lakhs
2 holes are provided in the bucket for water leakage

CAVO
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 Operated by Air Compressor pump
Capacity 2.75 ton
It takes certain time for full load
It sounds noisy

LINE LOADER

Operated by motor
Bucket is attached by Chain
It collects from front through bucket and
stores at back tub
Moves on Rail
Electrically operated

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BLASTING
Blasting is the only mean for development and stoping
in Surda mine .For development i.e. sinking, drives,
cross cut, raise/winze and stoping at face is operated
by blasting. Burn cut is practiced here. For blasting
rimmer hole bit is drilled in the centre of drilling pattern
are of dia. 57 mm for providing free space and the
other holes is dia. 32 mm are drilled for inserting
explosive cartridges of dia.25 mm.

For blasting the exploder is used are of condenser

as well as generator type.
Electric detonator(ED) and non electric
detonator(NED)are used.
Detonating of cordtex are used which has burning
rate of 6500m/s ,250m length and core load is
10gm/s/m.
Fuse wires are of length 3m and with special
permission they can be of length of 5m.
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 Indirect/Direct method is used for blasting.
For stemming solid mixture of clay and sand are
used. The ratio of filling of cartridges and
stemming material is 3:1. Series/Parallel
connection may be used for blasting.
For blasting the blaster uses the master key of the
exploder to trigger the detonator and takes two
zig-zag turns (Z shape) before blasting.

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EXPLOSIVES
Explosive Name POWERGEL 801
Diameter 25 mm
Length 200 mm (each)
Weight = 125 gm
Cartridge 200 in a box
Gross Weight 200 125 gm = 25 Kg
Emulsion type explosive
Non permitted
High Explosives
Manufactured by Indian Explosives
Pvt. Ltd., Gomia Works, Bokaro

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 SURVEYING
In earlier times, surveying was used to be done by conventional
method

Traversed using optical theodolite, chain and back station. Level

plans and cross section were drawn at various scales.

But now a days, Leica TCRA 1200 series(Leica TCRA 1205). Total
station wall stationmethods are being used for underground survey
traversing. Surpac Mine planning software is being used extensively.
Surveying methods and standards as accepted in the metalliferous
mining industry.

In underground station are fixed on the Hangwall, Footwall or on the

Pillar which are not extracted for mining hence not altered for further
resection and on the surface the traverse station are chosen which
are not be permanently staying here.

After that the data fitted in the memory card are pulled out and
synchronized with the national grid with surpac. This provides very
easily 2D and 3D view of the mine including plan, vertical section and
oblique view which makes it very handy for planning and designing of
the mine. It makes it simple to understand the stope and block under
production.

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