Attock Cement Pvt. Ltd Internship report. VISION: To be the leading organization continuously providing high quality cement, excelling in every aspect of its business and to remain market leader in cement industry.

1. Internship Report
Title: Internship Report of Quarry Operation in ACPL, Hub
Submitted To:
 ISO & Training Center
 Buitems, Quetta
Submitted By:
 Ghulam Mehdi CMS ID: 23101
(mehdishaheen005@gmail.com)
 Syed Ali Muhammad Shah CMS ID: 21465
 Azam Azeem CMS ID: 20996
Affiliation: Department of Mining
Program: BS Mining Engineering (6th Semester)
University: Balochistan University of Information Technology, Engineering & Management
Sciences, Quetta (Buitems)
Address: Takatu Campus, Airport Road, Baleli, Quetta
Date: 04-04-2015

2. Contents
 Introduction
 Location
 Geology of ACPL Area
 Sections
(i) Limestone Quarry
(ii) Shale/Overburden Quarry
 Mining Method (Drilling, Blasting & Ripping)
 Usage of Explosives
 Equipment Used
 Production & Capacity
 Conclusion

3. Introduction
ACPL is a member of Pharon Group of Companies Operating in Pakistan. It’s started production
in 1986. The project is Pak Saudi venture. ACPL’s Manufacturing plant is located in Tehsil Hub,
District Lasbella, Balochistan, at a distance of about 45km north west of Karachi. It covers total
area of about 17500acres. The Plant area is about 75 acres. It was the first plant in the country
to be based on the latest suspension, pre-heater/pre-calcination. The Total Capacity of plant is
around 5700 tpd to 6000 tpd and 1,710,000 MT of clinker per annum. The cement
manufactured and being marketed under the “Falcon” brand name is of the highest standard
and truly the market leader. There are two types of cement mostly prepared in ACPL “Ordinary
Port Land Cement” & “Sulphate Resistant Cement”. The Export Zones of ACPL’s cement are
Srilanka, UAE , India , Southafrica etc and also sold in local country market .
Location
It is located in Sakaran, Tehsil Hub, District Lasbella, Province Balochistan, Pakistan. It is situated
at 35 km far from Karachi.
Geology of ACPL Area
The geology of ACPL consists of merely two Geologic structures
 Folded zone
 Faulted zone
Folds are wavy undulations of rock beds. It is formed due to the compressional, tensional and
tectonic forces acting regionally while faults are the fractures along which the blocks of rocks
have been displaced relative to each other. The limestone quarry is majorly faulted zone. These
faulted zones are composed of deposition of limestone layers. They are developed due to
sedimentation. Sedimentation is the process in which the accumulation of sediments occurred.
There are three main factors involved. These are;
 Temperature
 Pressure
 Time
The limestone quarry section has composed of faulted and folded region. While shale/
overburden quarry section has composed of physical weathering and the fragmentation of
shale is transported by wind and water. As a result conglomerates are formed in overburden
quarry. The layers are formed by graded bedding. In graded Bedding the coarser particles tend
to settle down more quickly in comparison to finer ones. The rate of graded bedding may also
depend upon the density of particles. The particles with greater density settle down more
quickly while the less dense particles remain in suspension in longer period of time.
Sections
In ACPL Hub plant there are two main sections of quarry. These are;
 Limestone Quarry
 Overburden Quarry
Limestone Quarry
There are two leases for limestone quarry.
a) Lease area (ML3) = 2802.94 acre
b) Lease area (ML4) = 1861.07 acre

4. TOTAL AREA = 4664.01 ACRE
There are four areas in which ACPL quarry is divided. Areas A, B, & C a number of benches are
developed which is under use & Area D called Chiroli Platform is under construction.
A = Consumed all Benches
B = 04 Benches
C = 11 Benches
Total Number of Benches = 15
A-area has total reserve of 2.6M/ton which are completely consumed, so Nowadays from A-
area has no production and it has at altitude of 210m from sea level. The B-area has reserve of
28.26M/ton and 1 M/ton is consumed. It is under process and it has at altitude of 410m from
sea level and C-area has reserve of 48.2M/ton and is producing the limestone in these days. The
Chiroli has reserve of 45M/ton and has altitude of 509m and it is future program. The limestone
content of ACPL Quarry is 92%-96%.In the C-area there are 15 benches out of which 3 benches
has consumed. The height of bench is 15m. The maximum height of C-area is approx: 370m
above sea level.
Overburden Quarry
There are two leases for Overburden quarry.
Lease 1 (ML2) = 11410.02 Acre
Lease 2 = 13325.01 Acre
Total = 16 Million Tons
Consumed = 12 Million Tons
Remaining = 04 Million Tons
Mining Method (Drilling, Blasting & Ripping)
There are two mining methods applying in ACPL limestone quarry and overburden quarry.
 Quarrying Method
 Ripping Method
Quarrying Method
Quarrying method is used in limestone quarry operation. Almost all equipment is used in this
method. Drilling and blasting is the way to mine the rock. In blasting explosive materials are
used, these material are charged in holes through drilling.
In ACPL two types of explosives are used
High Explosives like Gelatin Type and Nitro Glycerin,
Low Explosives like Ammonium Nitrate + Diesel Oil, and other accessories are used like
Detonator, Detonating Card and Safety Fuse.
Quarrying of limestone is accomplished by using explosives to blast the rocks. In blasting
techniques, we make holes through drilling. The hole height is approx. 15m-16m & the
diameter of hole is 105mm. The hole contains three portions, Bottom, Column & the stemming
portion. In Bottom portion, we use 14% -17% high explosives and height of bottom portion is
2m. The height of column portion is 13m and we use 84% - 87% Ammonium Nitrate Fuel Oil
(ANFO) & in stemming portion we used drill hole cuttings for stemming. If we make more than
one holes for blast, the vertical distance between holes is called burden & horizontal distance
between holes is called spacing & the distance between holes of spacing & burden will be
3.5*4m.

5. After blasting, if the rocks are still in huge size then we use secondary blast or using via
hydraulic breaker for further size reduce.
Usage of Explosive
The most important characteristics of an explosive are:
 Velocity of detonation (VOD)
 Strength
 Detonation stability
 Sensitiveness (Propagation ability)
 Density
 Water resistance
 Sensitivity
 Safety in handling
 Environmental properties
 Resistance to freezing
 Oxygen balance
All these properties are considered closely in ACPL Quarry Operation, Hub.
The explosives used in ACPL Quarry Operation can be classified in to:
 High Explosives
 Low explosives
 Blasting Agents
High explosives:
High Explosives have the susceptibility of initiating to Number 8 detonator and reacts
supersonically. In ACPL Quarry operation these high explosives are used;
Dynamite, Detonator and Milli-second detonator have 25 MS- delay, detonating cord/waboh
cord.
Low Explosives:
Low explosives have the capability of deflagration and reacts sub-sonically. These low
explosives are used in Hub Plant;
Safety Fuse
Blasting Agents:
Blasting Agents are mixtures consisting of a fuel and oxidizer. Blasting agents have to be
initiated by a primer. ANFO is used in this operation.
Equipment Used
Following equipment is used in ACPL Hub plant by department of mining in Quarry operations;
 Crawler Drill Machine
 Air compressor (6-21 Bars Air Pressure)
 Dumper
 Bulldozer D-8K
 Wheal Loader excavator
 Tractor
 Jack Hammer
 Hydraulic Drill Machine
 Pneumatic Drill Machine

6.  Down the Hole (DTH)
Production & Capacity
The Total Production of the Company is around 5700 metric tons which is achieved through two
Production Lines. Some of the specifications regarding the two lines are given below:
Line - I
 Production: 2400 metric tons
 Origin: Romania
 Crusher Type: Hammer Mill with a capacity of 600 tons/h
 Grinding Mill: Tube mill with a capacity of 170 tons/h
 Cooler type: motor driven grate cooler with capacity of 2000 tons per day.
Line - II
 Production: 3300 metric tons
 Origin: China
 Crusher Type: Hammer Mill with a capacity of 800 tons/h
 Grinding Mill: Vertical Roller Mill with a capacity of 260 tons/h
 Cooler type: Hydraulic Grate cooler with a capacity of 3300 tons/h.
Conclusion
The particular Internship in Quarry Operations Department under the supervision of Senior
Mining Engineers of ACPL helped us to conduct a conceptual practical study towards theoretical
study. We saw different standard machinery according to the need of modern Mining that has
not only saved sufficient time but also labor costs. We learnt about the usage of latest Drilling
technology Including Hydraulic, pneumatic, and Jack hammers.
The Quarry operations lead us towards positive aspects of blasting the horizontal rock shelf
called Benches. ISO and training provided information to standards. Safety precautions and
explosive handling was the main criteria completed.
A brief idea towards the cement plant layout, design, project evaluation was given to us
by TSD (Technical Support and development). They also briefly guided us towards the cement
preparation cycle from quarry to packing.
Drilling, blasting, blast lay out, pattern design, spacing and burden determination,
Primary and Secondary blasting, boulders reduction, base charge, detonating cord
Connecting wires, column charge, stemming and stemming percentage, Aluminum stemming
rods, and other important Mining operations were sophisticatedly seen and understood
through practical means…!!!