Document Prepared By Mohammad Khalid Qamar, Sajan Thomas,Kandan Munia Pillai

Document Reviewed By Rajesh Nampoothiri

Document Approved By Adriaan Van Der Merwe

Shift Report-Concentrate Receiving

Date Shift (D/N)/Time
Supplier Name
Invoice No
Gross Weight (WMT)of Consignment
Moisture Content
Net Weight of Consignment
Vehicle No.
No. of Bags received
S.No. Bag No. Gross Weight ( ton ) Net Weight ( ton )
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
 Operator's Name & Signature

Operator's Comment

Sample Sent to Lab (Yes/No) & Time

Sample ID
 Shift Report- Concentrate Charging
Shift D/N Date
Shift Supervisor Name
Operator Name/ID
Parameters UOM
No. of Bags available (opening stock) No.
Total No. of bags Charged No.
Weight of charged bags ton
Running hours,Hopper #1 hr
Running hours,Hopper #2 hr
Total No. of bags received No.
Weight of Received Bags (WMT) ton
No. of bags remaining ( closing stock) No.
Time
Parameters 7:30 9:30 11:30 13:30 15:30 17:30
Pulsing Air Pressure, 1210 PG002, 009 bar
Pressure drop across Hopper 1 bag filters bar
Pressure drop across Hopper 2 bag filters bar

Details of safety incidents ( if any)

Major Breakdown (if any)

Details of Ongoing Maintenance Activities

Remarks

Operator's Sign SS Sign

 Shift Report- Concentrate Drying
Shift D/N Date
Shift Supervisor Name
Operator Name/ID
Time
Parameters UOM 7:30 9:30 11:30 13:30 15:30 17:30
LPG pressure & flowrate bar/kgph
Nitrogen presure & flowrate bar/kgph
Temp Zone-1 °C
Temp Zone-2 °C
Temp Zone-3 °C
Temp Zone-4 °C
Dryer speed RPM
Dryer outlet temperature °C
Diff Pressure across Bag House Filter kPa
Bag House fan discharge outlet temperature °C

Details of safety incidents ( if any)

Major Breakdown (if any)

Details of Ongoing Maintenance Activities

Remarks

Operator's Sign SS Sign

 Shift Report- HTF & Calcine Cooling
Shift D/N Date
Shift Supervisor Name
Operator Name/ID
Time
Parameters UOM 7:30 9:30 11:30 13:30 15:30 17:30
Burner LPG pressure & flowrate bar/kgph
Furnace Inlet temperature °C
Furnace inlet pressure bar
HTF speed RPM
Feed rate to HTF t/hr
Furnace outlet calcine temperature °C
Calcine Cooler outlet temperature °C
CW return pump pressure/temp bar/C
Bag House inlet temp °C
Diff Pressure across Bag House Filter kPa
Bag House outlet temperature °C
HTF Feed Bin levels:1,2,3 %

Details of safety incidents ( if any)

Major Breakdown (if any)

Details of Ongoing Maintenance Activities

Remarks
Operator's Sign SS Sign
 Shift Report- Dry Gas Treatment
Shift D/N Date
Shift Supervisor Name
Operator Name/ID
Stream In Line: Time
Parameters UOM 7:30 9:30 11:30 13:30 15:30 17:30
HTF Dust Cyclone Inlet Pr/Temp bar/C
HTF Dust Cyclone Outlet Pr/Temp bar/C
High Temp FDC fan discharge pressure bar
Gas temp after primary FDC °C
Secondary Cyclone Inlet Pr/Temp bar/C
Secondary Cyclone Outlet Pr/Temp bar/C
Low Temp FDC fan discharge pressure bar
Gas temp after secondary FDC °C
RF bag filter pressure drop kPa
Gas temperature after RF bag Filter °C
ID fan Load 1/2/3 amp

Details of safety incidents ( if any)

Major Breakdown (if any)

Details of Ongoing Maintenance Activities

Remarks

Operator's Sign SS Sign

 Shift Report- WGT & Gypsum Plant
Shift D/N Date
Shift Supervisor Name
Operator Name/ID
Time
Parameters UOM 7:30 9:30 11:30 13:30
Gas temperature at Quench inlet °C
Gas pressure at quench inlet kPa
dP across the Venturi throat kPa
Conductivity of acidic liquor in quench µS/cm
Gas temperature at Quench outlet °C
Quench H/E inlet temp: °C
Quench H/E outlet temp: °C
V-Tex Section
Inlet gas temp °C
Inlet gas pressure kPa
SO2 concentration in V-tex scrubber inlet ppm
SO2 concentration in V-tex scrubber outlet ppm
Outlet gas temperature °C
pH of V-tex liquor
Density of V-tex liquor kg/m3
V-tex H/E inlet temperature °C
V-tex H/E outlet temperature °C
Limestone slurry density(Tank) kg/m3
Slurry Preparation Tank level %
Scrubber & Carbon Filter
Inlet SO2 Conc: ppm
Outlet SO2 Conc: ppm
Inlet gas temp °C
Outlet gas temperature °C
Caustic Scrubber sump level m
dP across the packed tower kPa
pH of caustic solution in caustic scrubber
Conductivity of caustic liquor µS/cm
H/E Inlet temperature of caustic liquor °C
H/E outlet temperature of caustic liquor °C
Temperature of gas at heater inlet °C
dP across the carbon filter kPa
dP across the Fan kPa
Gypsum Plant
Belt filter flowrate m3/hr
Hydrocyclone Feed tank pressure kPa
Belt Filter Vacuum pump suction pressure kPa
Steam pressure kPa

Details of safety incidents ( if any)

 Details of safety incidents ( if any)

Major Breakdown (if any)

Details of Ongoing Maintenance Activities

Remarks

Operator's Sign SS Sign

15:30 17:30
 Shift Report- Control Room Operation
Shift D/N Date
Shift Supervisor Name
Operator Name/ID
Time
Parameters UOM 7:30 9:30 11:30
Concentrate Yard
Concentrate Receiving Hopper in Line (1/2)
Concentrate Identification
Dryer & HTF Feed Bin
LPG pressure & Flowrate bar-kg/hr
Dryer Rotation speed RPM
Dryer outlet Temperature °C
Nitrogen pressure available for schenck system bar/C
Feed Bin levels (1/2/3) %
Feed recipe ratio (1:2:3) %
HTF & Calcine Cooling
LPG pressure available pressure for HTF bar/C
HTF Rotation speed RPM
HTF inlet temperature/pressure C/bar
HTF Feed Rate Ton/hr
Oxygen content in HTF outlet gas %
HTF outlet gas temperature °C
Calcine cooler outlet temperature °C
Dry Gas Treatment
Pressure Drop across HTF Dust Cylone bar
Primary FDC discharge pressure & Load bar/amp
Pressure drop across Primary FDC bar
Inlet gas temperature to Primary FDC °C
Gas Temperature after primary FDC °C
Pressure Drop across Secondary Cylone bar
Inlet gas temperature to Secondary FDC °C
Gas Temperature after Secondary FDC °C
Pressure drop across Secondary FDC °C
Activated Carbon addition rate kg/hr
Pressure drop across RF bag filter bar
Gas temperature after RF bag filter °C
ID fans in service (1/2/3)
ID fan suction pressure bar
ID fan discharge pressure/load bar/amp
Wet Gas Treatment
Gas temperature at Quench inlet °C
Gas pressure at quench inlet Pa
dP across the Venturi throat kPa
Conductivity of acidic liquor in quench µS/cm
Gas temperature at V-tex inlet °C
Inlet Gas flow(V-tex scrubber inlet) kg/hr
SO2 concentration in V-tex scrubber inlet mg/Nm3
SO2 concentration in V-tex scrubber outlet mg/Nm3
pH of V-tex liquor
Density of V-tex liquor kg/m3
Limestone Slurry Preparation Tank level m
pH of solution in caustic scrubber
Conductivity of caustic liquor µS/cm
Temperature of gas at heater inlet °C
Belt filter flowrate m3/hr
Hydrocyclone Feed tank pressure kPa
Belt Filter Vacuum pump suction pressure kPa
Steam pressure bar
ETP
Acid quench tank Buffer level m
Lime precipitator tank buffer level m
Sb/As feed buffer tank level m
Stage 2 Product Water tank Level m
Treated Water Buffer Tank Level m
RO Feed Flowrate m3/hr
Cooling water pressure bar
Cooling water conductivity µS/cm

Details of safety incidents ( if any)

Major Breakdown (if any)

Details of Ongoing Maintenance Activities

Remarks

Operator's Sign SS Sign

Time
13:30 15:30 17:30
 SHIFT REPORT-ROASTING PLANT,SPMP
SHIFT D/N DATE
SUPERVISOR NAME S.No. OPERATORS
Dryer Running hours 1
HTF Running Hours 2
Gypsum Dispatch 3
Average SO2 Discharge (ppm) 4
Average sulphur in calcine (%) 5
Caustic Receipt (Ton) 6
Lime Receipt (Ton) 7
S.No. EHS
1
2
S.No OPERATIONAL ACTIVITIES
1
2
3
S.No MAINTENANCE ACTIVITIES
1
2
3
S.No GENERAL
1
2
3
No's bag charged No's bag received Total No's bag in
Bulk bag unloader I/S HTF Feed bin's level %
( No./T) (No./Ton) stock
1 2 1 2 3

Calcine Bin level % IATO Bin level % CATO Bin level % Lime stone Bin level % Caustic Tank level %
 MONTHLY REPORT
S.No. Material Material Code UOM
1 Concentrate Yard availability hr
2 Dryer Availability hr
3 HTF Feed System Availability hr
4 HTF Availability hr
5 Dry Gas Treatment Plant Availabilty hr
6 Wet Gas Treatment & Gypsum Plant Availability hr
7 ETP Availability hr
8 Concentrate Receipt MT
9 Concentrate Consumption MT
10 Concentrate Closing Stock MT
11 Activated Carbon Receipt MT
12 Activated Carbon Consumption MT
13 Activatec carbon closing stock MT
14 Limestone Receipt MT
15 Limestone Consumption MT
16 Limestone Closing Stock MT
17 Caustic Lye Receipt MT
18 Caustic Lye consumption MT
19 Caustic Lye Closing Stock MT
20 Sulphuric Acid Receipt MT/Lit
21 Sulphuric Acid Consumption MT/Lit
22 Sulphuric Acid Closing Stock MT/Lit
23 LPG consumption in Dryer kg
24 LPG consumption in HTF kg
25 Process Water Consumption in Lime slurry Preparation m3
26 Process Water Consumption in Calcine Cooler m3
27 CATO Production MT
28 CATO consumption in Smelting MT
29 CATO Closing Stock MT
30 IATO Production MT
31 IATO consumption in Smelting MT
32 IATO Closing Stock MT
33 Gypsum Production MT
34 Gypsum Sale MT
35 Gypsum Closing Stock MT
 EFFLUENT TREATMENT PLANT
Shift D/N Date
Shift Supervisor
Operator
Name/ID
Operator's Sign SS Sign
PARAMETERS Instrument Tag Id UOM 7:30
Flocculant pH 3420-AE002 NA
PRECIP PRECIPIT
ITATOR ATOR
LIME

Lime precipitator pH 3420-AE001 NA

Acid quench Buffer level 3420-LIT001 m
Lime precipitator buffer level 3420-LIT002 m
Sb/As pH stage 1 3410-AE001 NA
Sb/As

Sb/As pH stage 2 3410-AE002 NA

Sb/As feed buffer level 3410-LIT001 m
Stage 1 Product pH 3430-AE001 NA
Sulphuric Acid Make-up EC 3430-AE002 µS/cm
Stage 1 Desorption Column EC 3430-AE003 µS/cm
DESALX SECTION

Stage 2 Product EC 3430-AE004 µS/cm

Stage 2 Product pH 3430-AE005 NA
Lime Make-up pH 3430-AE006 NA
Stage 2 Desorption Column pH 3430-AE007 NA
DeSAlx Feed Tank Stage 1 Level 3430-LIT001 m
Adsorption Column Resin Level-Stage 3430-LIT002 m
1
Stage 1 Product Water Level 3430-LIT003 m
Stage 1 Makeup Tank Level 3430-LIT004 m
Adsorption Column Resin Level-Stage
3430-LIT009 m
2
Stage 2 Makeup Tank Level 3430-LIT011 m
Stage 2 Product Water Level 3430-LIT012 m
Air Supply Pressure 3430-PIT005 m
Inlet water Conductivity 3440-AE001 m
REVERSE OSMOSIS

Inlet water Temperature 3440-TIT001 m

Feed Buffer Tank Level 3440-LIT001 m
Product Water Conductivity 3440-AE003 m
SYSTEM

Product Water pH 3440-AE002 m

Treated Water Buffer Tank Level 3440-LIT007 m

RO Feed Pressure 3440-PIT010 bar

RO Brine Pressure 3440-PIT011 bar

RO Feed Flowrate 3440-FIT001 m3/hr

µS/cm
Cooling water conductivity AIT001
COOLING
TOWERS

Cooling water pressure PIT-012 kPa

COOLING
TOWERS
Cooling water incoming water temp TIT-008 °C

Cooling water outgoing water temp TIT-001 °C

REAGENTS SHIFT-
Reagent Consumed

Hydrated lime (LP)

Flocculent consumed(LP)

Flocculent consumed(Sb/As)

Ferric chloride

Hydrochloric Acid

DURATION
STOPPAGES

SECTION
FROM TO
REMARKS

MAINTENANCE /OPERATIONAL/SAFETY I
ENT PLANT

9:30 11:30 13:30 15:30 17:30

 REAGENTS SHIFT-

Sulphuric Acid (DeSalx)

Hydrated lime (DeSalx)

Sulphuric Acid(98%)(RO)

Sodium Meta Bisulphite

Antiscalant

TIONAL/SAFETY ISSUES