Kahatagaha Graphite Lanka Limited
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This report contains details of the Industrial Training which I have gone through for 8 weeks out of 12 weeks at Kahatagaha Graphite Lanka Limited in completely with the BSc. Mineral Resources and Technology (Special) Degree program conducted by the Uva Wellassa University.
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Kahatagaha Graphite Lanka Limited
- 1. Industrial Training Presentation Chanaka Wickramasinghe UWU/MRT/11/0018 UWU/EX/11/0386
- 2. Industrial Training Details Training Organization: Kahatagaha Graphite Lanka Limited Mine and Processing Plant, Maduragoda, Kurunagala. Training Individual : E.M.C.G. Wickramasinghe UWU/MRT/11/0018 Supervisor : Eng. K. Warusawithana, Mines Manager, Kahatagaha Graphite Lanka Limited, Maduragoda, Sri Lanka.
- 4. Organization Details (continue) Kahatagaha Graphite Lanka Limited holds best vein graphite deposit in the world
- 5. Chairman Manager Assistant Manager Mining Department Processing Department Plant Engineering Department Organization Details (continue) Vision To be the most leading supplier of the natural crystalline vein graphite to the world. Mission To earn foreign exchange to the country and fulfill the social obligation providing job opportunity to the society with optimum utilization of graphite mineral resource of the country.
- 6. Training Programme The main processes of an active mine, • Cross Cutting • Driving • Winzing • Stoping and Vertical Slicing • Shaft Sinking 1. Profiling 2. Drilling 3. Charging 4. Blasting 5. Washing & scaling 6. Mucking 7. Supporting
- 7. Training Programme (continue) The main processes of an active mine, • Cross Cutting • Driving • Winzing • Stoping and Vertical Slicing • Shaft Sinking Preparation for blast Drilling Charging Blasting Washing & scaling Mucking Supporting
- 8. Training Programme (continue) • DIAMOND DRILL MACHINE Advantages of Diamond Drilling Fast Highly cost-effective Very safe Low work force required • UNDERGROUND MINE SURVEYING
- 9. Training Programme (continue) • MACHINE ROOM AND MACHANICAL UNIT • MINE VENTILATION exhaust (pull) system blowing (push) system combined system (push-pull)
- 10. Training Programme (continue) • GRAPHITE PROCESSING DEPARTMENT Mineral Processing Section • Material Handling • Sorting • Particle Size Reduction • Sewing • Packaging Laboratory • R & D • Quality assurance & control
- 11. Training Programme (continue) • GRAPHITE PROCESSING DEPARTMENT• The use of graphite in Sri Lanka has a long history, from 1675. • Sri Lankan graphite is very popular all over the world for its high purity. • • There are two major mines for graphite, KahatagahaKolongaha and Bogala. • The largest mine is Kahatagaha-Kolongaha close to Matale- Kurunegala road. This is deeper than 650 m. Slab Yard Ore Chute and Stock Cylinder Curing Yard (Manual Sorting) MATERIAL FLOW CHART OF THE KGLL PROCESSING SECTION 12
- 13. Training Programme (continue) • PLANT ENGINEERING DIVISION Main Power Lines from Kurunagala &Mathale 33000V Step Down into 415V using 03 Transformers Kahatagaha 02 Transformers (parallel) Compressors Underground Servises Main Winch Kolongaha 01 Transformer Kolongaha Water Pumps Processing Plant
- 14. • PROJECTS AT KAHATAGAHA Experience Gained 1. Draw AutoCAD 3D & 2D model of Kahatagaha Mine using survey data 2. Dewatering electronic automation project – Case study 3. Processing Plant Dispatch data digitalizing project (Year 2008 to 2015) 4. Safety Sign Designing Project 5. Emergency evacuation path design project 6. Electricity consumption kVA valve of KGLL - Case Study (Saving 1.5 Lk/month)
- 16. 17
Notes de l'éditeur
- Good Morning, I’m Chanaka Wickramasinghe and this is my final year Industrial Training Presentation about the training I gained at “Kahatagaha Graphite Lanka Limited, Mine and Processing Plant, Maduragoda” My IT supervisor was Eng. K. Warusawithana, Mines Manager, Kahatagaha Graphite Lanka Limited, Maduragoda, Sri Lanka. This Presentation prepared to summarize my training experiences at Kahatagaha Graphite Lanka LTD during the 16-week training program. The training program offered ample experiences and knowledge in the overall Mining / Mineral Processing activities and the industry in Sri Lanka.
- The word 'Graphite' derived from the Greek word 'Graphit' which conveys the meaning 'to write'. Graphite is one of the two naturally occurring crystalline materials of Carbon with the other being Diamond. Out of all the graphite producing countries, Sri Lanka is highly renoved as the home to the world's best quality graphite. Kahatagaha Mines are located in North Western Province of Sri Lanka at Maduragoda, Dodangaslanda in the Kurunegala District, approximately 90 km. from the Colombo, and managed by Kahatagaha Graphite Lanka Limited. (KGLL) It is a fully government owned public limited liability Company, supervised under the Ministry of Industry and Commerce and the share holder being Secretary to the General Treasury.
- Kahatagaha Mine is 2000 feet (610 meters) deep which makes it is the deepest mine in Sri Lanka and accessed by 3 shafts. The one at Kahatagaha is 1132 feet (345 meters) and Kolongaha goes up to 330 feet (101 meters). The below shaft bottom access is by a series of winches up to 2000 feet (610 meters) Kahatagaha Mines shows a vein type Graphite distribution. There are approximately 100 veins at Kahatagaha. But only about 32 are feasible enough to extraction. Earlier Kahatagaha and Kolongaha mines were working as two mines and operated since 1872. Presently these two mines are merged together and work as a single mine.
- Kahatagaha Graphite Lanka LTD is an organization, which has build up by 03 major departments such as underground department processing department plant engineering department
- My training period was started on 11th of May 2015 & it was ended on 11th of September 2015. I had gathered a good knowledge about mine development, services as well as processing by practices, & it was a grate opportunity to connect my theoretical knowledge to practices, The main processes of an active mine would be, Cross Cutting Driving Winzing Stoping and Vertical Slicing Shaft Sinking Cross Cutting Cross Cutting took place on the 1132ft, 1655ft levels. Cross Cut is the base of all mining activities, without this Stoping, Winzing, Driving are impossible. The cross cut is belongs to mine development work which links the shaft with the ore body or two drives. Working cycle of cross cutting 1. Profiling 2. Drilling 3. Charging 4. Blasting 5. Washing & scaling 6. Mucking 7. Supporting DRIVING Drives are excavated along a graphite vein. When the vein gets thin or ends a winze or a stope is started from a suitable place. WINZING Winzes are vertical or inclined underground opening that is driven through the graphite vein from top level to bottom level.
- STOPING Mining Method – Open Stoping Stoping is process of ore extraction and is directly correlated with the mine’s production. Stoping take place in drives SHAFT SINKING Shaft sinking consists of six major activities. Preparation for blast Drilling Charging Blasting Washing & scaling Mucking Supporting These activities are much more similar to activities carried out in winzing.
- UNDERGROUND MINE SURVEYING Surveying plays an integral part in Mining. Since Kahatagaha Graphite hasn’t any surveying team within company, I’m fortunate to work with Bogala G/ surveying team in underground mapping project by total station. The team was responsible for develop the total K/K mine map. Diamond drilling Diamond drilling became more advantages among all the other Graphite exploration technique due to Diamond drilling is Fast Highly cost-effective Very safe Low work force required
- MACHINE ROOM AND MACHANICAL UNIT In Kahatagaha mine, rock drill machines, hydraulic air legs inside the mine are addressed by the machine room. Maintaining machines, amputations, replacements etc. are taken care by this functional area. MINE VENTILATION With respect to fan locations and airflow direction, there are primarily three ventilation systems: exhaust (pull) system, where the mine fan is located on top of the return airshaft; blowing (push) system, with the mine fan installed at the intake airshaft; combined system (push-pull), with fans on both the intake and return airshafts. Out of these three systems Kahatagaha used exhaust (pull) system.
- Underground transportation is done using mine trolleys. Trolleys are driven on track rails from working place to the shaft in every crosscuts and drives.
- GRAPHITE PROCESSING DEPARTMENT Mineral Processing Section Material Handling Sorting Particle Size Reduction Sleaving Milling Packaging 2. Laboratory R & D Quality assurance & control
- PROCESSING PLANT After the extraction of the raw graphite from underground, it has to be processed with accordance to the needs of the customer. There are 7functional areas within the processing plant. 1. Grizzly Screen, Ore Chute and Stock Cylinder 2. Trommel and the Curing area. 3. Crushing and a Screening plant 4. Raymond Mill and Cyclone 5. Mixing Machine 6. Flake Production Machine Packing Plant GRIZZLY SCREEN, ORE CHUTE AND STOCK CYLINDER The run of mine (ROM) is first brought up to the grizzly screen. It is the primary impact screen of plant TROMMEL AND THE CURING AREA Tommel Screen 01 – TD/No1KL/No2KL Tommel Screen 02 – No3 TD / No 2 TD / No 1 TD Manual sorting
- CRUSHING AND A SCREENING PLANT Conveyor belt make the path to materials to crushers. While materials passing through bucket elevator undergoing magnetic separation process. After the mills materials are separated by passing them through set of screens. The sizes of the screens are controlled according to the particle size of the final product needed. RAYMOND MILL BR mill consists of the following sections Feeding unit Double cone separating unit with trapezoidal Ramond mill Pressure gradient controlling unit Cyclone separator (dust remover) Output controlling valve LABORATORY It is in the laboratory that all the parameters testing carried out regarding to the quality of the products in the Kahatagaha Graphite Lanka Ltd. Main parameters tested in the laboratory are, Particle size Carbon percentage Tap and bulk density Moisture content Volatile material content (Ash test) Specific surface area (SSA)
- Plant Engineering Plant Engineering division takes care of the all major maintenance aspects of the complete mine area. It covers both underground and surface. Kahatagaha is used to develop its own machinery parts to avoid unnecessary spending of money. There are two different areas in operation in the plant. Electrical Section Mechanical Section 1. Electrical Section Following figure will show the electricity distribution of Kahatagaha from main power lines. Generators The engine is the most important part of the generator. Other integral parts are as follows, Alternator Fuel system Voltage regulator Cooling and exhaust system Lubrication system Battery charger kVA meters and Power Bank for Efficiantcy Compressors There are four Piston type functioning compressors at Kahatagaha Mines to date. These are used to provide compressed air to the underground activities. 2. MECHANICAL SECTION Mechanical section is the main contributor for all maintenance related work. Lathe and the Welding plant are the main assets of the section. Lathe Cutting Sanding Knurling Drilling Facing Turning Tapering Threading
- PROJECTS AT KAHATAGAHA A four month training underground, Processing Plant and Plant Engineering I did following projects, Draw AutoCAD 3D model of Kahatagaha Mine using 2D survey data Dewatering electronic automation project – Case study Processing Plant Dispatch data digitalizing project (Year 2008 to 2015) Safety Sign Designing Project Emergency evacuation path design project Electricity consumption kVA valve of KGLL - Case Study – Reduce Company Electricity bill 1.5 lacks per onth (Tot bill 1.25 mil)
- The training period at Kahatagaha Graphite Lanka LTD was truly an awesome and unforgettable experience in my life. In the beginning it was a struggle to adapt but eventually things worked out just fine. After the completion of the training period I felt stronger than ever. During the training period I had to be stationed there. The accommodation was more than satisfactory. In a nut shell the whole training was about Mining, Processing, Quality Controlling, Servicing and Maintaining. The placements were in such a way that the main exposure was into the Mining section. Most of the stuff learnt at Kahatagaha was practical based. Kahatagaha has proved to me that it stands as the kindergarten of all mining professionals. The training program was wonderfully coordinated. The training period made me understand my capabilities and direction I should be heading. I am not the person I used to be. I am much stronger and mentally challenged. Working with people and facing challenges molded me well and made me realize the task before me. People were absolutely wonderful. Truly, I will cherish the wonderful memories of learning and friendship I shared with all at Kahatagaha.