NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

“Think in other Terms”

NAME AYIBONGWE SIZIBA

STUDENT NUMBER N0165570P

COMPANY HWANGE COLLIERY COMPANY LIMITED

INSTITUTION NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

FACULTY INDUSTRIAL TECHNOLOGY

DEPARTMENT CHEMICAL ENGINEERING

TITLE ATTACHMENT REPORT

ACADEMIC SUPERVISOR DR J. TSHUMA

INDUSTRIAL SUPERVISORS MR. M NYANHONGO

MR. T MASUNDA

DURATION JAN 2020 – SEPT 2020

1
ACKNOWLEDGEMENT
I would like to acknowledge the Hwange Colliery Company Limited for giving me the
opportunity to be part of their institution. This enabled me to acquire new engineering skills as
well as apply all the theoretical knowledge that I had amassed at school on the field. The
foremen as well as the plant operators across all the sections I went to were very welcoming as
well as open to answer any question that I had thus quelling all curiosity. Special mention to my
supervisors who were a pillar of strength and offered me valuable advice as well as making me
feel at home in a new geographical location. This made me acclimatize to my surroundings
easily and get to the nitty gritties as early as possible. Above all I would like to thank my family
for their prayers that preserved and nurtured me. All this would not have been possible without
the Almighty. To God be the Glory!

2
ABSTRACT
The report covers the work done by the student (author) from 20 January 2020 to 11 September
2020 on industrial attachment done at Hwange Colliery Company Limited. The company has an
extensive training program that exposes the learner to a wide variety of information and skills
about the mining industry. The aim of this report is to highlight the operations of the company in
brief as well as give a brief account of the work (project) done by the author. All the major
processes that are currently in operation have been covered. The reports also include problems
faced by the company in some processes and suggest possible solutions to counter the problems.

3
4
Table of Contents
1.0 INTRODUCTION TO HWANGE COLLIERY COMPANY LIMITED (HCCL)..........................9
1.1 HISTORY OF HWANGE COLLIERY COMPANY LIMITED...........................................................9
1.2 SAFETY................................................................................................................................................9
1.3 HEALTH.............................................................................................................................................10
1.4 ISO CERTIFICATION........................................................................................................................10
1.5 VISION...............................................................................................................................................11
1.6 MISSION STATEMENT....................................................................................................................11
1.7 STRATEGIC INTENT........................................................................................................................11
1.8 CORPORATE DIRECTIONAL STRATEGY..............................................................................12
1.9 CORE VALUE STATEMENT............................................................................................................12
2.0 EQUIPMENT AND MACHINERY USED AT HCCL.................................................................14
2.1 Transportation................................................................................................................................14
2.2 Crushers...............................................................................................................................................14
2.3 Screens................................................................................................................................................18
2.4 Electromagnet......................................................................................................................................19
2.5 Centrifugal Pumps...............................................................................................................................20
3.0 FAMILIARIZATION..........................................................................................................................24
3.1.0 OPEN CAST MINE.........................................................................................................................24
3.1.1 INTRODUCTION..........................................................................................................................24
3.1.2 MINE PLANNING.........................................................................................................................24
3.1.3 DRAGLINE OPERATIONS..........................................................................................................24
3.1.4 DRILLING AND BLASTING.......................................................................................................24
3.1.5 SUPPLEMENTARY STRIPPING AT RAM 12..........................................................................26
3.1.6 COAL HANDLING PLANT............................................................................................................27
3.2.0 UNDERGROUND MINE................................................................................................................28
3.2.1 INTRODUCTION............................................................................................................................28
3.2.2 EQUIPMENT USES................................................................................................................29
3.2.3 COAL PRODUCTION............................................................................................................29
3.2.4 ROOF SUPPORT....................................................................................................................29

5
3.2.5 VENTILATION.......................................................................................................................30
3.2.6 STONE DUSTING...................................................................................................................31
3.2.7 WATER MANAGEMENT.....................................................................................................31
3.3.0 MINE PLANNING.........................................................................................................................31
3.3.1 SAFETY, HEALTH AND ENVIRONMENT SECTION............................................................31
3.3.2 MINE PLANNING SECTION......................................................................................................32
3.3.3 STAGES OF MINE PLANNING..................................................................................................33
3.3.4 SURVEY SECTION.......................................................................................................................33
3.3.5 GEOLOGY SECTION...................................................................................................................34
3.3.6 ROLES OF GEOLOGY AT HCCL..............................................................................................34
4.0 METALLURGICAL OPERATIONS SECTION..........................................................................37
4.1.0 INTRODUCTION............................................................................................................................37
4.2.0 CHABA............................................................................................................................................37
4.2.1 Objectives of the department............................................................................................................37
4.2.2 Environmental, Safety and Health considerations............................................................................37
4.2.3 Top twenty risks in the department...................................................................................................38
4.2.4 Chaba mobile plans..........................................................................................................................39
4.2.5 Coal sources.....................................................................................................................................40
4.2.6 Run off Mine (ROM)........................................................................................................................40
4.2.7 Size reduction...................................................................................................................................41
4.2.8 Removal of harmful material............................................................................................................41
4.2.9 Screening..........................................................................................................................................42
4.3 JIGS AND FLOATATION PLANT....................................................................................................43
4.3.1 INTRODUCTION TO JIGS AND FLOATATION PLANT.......................................................43
4.3.2 HANDLING.............................................................................................................................45
4.3.2.1 Removal of harmful material..................................................................................................45
4.3.2.2 Transportation.............................................................................................................................45
4.3.2.2 Storage......................................................................................................................................45
4.3.3 JIG AND FLOATATION PLANT................................................................................................46
4.3.3.1 Jigs and Floatation Coal flow......................................................................................................46
4.3.3.2 Jigs and Floatation Water Circulation.......................................................................................48
4.3.4 Quality Analysis..............................................................................................................................50

6
4.3.4.1 Methodology for ash content determination in coal and coke samples....................................50
4.3.4.2 Principle.......................................................................................................................................50
4.3.4.3 Materials.......................................................................................................................................50
4.3.4.4 Procedure.....................................................................................................................................50
4.3.4.5 Interpretation of analysis data at the plant................................................................................52
4.3.5 Problems experienced at the plant................................................................................................54
4.4 COAL PREPARATION PLANT (CPP)........................................................................................54
4.4.1 INTRODUCTION..........................................................................................................................54
4.4.2 COAL HANDLING........................................................................................................................55
4.4.2.1 MINE YARDS.............................................................................................................................55
4.4.2.2 RUN OFF MINE..........................................................................................................................55
4.4.3 Plant Feeding.................................................................................................................................56
4.4.4SCREENING...................................................................................................................................58
4.4.4.1 WET SCREENING.....................................................................................................................58
4.4.4.2 DRY SCREENING......................................................................................................................59
4.4.4.3 FACTORS AFFECTING SCREEN EFFICIENCY.................................................................60
4.4.5 COAL GRADES AT THE CPP.....................................................................................................61
4.4.6 WATER CIRCULATION SYSTEM.....................................................................................62
4.4.7 THICKENER.................................................................................................................................63
4.4.7.1 PARAMETERS...........................................................................................................................65
4.4.7.1.1 BED LEVEL.............................................................................................................................65
4.4.7.1.2 THICKENER UNDERFLOW.................................................................................................65
4.4.7.1.3 THICKENER OVERFLOW...................................................................................................66
4.4.7.1.4 TRACTION DRIVE.................................................................................................................66
4.4.8 SLURRY DAMS......................................................................................................................67
5.0 RESEARCH WORK CONDUCTED..................................................................................................69
INVESTIGATING THE INDEPENDENT FACTORS THAT AFFECT JIG PERFORMANCE
TOWARDS OPTIMIZING JIG PERFORMANCE AND THE BENEFICIATION OF THE TAILINGS
WASTE DUMP.........................................................................................................................................69
5.1 Introduction.........................................................................................................................................69
Problem Background.................................................................................................................................69
Problem Statement....................................................................................................................................70

7
Aim............................................................................................................................................................70
Objectives..................................................................................................................................................70
Assumptions..............................................................................................................................................70
Justification...............................................................................................................................................71
Methodology.............................................................................................................................................71
Research findings......................................................................................................................................72
Comments.................................................................................................................................................74

Waste ash vs Recovery

120

100

80

60

40

20

0
28-Jul 2-Aug 7-Aug 12-Aug 17-Aug 22-Aug 27-Aug

Jig Recovery Jig Waste Ash

.................................................................................................................................................................. 80
Conclusion.................................................................................................................................................81
Recommendations.....................................................................................................................................81
6.0 Hwange Colliery Company Limited Training Program.......................................................................82

8
1.0 INTRODUCTION TO HWANGE COLLIERY COMPANY LIMITED
(HCCL)

1.1 HISTORY OF HWANGE COLLIERY COMPANY LIMITED

Hwange Coal was founded in 1893 and was known to the locals as the “the rock that burns”. The
first coal mining expedition began in 1902. The coal was initially transported by ox wagon and
later by rail as a railway line from Bulawayo to Hwange was constructed in 1903.

This development enabled the company to increase its coal supply. Mining was primarily by
underground pillar mining hand got system. Opencast mining was intermittent and limited to
small pits to supplement underground mining operations during times of increased coal demands.
In 1927 and 1953 number two and three collieries were commissioned respectively to increase
coal production. However, number one colliery was decommissioned in 1961 and after the
Kamandama mine shaft disaster of 1972, number two shaft was sealed off.

To make up for the lost production number four mine shaft was commissioned in 1976. Due to
the increased demand for coal and the opening up of the Hwange thermal power station, the
Opencast mine was commissioned in 1982 to meet the coal demands from the power station. To
date several, the company continues to implement several initiatives including investing in
equipment in order to increase the mines production capacity.

1.2 SAFETY

Involvement and joint commitment of management and staff has resulted in the development of
work policies and procedures, as well as first aid, rescue and safety training at the Main Training
Centre to create a safe working environment. Sub-committees of the main SHE (safety, health
and environment) committee, made up of a cross section of employees from workers and
management, have been formed throughout the Colliery to encourage worker participation in

9
such matters that affect them on daily basis. Safety talks are held before every shift or work day
commences to heighten employee awareness to dangers that he/she may encounter during the
day thus staying vigilant and aware. Employees are motivated through section and
interdepartmental safety competitions based on accident frequency and severity rates.

1.3 HEALTH

The company administers a hospital and associated health services. A modern well-equipped
hospital complex provides medical care for employees, their dependents, Hwange residents and
members of the rural community up to a distance of 150km from the town. The hospital has five
doctors, 325 beds, two operating theatres and all other equipment that is required in a modern
hospital. Nurses and midwives are trained in excess of the hospital’s needs contributing to the
nation’s requirement for medical staff.

1.4 ISO CERTIFICATION

Hwange Colliery Company is certified into ISO 9001:2008. The company attained its first
certification in 2005 when it was certified into ISO 9001:2000. The standard was over the years
revised into ISO9001:2008 and recently ISO9001:2015.

The company has enjoyed a continuous membership to the body of certified companies to this
world wide standard. ISO 9001:2008 standard is focused on meeting customer expectations and
delivering customer satisfaction (quality and consumer satisfaction). It has become the basis for
creating a quality management system around the world. ISO 9001:2015 sets out the criteria for a
quality management system and is the only standard in the family that can be certified to. It can
be used by any organization, large or small, regardless of its field of activity. There are over a
million companies and organizations over 170 countries today certified to ISO 9001. This
standard is based on a number of quality management principles including a strong customer
focus, the motivation of top management to drive the system, the process approach and continual
improvement. Using ISO 9001:2015 helps ensure that customers get consistent, good quality

10
products and services, which in turn brings many business benefits. ISO 9001 is based on the
plan-do-check-act methodology and provides a process-oriented approach to documenting and
reviewing the structure, responsibilities, and procedures required to achieve effective quality
management in an organization. The quality management system includes documented
information, planning and determining process interactions. Responsibilities of management
include management of resources, human resources and work environment. Product realization
includes the steps from design to delivery, measurement, analysis, and improvement of the
quality management system itself through activities like internal audits and corrective and
preventive action.

1.5 VISION

We strive to be the number one in coal mining and production of coal related products at the
least cost in the region.

1.6 MISSION STATEMENT

To provide competitive coal and coal related solutions to our customers using modern and
efficient production techniques.

1.7 STRATEGIC INTENT

HCCL’s strategic intent seeks to maximize the value of current operations and opportunities
down the value chain, execute growth projects with the potential of becoming a 12Mtpa coal and
coke supplier by 2021 while being a company that cares for its people, communities and the
environment it operates in.
It will be critical for the company to focus on the more lucrative export and seaborne markets as
well as shift the balance from HPS to higher value products such as coking coal and coke. This
will serve to maintain real shareholder value over time but also mitigate risk through
geographical diversification.

11
1.8 CORPORATE DIRECTIONAL STRATEGY

The strategy of choice out of various available options (Growth, Consolidation, Stability and
Decline) is a Growth strategy. The Corporate Directional Growth Strategy is underpinned by the
pursuance of a market penetration and cost leadership strategy at business level. The growth will
be realized through volumes, value and profitability.

1.9 CORE VALUE STATEMENT

Our core values define who we are, lead us, direct us, guide us, strengthen us and set us apart
from the competition. They govern the manner in which we do business and will not be
compromised as we seek greater profitability. Hence these values form the basis for the enduring
positive growth of our company. We value the following:

 Safety The safety of our employees is top priority and pivotal to our success. We ensure
employees understand the Company’s Safety credo and practice safe working practices.
We continually provide employees with adequate safety equipment and knowledge in
order for them to work safely.

 Innovation
The Company believes innovation is key for business growth, survival and excellence.
We value individuals that innovate, hence, we are open to ideas that challenge the norm
and drive innovation.

 Efficiency
We recognize efficiency as vital to our business hence we strive to achieve the highest
levels of efficiency at all times and at all levels of the business. Therefore, we strive to
manage resources while delivering at appropriate costs, speed and quality.

12
 Competency
We have a rich mix of interrelated competencies from which we derive our competitive
advantage, which also forms the future development of our company. Hence, we ensure
we have the right people with the right skills in the right jobs doing the right things.

 Team Work
We value teamwork and the synergies that come from the ability to work together
efficiently and effectively for a common purpose.

 Execution
We value the quick translation of strategic and operational decisions into action. We
effectively link our goals, people and work processes while following through and
ensuring accountability

13
2.0 EQUIPMENT AND MACHINERY USED AT HCCL

This chapter focuses on describing in brief some of the equipment and machinery used at
Hwange Colliery Company Limited.

2.1 Transportation
Trucks: Haulage trucks are major mode of coal transportation within the company. With the
WPC system of conveyors that linked the open cast mine site to the Coal Preparation Plant,
trucks have taken over the load of transporting the coal. They carry coal from mines to
processing plants, they also transport from one plant to the other, as and when required. For
instance from Chaba dry screen plants to Coal Preparation Plant (CPP) and/or Jig and Float
plant.

Conveyors; A conveyor system is a common piece of mechanical handling equipment that

moves materials from one location to another. Conveyors are especially useful in applications
involving the transport of heavy or bulky materials. Conveyor systems allow quick and efficient
transport for a wide variety of materials.

Accessories of a conveyor belt;

The belt itself, idlers, head and tail pulleys, motor drive, V-belts/or gear couplings, scrapers and
ploughs.

A conveyor system has the following advantages over trucks: cheap to move material over long
distance, no degradation of product due to conveying, belts can be loaded virtually from any
place along transmission, fast and can carry a bulk material.

2.2 Crushers
Jaw crushers

Jaw crusher is widely used in industrial and mining enterprises, this is because the aircraft
structure is relatively simple, and has a large range of models. Jaw crusher is mainly used as the

14
primary crusher. It can be used with mineral processing equipment, gravel ancillary equipment;
it also can be used alone (https://www.gravelmill.com/solutions/jaw-crusher-working-
principle.html).

One of the most commonly used crushing machines is the jaw crusher. It is a heavy-duty
machine that is generally used for crushing different kinds of raw materials into smaller pieces.
The jaw crushers can be seen in the mining and disposal industry where large rocks need to be
crushed into smaller pieces for further use.

There are different jaw crushers on the market, but all of them are designed and are consisted of
fixed and moveable parts.

Fixed parts are the frame is the main fixed part of the jaw crasher. There are also two mechanic
build crafts: medium carbon steel and steel welding plate frame. Moveable parts are jaw plate,
eccentric shaft, bear, belt pulley and other components.

The working principle of the jaw crushers is very simple. A jaw crusher cruses the material
inside the crushing chamber. It can be diesel or gas power. The materials are pushed inside the
chamber from the top opening and when crushed they are released through the bottom opening.
The crushing power of the jaw crushers depends on the size of the chamber. The crusher’s
efficiency becomes better with increasing size of the chamber. The crushing process can be
basically explained as a process where the materials are sandwiched between two jaw plates. The
movable jaw plates crush the material into smaller chunks by squeezing.

There are two main types of jaw crushers: double toggle and overhead eccentric jaw crusher. The
only difference between these two crushers is the location of the pivot joint. In the overhead
eccentric jaw crushers, the pivot joint is located at the bottom of the chamber, while at the double
toggle crushers; the pivot joint is on the top. The double toggle jaw crushers are more preferred,
simply because these crushers are described as fuel-efficient and easy to operate machines.

The jaw crushers can be used for crushing all kinds of hard materials quickly and efficiently.
Powerful and highly efficient, the jaw crushers are essential pieces of equipment in the
construction and mining industry. They can be used in combination with other crushing

15
machines for more efficient performance. In most cases, the jaw crushers are used as primary
crushing machines in projects where high quality materials are not needed

The main technical features of the jaw crushers are: simple structure and convenient
maintenance, stable performance and low operation cost and even particle and large crushing
ration. These are good features and jaw crushers are used as primary crushers by Hwange
Colliery Company limited (https://www.editorstop.com/the-working-principle-of-a-jaw-crusher).

The following diagram below shows a cross section of a jaw crusher extracted from
cementequipement.org

Figure 2.1: cross sectional view of a jaw crusher

Roll crushers

The mode of operation of roll crushers is extremely simple, the standard spring rolls consisting
of two horizontal cylinders which revolve towards each other. The set is determined by shims

16
which cause the spring-loaded roll to be held back from the solidly mounted roll. Unlike jaw and
gyratory crushers, where reduction is progressive by repeated pressure as the material passes
down to the discharge point, the crushing process in rolls is one of single pressure. Roll crushers
are also manufactured with only one rotating cylinder, which revolves towards a fixed plate
however; some newly manufactured crushers have both rolls rotating in counter motion. Other
roll crushers use three, four, or six cylinders. In some crushers the diameters and speeds of the
rolls may differ. The rolls may be gear driven, but this limits the distance adjustment between the
rolls; and modern rolls are driven by V-belts from separate motors. Roll crushers have a useful
application in handling friable, sticky, frozen, and less abrasive feeds, such as limestone, coal,
chalk, gypsum, phosphate, and soft iron ores. Their capacity are usually lower than jaw crushers
for course material but they are very effective with good reduction ratios for small particles,
hence their use as secondary crushers at Hwange Colliery Company Limited.

The two figures below show a sketch and a toothed double roll crusher.

Figure 2.2: sketch of a double roll crusher

17
Figure 2.3: Toothed roll crusher

Impact (hummer crushers)

In this type of a crusher, size reduction is achieved by impact stresses rather than presser
application like in other types of crushers such as the jaw crusher and the rolls crusher. A falling
rock is hit by a fast blows applied at high speed. The moving parts are called beaters and they
transfer the kinetic energy to the falling rocks causing them to shatter. The internal stresses
created in the particles are often large enough to cause them to shatter. These forces are
increased by causing the particles to impact upon an anvil or breaker plate.

2.3 Screens
These are industrial units that have multipurpose. The screens may be used for sizing or
classifying, to separate particles by size, usually to provide a downstream unit process with the
particle size range suited to that unit operation. They may also be used for scalping, to remove
the fraction that are very course in the feed material, usually so that they can be crushed or

18
removed from the process. Screens may be used for grading, to prepare a number of products
within specified size ranges. It is also done for media recovery, for washing magnetic media
from ore in dense medium circuits. Finally it can be utilized for dewatering, to drain free
moisture from wet sand slurry. Hwange Colliery Company Limited (HCCL) use screens mainly
for sizing and dewatering. Screens at HCCL are also used for scalping purposes.

Screen types

There are many different types of screens in the industry. These vary from grizzle screens, wire
mesh screens, perforated metal plate screen etc. the screens may be operated in a vibrating
manner or shaking manner. Most industries use vibrating one for efficiency sake. The screens
will be inclined to allow material to flow from one end to another. Mostly HCCL uses the wire
mesh screens.

Figure 2.4: wire type industrial screen

2.4 Electromagnet
This is a device consisting of a core of magnetic material surrounded by a coil through which an
electric current is passed to magnetize the core. An electromagnet is used wherever controllable
magnets are required, as in contrivances in which the magnetic flux is to be varied, reversed, or
switched on and off. Its main purpose in the coal industry (HCCL in particular) is to remove
magnetic material regarded as harmful material from coal before processing to avoid damage of
downline equipment such as screens and secondary crushers. These harmful materials may be
manganese steel mantles, bucket teeth where front end loaders has been used or excavators.
(Britannica)

19
Figure 2.5: Electromagnet (magnetic material with a coil around it)

2.5 Centrifugal Pumps

The centrifugal pump definition is, a device which can be used for handling huge amount of
liquids to provide extremely high flow rates, and they have the capability to regulate their flow
of liquid rates over a wide range.

Generally, these pumps are designed for liquids which have a comparatively low viscosity that
transfers like light oil otherwise water. Some of the viscous liquids will require extra horsepower
to work the centrifugal pumps. Centrifugal pump components mainly include three parts such as
an impeller, a casing, suction pipe by a foot valve & strainer delivery pipe.

A centrifugal pump utilizes rotation to pass on velocity in the direction of the fluid. Each
centrifugal pump uses a hydraulic component like an impeller that turns to pass on velocity
toward the pumped fluid.

20
This pump is mainly used to change the velocity into liquid flow. Each pump uses a component
like a casing that captures the fluid which is informed by the impeller & directs the pushed fluid
toward the pump expulsion end.

Centrifugal Pump Working Principle

The centrifugal pump working principle mainly depends on the flow of forced vortex which
means whenever a certain accumulation of liquid or fluid is permitted to turn with an exterior
torque than there will be an increase within rotating liquid pressure head takes place.

The increase in pressure head can be used to carry water from one site to another site. It is the
force performing on the liquid that makes to supply in the casing.

The conversion of energy occurs manly by two parts of the pump, an impeller and a casing. The
impeller generates kinetic energy from driver energy which will then be converted to pressure
heads by the diffuser.

When the impeller rotates, it makes the fluid around it to rotate also but radially outwards. Both
pressure and kinetic energy of the fluid rise. At the suction end, a negative pressure is created a
fluid moves in.

NB: priming of these devices is essential because if no water is present at the beginning of the
pumping process, the negative pressure developed by pumping air will be small and hence less
fluid will be sucked into the system. The impeller is housed inside a casing that collects fluid and
discharge the fluid at the discharge nozzle. The casing has an increasing area in the direction of
flow to accommodate the moving fluid.

Please note: if the pressure build up at the suction side is less than the vapor pressure of the
operating fluid then an undesired phenomena called cavitation will occur. This is when the fluid
start to boil forming vapor bubbles which and it damages the impeller. The higher the suction
head the lower the suction pressure to lift the fluid hence more chances for cavitation.

Accessories of a centrifugal pump

Impeller, the impeller can either be closed, open or semi closed. A closed impeller has plates
covering the blades at both sides while a semi closed one has only one casing at one side and at

21
the other side the blades are exposed. An open impeller has no cover on the blades. Below is a
diagram that shows the three types of impellers.

Figure 2.6: Three types of impellers

Casing: it has an increasing area toward the discharge to accommodate the water that is
continually being pumped towards the discharge nozzle.

Figure 2.7: Typical centrifugal pump casing

22
Shaft: it connects the impeller to the drive motor.

The diagram below shows the cross section view of an assembled pump.

Figure 2.8: assembled pump

APPLICATIONS

 Suitable for low viscosity fluids

 Suitable where there are variations in flow rate
 Pumps can handle large volumes of fluid

The pumps have being used in water industries to boost pressure, mining industry to pump light
slurry and manufacturing industries for various purposes.

23
3.0 FAMILIARIZATION

3.1.0 OPEN CAST MINE

3.1.1 INTRODUCTION

Hwange Colliery Company Limited boasts both open cast and underground mining. Currently
open cast mining is being undertaken at the JKL (RAM 9 and RAM 12) and Chaba II open cast
mines. The first thing to be done before mining operations can be commenced is the clearing of
the bushes followed by the removal of the supplementary bench, then the main bench, shale and
finally the coal.

3.1.2 MINE PLANNING

The mine planning at the open cast is similar to the work done at technical services and is
already laid down under the mine planning section (refer to section 2.2 of this report). Besides
that, during the induction the top 20 risks were spelt out.

3.1.3 DRAGLINE OPERATIONS.

The dragline has been out of commission since 2016 and excavators and blasting are used in its
place on the dragline work bench.

3.1.4 DRILLING AND BLASTING

In mining, usually the valuable mineral lies below a stratification of rocks that hinder direct
access to the mineral. As a result, there are means that have to be developed to remove the
overburden so as to expose the mineral for exploitation. This is an energy intensive process and

24
involves energy application and can be achieved by drilling and blasting. Hence drilling and
blasting is considered to be the first phase of the production cycle in most mining operations.
Today technology has shown much advancement in several activities of mining. In spite of that,
there is no alternative to blasting or drilling. Quiet a lot of improvements have been shown by
experts in controlled blasting operations which are more beneficial not only on the production
point of view, but also on the safety point of view for mine workers. This operation makes use of
drill rigs as well as explosives. A drill rig consists of a bit of ranging diameters (191mm, 171mm,
165mm) attached to a barrel of one meter length, both of which make up what is known as the
hammer. A drill bit can have a lifespan of about 4500 – 5000m depending on the rock type, with
sandstone being the strongest. A leading rod is attached to the barrel and has a length of 6m. For
a leading rod, the bit cycle time is around 4-5 minutes. After drilling, the holes are charged with
explosives. There are two main types of explosives used in open cast mining, namely water
resistant (emulsion) and non-water resistant explosives (ANFO). The explosives are comprised
of ammonium nitrate fertilizer mixed with fuel and oil. The fuel is usually diesel and the mixture
is 94% ammonium nitrate and 6% fuel per 50kg bag with 8 bags being mixed per cycle at the
mixing plant. Outlined below is the procedure to be followed for charging and blasting a hole:

1. Barricade the area (red flags)

2. Put signs alerting people that the area poses danger
3. After charging, pick up all the guards, place them at the entry points to the blasting area
and then notify everyone of the intention to blast (issue out a book where everyone can
sign so that they can be accounted for after blasting is completed.
4. Check for cut-offs and misfires after blasting

Below are a number of crucial terms to be aware of when discussing the topic of drilling and
blasting in mining:

 Meter rise – amount of explosives put into a hole per meter.

 Powder factor – Amount of explosives to be used for the entire blasting operation.
 Pre-split – method of shaping the wall face so as to reduce back break as well.
 Open chevron – throw the fragments in front during blasting (supplementary bench).
 Closed chevron- gather material to the center during blasting (main bench).

25
3.1.5 SUPPLEMENTARY STRIPPING AT RAM 12

This is concerned with the removal of the sandstone which is about 10-14m deep depending on
the geology. Sandstone is the hardest rock type and therefore requires more explosives for
fragmentation. The drilling of holes for explosives follows an equilateral triangulation system to
locate holes. The spacing between each hole is 4.6m whereas the burden is 4m. The depth of the
holes is roughly 15m and each hole is two thirds filled with explosives and the other third is
stimmed. The spacing, burden and depth of the holes vary depending on the strength of the bench
being worked on. For example, for the main bench, the spacing will change to 6.5m with burden
of 5.6m and a hole depth of 21m usually. Water resistant explosives (emulsion) were used at
RAM 12 due to the collection of water in the area as a result of the season rains. About 230 holes
were drilled for supplementary stripping of the work bench at RAM 12 with each hole requiring
about 330kg of explosives.

FIG 3.1 open cast mining methods at HCCL.

26
3.1.6 COAL HANDLING PLANT
Fig 3.2 Open Cast Mine Coal Handling Plant

27
3.2.0 UNDERGROUND MINE

3.2.1 INTRODUCTION

Underground mining at HCCL has always been the favored type of mining. Open cast mining
was adopted to meet the increased demand for coal and after the Kamandama disaster. 3 Main
underground mine is labelled a fiery mine due to the presence of inflammable gases as well as
the combustible coal dust formed during mining operations. The mine only mines coking coal
and uses the board and pillar method in its operations shown below.

Fig 3.3 Board and pillar mining method

28
3.2.2 EQUIPMENT USES

 The continuous miner as the name suggests is used to cut (mine) the coal. When
operating optimally, a continuous miner can process about five tonnes of coal per minute.
 The shuttle cars serve to transport the mined coal from the continuous miner to the feeder
breaker.
 The feeder breaker crushes the coal into smaller chunks that can be easily conveyed to
the surface.
 The LHD is used to transport materials into the mine as well as clearing the roadways for
heavier vehicles to move about unhindered.
 The MPV function the same way as the LHD with regards to transporting material into
the mine. It is also used in the stone dusting of the mine as well.
 The RBT is used for roof support.
 The exhaust fan is used in the ventilation of the mine.
 Pumps are used to pump underground water out of the mine.

3.2.3 COAL PRODUCTION

The continuous miner cuts the coal and stores it in its bunker. The shuttle cars then conjoin to the
miner and the coal is loaded and transported to the feeder breaker for size reduction. The coal is
then loaded onto a series of conveyor belts for transportation to the surface where it is stockpiled
ready for transportation to the number two Metallurgical operations plants for washing.

3.2.4 ROOF SUPPORT

3 main uses the board and pillar type of mining and the pillars that are left behind when mining
provide support to the overlaying ground. The predominant method of roof support besides the
pillars is roof bolting. This method of support is preferred because the bolts and associated
29
accessories are easy to handle and store, light to transport into the mine, easy to install and offers
little to no resistance to ventilation. Due to the removal of chunks of coal, the absence of support
for the ground above will necessitate a method of support to prevent the sagging at this zone of
softening. Roof bolts function to support this “extra” weight. The method employs a 1.8m rebar
with a nominal diameter of about 20mm, a bolt washer that is 120mm square and 5mm thick and
a double winged 28mm drill bit. The bit drills the ground and a plastic tube is used to supply a
mixture of resin and catalyst into the hole. The bolt is then screwed into the hole, its rotation into
the hole mixing the resin and catalyst, in the process forcing them to set. When set, the resin
holds the bolt in place and each bolt can support up to 7.5 - 12.7t. the first bolt is drilled about 1-
1.5 m from the wall and usually there are about five bolts per row at 1.5m away from each other.
At the entrance to the main there is a temporary roof support (TRS) made of concrete and other
types of roof support used at 3 Main include RSJs, wire mesh for friable ground and cable ropes.

3.2.5 VENTILATION

The presence of methane gas and coal dust in the underground mine presents a hazard for all
working in the mine due the explosive nature of these two. Methane is explosive at
concentrations of about 5-15% thus a ventilation system is required to dilute these concentrations
to safe levels for employees working underground. More obviously is the need to supply
breathing air for workers working in the section. The mine makes use of an exhaust fan that
draws air out of the mine at 90m 3 /s. The mine is divided into two passage ways through walls,
brattices and doors. This creates an inlet passage way and a return airway. The fan functions to
suck air out of the return airway thereby creating a negative pressure which draws in air into the
mine through the inlet air passage to counter the deficit or shortage of air due to the exhausted
air. That way the mine is ventilated. Ventilation is controlled through the presence of walls,
doors, brattices (temporary walls) and air crossings. As the mining operations go further
underground, the ventilation is compromised and this has necessitated the presence of booster
fans to push air to the section.

30
3.2.6 STONE DUSTING

One of the lessons learnt from the Kamandama tragedy has been the use of stone dust, an
incombustible material (limestone) that is used to prevent the spread of fires under ground. When
the MPV is functional, it is used to spray the dust onto the roof and sides of the mine such that
the coal walls appear greyish. In its absence, men are used to spray the walls. Stone dust bags
also hang loosely from the roof of the mine at pre-determined distances. These give in and spray
a mist of inert dust in the air at the slightest of trembles thereby preventing the spread of fire
from one section to the other. The founding principle for stone dusting is that the heat from the
fire is used to decompose the calcium carbonate to form calcium oxide and water thereby
preventing its progression. This decomposition is an endothermic reaction.

CaCO3 + heat CaO + CO2

3.2.7 WATER MANAGEMENT

Due to the presence of springs, waste water to cool machinery during operation and water
seepage from the rooftops (from the water table), water accumulates in different sections in the
mine and it is paramount that the water be pumped out of the mine for safety reasons. At three
main there are three pumps underground, one at 12xcut Main East, the other at 28xcut Main East
and the last one that pumps to the sump out of the mine is located at 3xcut Main West.

3.3.0 MINE PLANNING

3.3.1 SAFETY, HEALTH AND ENVIRONMENT SECTION

This section is concerned with the safety and health of working personnel at the work place as
well as the preservation of the environment. Before any task can be done, a worker is supposed
to complete a Hazard Identification and Risk Assessment form about the likely dangers he/she

31
may encounter during the completion of a given task. Consequently actions to be taken in
response to these hazards were discussed. In the instance of a fire breaking out at the Technical
services department for example, all personnel are supposed to gather and assemble at the fire
assembly point, moving orderly and briskly to the assembly point. Environmental aspects and
impacts were also discussed. At HCCL, the mining operations can interact with the environment
one way or the other. Thus there are twenty six boreholes in and around the Hwange mining
concession area that are used to monitor the underground water for any contamination. To
promote and avert any health complications during working hours, the environmental department
makes use of a four in one environmental meter (measures light intensity, temperature, relative
humidity and sound levels) to ensure the aforementioned are within safe levels and do not cause
any harm to the ordinary worker. Sound levels should never exceed ninety decibels and intensity
should never be below five hundred on the LUX scale for workers on the night shift. Above all
else, we learnt about the Quebec five point system :

1) Check entrance to the working place.

2) Are the working tools and equipment in good order.
3) Is the team working safely and properly.
4) Do an act to promote safety.
5) Can and will the team continue to work safely and properly.

3.3.2 MINE PLANNING SECTION

This section deals with coming up with medium term mining plans (five years) by applying
geological, geotechnical and engineering knowledge to come up with models utilized for mine
planning. Conditions that need to be satisfied to choose a particular mining method like ore body
size, the shape of the ore body, its strength, the production costs and rates as well as the grade
and stripping ratio among other factors were discussed and explanations accordingly given to
support the choice of mining method to be adopted. A brief overview of the mining methods
used at HCCL (Hwange Colliery Company Limited) was given, namely the surface mining
method (strip mining at Open Cast) and underground mining which is used for massive ore

32
bodies which are flat and slightly deeping at less than or equal to fifteen degrees to the horizontal
(board and pillar at 3 main).

3.3.3 STAGES OF MINE PLANNING

There are basically five stages that need to be satisfied during mine planning, namely:

1) Prospecting – searching for the minerals.

2) Exploration – grade calculation and ore body size determination, pilot tests.
3) Construction and development – building of required infrastructure like access roads,
shafts, houses etc.
4) Active mining – the actual production.
5) Rehabilitation – post mining land use.

3.3.4 SURVEY SECTION

Surveying at HCCL can be divided into two, open cast survey and underground mining survey.
Equipment used for surveying ranges from equipment like the theodolite (measures angles),
drones (unavailable) and total station (measures angles and distance). Survey makes use of the
SURPAC vision software that processes raw data to calculate volumes of stockpile, making use
of the stockpile geometry and given the coal density is known, its tonnage as well. The vital
information required is the number of points taken, the horizontal and vertical angles as well as
the horizontal and vertical distances, all acquired using the total station. The objectives of the
survey section at HCCL are:

1) Control mining operations to ensure they adhere to mine plans.

2) Quantify moved material.
3) Product accounting.
4) Quantifying stocks.
5) Declared reserves trekking.
6) Production of plans and maps.

33
 7) Exploration and projects.

3.3.5 GEOLOGY SECTION

At the geology section, and introduction into the coalification process as well as a brief overview
of the Hwange main seam was covered with the differences in properties and appearance
between the different types of rocks clearly stated. Below is a table depicting the differences
between the three main types of coal (HPS, HCC, HIC) mined at HCCL in the order in which
they are found in the earth:

PHOSPHORUS
SULPHUR, SWELLING INDEX

CARBONACEOUS MUDSTONE
(< 40% ash, <20% volatiles)
HWANGE POWER COAL
(<26% avg ash, <20% volatiles)
HWANGE COKING COAL/HWANGE INDUSTRIAL COAL
(max. ash content 15%, 23.5% volatiles)
TABLE 2.1

The difference between Coking coal and Industrial coal is largely due to the maceral content and
its cokability with Industrial coal being made up of inert maceral content.

3.3.6 ROLES OF GEOLOGY AT HCCL

34
Geology has three main roles namely, production geology, rock mechanics and exploration
(currently on hold at HCCL). Production geology is concerned with providing geological models
for underground and open cast strips for example overburden and footwall plans, quality plans as
well as the interpretation of coal quality data. Exploration geology provides the borehole
information and delineates the coal resources. Moreover it is concerned with making sure the
company observes the exploration rights of the mining act. Target identification, target testing,
surface mapping, core and aerial pictography are other concerns under exploration.

35
36
 4.1 METALLURGICAL OPERATIONS SECTION

4.1.0 INTRODUCTION
This department presides over all coal processing processes. The Jig and Flotation plant, the wet
screen washing plant, Chaba mobile plants and the heavy medium separation plant (HMS) are
some the coal processing plants under the department’s jurisdiction.

4.2.0 CHABA
The Chaba Mine under the Hwange Colliery Company Limited concession is home to a couple
of mobile plants (Plant A and Plant B). The two plants serve to physically separate the coal
according to size through the use of dry screens. The plants fall under the Metallurgical
department of the Hwange Colliery Company Limited.

4.2.1 Objectives of the department

The departmental operations are guided by its objectives put in place to meet customer demand
and satisfaction. Product specification conformity is but one of the most vital objectives of the
department. Specification such as the ash content, size of the product, volatile matter, sulphur
content as well as the free moisture of the product should be regulated as per customer
requirements. For instance, the size compliance of the product should be as least within eighty-
five percent of the customer specification i.e. if the customer requires duff, then eighty-five
percent of the product processed should be within (-10mm). Given below are the department’s
objectives in full.

 Processing of 1.3 million tonnes of coal with 100% ash conformity and 85% percent size
compliance.
 Process at least fifteen thousand tonnes of coking coal with less than ten percent ash
conformity and eighty five percent product recovery on a monthly basis.

37
4.2.2 Environmental, Safety and Health considerations.

Like any other industrial operation, it is key that the safety of employees is considered first as
some would say that human life takes precedence to production. To ensure that human safety is
archived and hazard is reduced, the department has made sure that no employee performs any
duty without their full personal protective equipment (PPE). On health, the major concern is a
disease named caused by dust pneumoconiosis which affects the lungs. To control this, the
company has implemented the use of water buzzers to suppress dust in addition of the M3 dust
masks provided. On environment, standards and regulations put forward Environmental
Management Agent must be met. The department makes sure that it operates in such a way to
meet these standards. Measures include suppression of dust so that it doesn’t affect vegetation,
neutralization of chemicals used in the plant before discharging of it and recycling of the used
substances to reduce its disposal among others.

4.2.3 Top twenty risks in the department

Hazards found in the department have been found to be many. From the many hazards found, the
top twenty hazards have been documented. They are the top twenty because they are the ones
frequently reported and they have been classified to; health, environment, safety and quality.

Safety

 Collapse of plant structures

 Falling from heights
 Pressured acetylene gas explosion
 Movable machinery failure or faults
 Unguarded conveyor systems

Quality

 Low plant and movable equipment availability

38
  Poor product quality
 Inadequate resources
 Data capturing failures
 Spontaneous fires and fumes

Healthy

 Inadequate ablution equipment

 Eye strain
 Erratic supply of drinking water
 Noise from vibration of equipment
 Spread of communicable diseases

Environment

 Dust emissions
 Poor lighting
 Acidic effluents
 Poor oils management
 Generation and accumulation of tailings

4.2.4 Chaba mobile plans

This is a dry screen plant which is mobile. It consists of two plants namely plant A (P/A) and
plant B (P/B). Plant A is used mainly to process top coal and its products is mainly for
commercial purposes, which they are loaded to commercial trucks directly without further
processing. Main products that are produced by this plant are; duff, peas, nuts and cobbles
though currently cobbles are not being produced.

Plant B on the other hand is for processing of bottom coal and produces two products. The
products produced are; duff and peas. This plant is used to process coal that is to be supplied to
jig and floatation plant which then washes the coal to produce coking coal.

39
4.2.5 Coal sources

There are different sources of coal that supply Chaba plants. Main sources of coal that is
processed at Chaba are; Open cast mine, 3Main underground mine and Mota Engil Zimbabwe.

4.2.6 Run off Mine (ROM)

Coal received from different sources is stock piled on an open place known as the run off mine.
Different coal types are stock pilled on different points so as to know which type is being
processed at a given time.

ROM has three main purposes that are;

For storage: coal that is received might not be processed right away hence a storage point must
be available to keep coal. When the plant is on maintenance or breakdown before all coal has
been processed, the unprocessed coal is kept on a run off mine point.

For blending: different call types have got different grades. Some of the coal received will be of
low grade (high ash content) and does not meet customer requirements hence it is blended with
that of high quality so as to obtain an average ash content and make the product sellable.
Blending is done on recommended ratios for example 1:3, 1:5, 1: 10 depending on how bad or
good is the quality of one type of coal to another, ratios also depends on the desired average
output.

To supply a steady input to the plant: a plant needs to be fed with a steady input so as to avoid
gapes in production, avoid plant under usage and chocking. Moreover, to assist steady input to
the plant, the plant is fed through the jaw feeder bin.

40
4.2.7 Size reduction

For both plants, size reduction is archived by crushing first in a jaw crusher. Jaw crushers consist
of a fixed jaw and a mobile jaw. The gap between the jaws can be adjusted to desired size range
output. Further size reduction is done in recycle streams using a double rolls crusher to produced
desired size range to pass on screens. The gape between the rolls can be adjusted to produce a
desired product size. To avoid machinery damage, one of the rolls is spring loaded such that in
case of a very hard material that cannot be crushed in the system, the rolls moves outward and
allow the material to pass without damaging the teeth of the rolls. After the material has passed
through the crusher, the roll then returns to its initial position.

4.2.8 Removal of harmful material

This is done to prevent the hazardous effects of harmful materials in the down stream processes
such as in the screening of the material on screens and the secondary crushing in the double rolls
crusher in which scrap meatal may damage the screens or ware the teeth of a crusher.

The example of the scrap materials that may be found in the bulk material involves; manganese
steel mantles, bucket teeth where front end loaders has been used or excavators.

An electromagnet is hung on top of the belt to trap scrap metal that would have found its way
into bulk material accidentally during mining process.

41
4.2.9 Screening

Fig 4.1 Chaba Plant A process flow diagram.

Plant A consists of three screens as shown above, the first screen has three decks (top deck is
100mm, middle deck is 40mm and bottom deck is12mm), that it separate products into recycle
oversize, duff and remove peas and nuts as a combined product.

The second and then screens both consist of double decks, the first deck removes nuts, and the
second removes the duff that had passed the first screen unremoved. The products at the plant are
clearly shown at each process flow end with their size ranges.

42
Fig 4.2 Plant B process flow diagram

Plant B consists of one screen that is a double deck (top deck is 30mm and the bottom is 10mm).
First deck collects oversized material and recycles it, the second deck collects peas and its
underflow flow material gets into the duff chute. The products at the plant are clearly shown at
each process flow end with their size ranges.

4.3 JIGS AND FLOATATION PLANT

4.3.1 INTRODUCTION TO JIGS AND FLOATATION PLANT

The Jig and Floatation plant is one of several plants that are under the supervision of the
Metallurgical Operations department of Hwange Colliery Company Limited (HCCL). With the
Heavy Medium Separation unit at the Coal Preparation Plant (CPP) down at the moment, the Jig
and Floatation plant is the only available coal washing plant at the Company. Its main objective
when it was built was to maximize the recovery of coking coal fines but currently, with the

43
floatation cell down, it is mainly utilized for the production of coking coal. The products of the
jig plant as per customer requirement should have less than 10 percent ash content. The products
of the jig are usually duff and peas (sometimes mixed, depending on the Run Off Mine stores at
any given time). The products of this plant are termed Hwange Coking Coal (HCC) as they are
used for making coke.

The plant makes use of the differences in specific gravity between the coal and waste (tailings) to
separate the two. The jigging method of separation falls under gravity separation techniques that
exploit the difference in specific gravity to separate the material of interest (the valuable) from
that which is regarded as waste (tailings). The type of jig used at HCCL is the Batac jig that
consists of three compartments (each fitted with a screen at the top of the bed, the first one being
18mm, the second one being 16mm and the third 14mm) arranged in series. The reason for the
varying screen sizes is that most of the separation occurs in the first compartment. The separation
medium, water, is introduced from the bottom of the bed under pressure from a feed water pump.
Each compartment is also designed with a series of multiple air chambers, usually two per cell,
extending under the jig for its full width, thus giving uniform air distribution. The inlet and outlet
valves can be varied as and when is required depending on the quality analysis of the product.
The variance with regard to speed and length of the stroke basically means that the Batac jig can
process both coarse and fine sizes well. It also allows for the desired variation in pulsation and
suction by which proper stratification of the bed may be achieved for differing raw coal
characteristics (duff or peas).

As the coal feed is introduced into the jig, the air from the bottom initiates a series of pulsation
and suction strokes. As a result material with a higher specific gravity settles at the bottom of the
bed while the “lighter” material floats on top and is subsequently carried to the next
compartment by the flow of water. In the next compartment further separation takes places and
as a result, three tailings products end up being formed. Each compartment is fitted with a
tumbler that is linked to waste elevators at the bottom of the bed. These elevators are responsible
for removing the waste material (sinks) at the bottom of the bed and disposing of it to a tailings
stockpile at the side of the plant.

44
4.3.2 HANDLING
4.3.2.1 Removal of harmful material
The main harmful material present in coal is coal shale. It is removed through hand sorting at the
stockpiles. Shale is similar to coal but is heavier and has a brownish coating on its surface when
compared to the black of coal. Its shape is also different from that of coal and is used in the
sorting.

4.3.2.2 Transportation
Coal from the mining area (JKL and 3Main) is transported to the Chaba mobile plants for
crushing and screening by trucks. The products from plant B (Bottom HCC duff and peas) are
then transported from Chaba to the Jig plant for washing by use of trucks. With each truck
having a capacity of thirty tons, the amount of coal delivered to the plant can be easily
determined by multiplying the truck capacity by the number of coal delivery trips to the plant.

4.3.2.2 Storage
Coal is stored in stockpiles known as the Run Off Mine (ROM). The coal can also be stored in
bunkers. ROM serves for three uses:

 Storage
 Blending
 Supplying steady feed to the plant

The ROM at the Jig plant consists of both peas and duff from Chaba. When the ROM has both
products from Chaba, they are blended to improve the quality of the coking coal to be produced.
Blending can also be done as a result of “very dirty” coal like that received from 3 MAIN which
also has a lower caking index to improve these qualities. The plant can only handle coal that has
a 15% ash content and usually 3Main coal has a higher ash content so blending helps lower the
ash content. Moreover duff usually has lower ash content compared to peas and blending these
two is paramount in achieving a uniform product that is within specification.

45
4.3.3 JIG AND FLOATATION PLANT

Fig 4.4 Jig and floatation process flow diagram.

4.3.3.1 Jigs and Floatation Coal flow

Above is a process flow diagram showcasing the flow of material in the Jig and Floatation plant.
Below is a detailed account of what happens at the plant.

The Jig and floatation plant currently receives coal from JKL processed at Chaba though at times
coal from 3 Main is also processed. The fact that coal from 3Main has a lower caking index and
thus has lower market demand has resulted in reduced delivery of the coal with product
stockpiles lying desperately without any customers. Thus, currently most of the coal that makes
up the ROM is the JKL open cast mine duff and peas. The duff and peas is blended at the ROM

46
using the loader before it can be fed into the bunker. After all start up protocols are observed and
the plant has started to run, the loader feeds the plant by offloading the ROM coal to the bunker
underneath which is the first conveyor belt, JF1. The coal is transported by a series of conveyor
belts (JF1 to JF9) until it reaches the 30mm scalping screen deck. The screen is now a single
deck screen (as opposed to the initial design specification) because one of the crushers is
currently not available. So all material that is of size +30mm is sent to the remaining functional
crusher (hummer crusher) for size reduction while material less than 30mm is collected on the
JF10 conveyor belt which feeds to the feeder bin. The feeder bin on the process flow sheet is
identified as the intermediate storage bunker. Its purpose is to supply coal to the jig
compartments at a steady rate which is vital to the quality of product that can be achieved as well
as avoiding choking of the machine. From the feeder bin, the coal is transported to the jig
compartments via JF11. Water from the plant sump is used to provide a transport medium for the
coal going into the jig. Some of the water is also diverted and introduced at the bottom of the jig
beds. This water acts as the separating medium. Compressed air is also introduced from the
bottom of the jig beds. The introduction of the air from below the cell screens initiates pulsation
and relaxation phases within each compartment. During pulsation, the lighter coal is pushed
upwards and overflows to the next compartment whereas during relaxation, the heavier waste
(shale, rocks etc.) settles down.

The cell, as aforementioned has three compartments, thus if there is waste that has overflowed
with the coal from the first compartment will be removed in either the second or third
compartment. Below the beds there are tumblers that are linked to waste elevators which receive
the sinks (waste) and take it away. The product (coal) from the third compartment is transported
via a launder to a product box where product elevators, which are perforated to drain water, carry
the product and discharge it into desliming screens. From the screens, the coal is then transported
via conveyor belts JF13, JF14 and JF15 to the product stockpiles. The drained water from the
product box enters the water launder and eventually into an under pan. The desliming screen also
help recover more water that also reports to the under pan. This water has coal fines thus it is
then pumped to the floatation cells. The water with the coal fines first passes the conditioning
tanks where diesel and froth agents are added into the water so as to form froth bubbles that can
be skimmed off the top by the scavengers. The floatation cells consist of two lines, each with a
series of agitators at the middle and scavengers at the periphery of the lines. The agitators have

47
impellers that agitate the water-coal fines-diesel-froth agent mixture promoting air bubbles
which trap the coal fines in froth bubbles. The bubbles are skimmed off by scavengers into a
launder for deposition into the coal fines sump. A flocculation agent is added to the excess water
and the water proceeds into the thickeners [Pachuca tanks] (two of them). The froth in the coal
fines sump is pumped to the plate and frame filter press where it is compressed, in the process
removing excess water. Coal fines are recovered. The filtration cake is deposited into JF12 which
transfers it to the rest of the plant product line via JF13. The coal fines are, in the process
blended with the coal from the de-sliming screens.

4.3.3.2 Jigs and Floatation Water Circulation

Fig 2.2 Water Circulation flow sheet at the Jigs and Floatation Plant

The Jacaranda dam provides the main water source for the plant. Water is pumped from the dam
into the plant water reservoir. From the dam, water is pumped into the plant water reservoir. This
water is then pumped into the jig cell where it acts as a separation medium. Some of the water
branches and it used to propel the coal feed into the jig cell while another portion helps ferry the
jig product into the product box. Water that overflows from the product box is collected in the
under pan as well as the water that drains from the product elevators. The dry and rinsing screens
(de-sliming screens) also help recover more water that finds its way into the under pan. From the

48
under-pan water is pumped to the floatation cells. Once the froth bubbles have been skimmed
off, a flocculation agent is added to the water with the slurry and directed to the thickeners.
There free settling takes place and sludge collects at the bottom of the tanks to be pumped to the
slurry dams (Dam 5) whereas the overflow is channeled into the main plant resevoir for re use.
Water with the froth bubbles collects in the coal fines sump. It is then pumped to the plate and
frame filter press where it is compressed from the fines and redirected to the main resevoir for re
use.

Though the water circuit is a closed circuit, some of the water can be lost along the way through:

 Overflow of the coal fines sump

 pipe leakages
 slurry
 wet products and/or waste

49
4.3.4 Quality Analysis
Quality Analysis at the Jigs and Floatation plant entails the processes and measures through
which the company ensures the product is always within the correct specification. The product of
the plant should always have an ash content of less than ten percent and there are a variety of
factors that may affect or influence the ash content of the product as the plant is run. From the
number of strokes to the feed rate, all these factors influence the quality of the coking coal. The
quality analysis is carried out at the plant’s small laboratory. Samplers take samples of the feed,
product and tailings on an hourly basis and these are sent to the plant laboratory as well as the
central laboratory in number one. The results of such an analysis will then be given to the plant
operator to manipulate and dictate certain instructions to the plant attendants if, in any case the
quality of the product has veered off course. Below is a set of steps followed by the quality
analyst when determining the ash content of the coal from the plant;

4.3.4.1 Methodology for ash content determination in coal and coke samples

4.3.4.2 Principle
A known mass of test sample is heated in air at 815±10C and maintained at this temperature
until a constant mass is obtained. The percentage ash is calculated from the mass of the residue
remaining after incineration.

4.3.4.3 Materials
Reagents and Materials:- Certified Reference material and Internal standards.

Equipment and apparatus: crusher, furnace, analytical balance, tongs, silica crucible, desiccators,
computer.

Samples: Pulverized coal and coke samples passing through a sieve of 212µm are used. (The
samples are kept in air tight containers to prevent contamination/oxidation.

50
4.3.4.4 Procedure
1. The samples are from the plant are cone and quartered at the laboratory.

2. The sample of choice is then crushed to fine sizes using a small crusher. Place in a warmer.

3. Pre-place the crucibles in a furnace at 815±10C for 15 minutes. Remove and cool to room
temperature.

4. Accurately weigh the mass of the crucible to the nearest 0.0005g and record the mass in an
appropriate spreadsheet. Label it m1.

5. Weigh about 1±0.001g of coal/coke into a crucible and spread it evenly. Record the mass in an
appropriate spreadsheet. Label it m2.

6. Place the crucible + coal sample in a furnace ventilated by air at a temperature of 815±10C.

7. Prepare another sample the same way and also place into the furnace simultaneously for
reference purposes.

8. After an hour, the crucible is removed from the furnace using tongs.

9. The crucible is cooled in air for 10 minutes and then in a closed desiccator to room
temperature.

10. Afterwards, determine and record the mass of this crucible + burnt coal to the nearest 0.1mg
and label it m3.

Calculation and Expression of Results

m3 −m1
Ash % = ( ) × 100
m2−m1

Where m1 – mass of crucible

m2- mass of crucible + sample + cover

m3 – mass of crucible + sample (after heating) + cover

51
For urgent plant monitoring samples as is the case at the Jigs and Floatation plant, a sample of
0.5g±0.001g of coal is weighed in a crucible and the placed in the furnace for half an hour. This
is to cater for the hourly sampling that is done at the plant.

4.3.4.5 Interpretation of analysis data at the plant

The results obtained from the plant laboratory can tell us whether or not the plant is running and
producing the coal at the required specifications. From these results three scenarios can be
determined and these are:

1. The plant is running efficiently and the coal that is being produced as the waste and
products is of the required specification.
2. The recovery of the plant is low and the plant is discharging a portion of the clean coal as
waste.
3. The recovery of the plant is higher than is required and appropriate such that waste
material is being discharged as products.

For cases 2 and 3, the analyst reports these deviations to the plant operator and the plant operator
is responsible for informing and overseeing the necessary adjustments that need to be made to
return the plant to normalcy.

For the second case, the diagnosis being that the bed level produced in the jig plant is way less
than the set level thus the plant will tend to discharge clean coal up to the set bed level in the
process compromising plant recovery.

For the third case, the diagnosis is that the waste level in the bed will exceed the jig set bed level
and during jigging action, some of the waste is going to overflow and eventually end up
reporting to the product stockpile A depiction of the scenarios is given below:

52
Fig 3.1 the bed level concept

For illustration a, line b represents the bed level that is produced for case 2 that is lower than the
set point. Thus clean coal from the point above this line up until the set point will represent the
clean coal that is going to be discharged as waste.

For illustration b, line b represents the bed level in case 3, a level higher than the set bed level
point. Thus during plant running, the waste that settles above the set point is going to overflow
and report to the products stockpile.

These two cases can be easily determined. For case 1, the plant will be running smoothly with a
product that has an ash content of less than 10%. For case 2, the product ash content will be
within specification. However the recovery of the plant will be considerably lower in comparison
to that of case 1. For case 3, the product will have an ash content that is out of specification
(>10%). To fix cases 2 and 3 will require the plant operator to inform the plant attendant to make
proper adjustments to rectify the bed levels to the set bed levels.

Other factors such as the number of strokes (for pulsation), feed rate, type of coal being washed
(which mine does it belong to (3Main/JKL)), and these need to be monitored as well.

53
4.3.5 Problems experienced at the plant.
Water spillages from the plant from leakages and/or other sources can lead to water clogging.
Moreover acid mine drainage is also a result. The absence of neutralizers such as fly ash and
lime also means that this water is disposed off into the environment untreated.

Worn out belts like JF3 compromise the recovery of the plant by increasing coal feed spillages
along the production line.

The floatation cell is currently not working and is being by-passed so the plant cannot process
fines and these are lost.

Level indicators for the jig compartments need to be replaced to reduce over reliance on worker
experience in bed level determination and increase plant efficiency by increasing accuracy of the
system.

Only one pump at the plant water reserve is working and it is unwise to use one pump without a
standby pump. Standby pumps help to minimize losing production hours.

4.4 COAL PREPARATION PLANT (CPP)

4.4.1 INTRODUCTION
The Coal Preparation plant at number two is one of the processing plants under the jurisdiction
of the Metallurgical operations department. Its main purpose includes grading coal products with
six products produced at the plant. These are namely, duff, peas, nuts, small cobbles, large
cobbles and rounds. The plant has two screening sections, the wet and dry screening sections.
The plant also had a coal washing unit but the Heavy medium separation unit is currently down.
Thus the sole purpose of the plant currently is the production of a 15% ash content wet screen
product and an 18% ash content dry screen product.

Coal mined from Chaba, JKL and 3Main differ largely in their properties. Chaba coal is
industrial coal whereas 3Main and JKL coal is coking coal. JKL coal is usually cleaner than
3Main coal, that is, in terms of ash content. This is just but a highlight of the difference in coal
properties at Hwange. Properties such as volatile matter (VM), fixed carbon, inherent moisture,

54
ash content, phosphorus levels and Sulphur levels differs. This therefore raises the need to grade
the coal as per customer specifications. The coal grade and properties required by a hospital for
example differs from that required a cement producing company like PPC. Some companies
prefer a blend of two products like peas and duff, so an array of different products is thus
necessitated. Such differences raise the need for a Coal Preparation plant to grade different coal
products. The HMS unit was installed to enhance the quality of the coal product by washing it.
Since it is currently down, the Jig and Floatation plant has taken over the duties of washing coal
from the plant. So after the coal has been graded, any stockpiles that need to be washed are sent
to the Jig and Floatation plant for washing.

4.4.2 COAL HANDLING

4.4.2.1 MINE YARDS

The mine yards section of the Coal Preparation plant is responsible for receiving and
documenting all coal that enters the plant premises. It receives coal from Chaba, 3Main and the
slurry dams. It is also responsible for approximating the amount of coal received on any given
day by sending some of the haulage trucks to the weigh bridge for tonnage determination. The
total tonnage is then calculated by multiplying by the number of trucks that brought coal to the
plant. The section is also responsible for stockpile management and only receives coal stocks as
per an order for loading onto the wagons. Different grades are stockpiled on different loci so as
to avoid product contamination. The section is also responsible for product blending as is the
case with the NPD (nuts, peas and duff) that is largely supplied to ZPC Munyati.

4.4.2.2 RUN OFF MINE

The Coal preparation plant’s run off mine (ROM) has a carrying capacity of about 13000 tons.
Different types of coal are stockpiled in different loci around the ROM depending on where the
coal is mined from. This helps to easily determine which type of coal is being processed at any
given time. Coal from Chaba and 3Main are stockpiled next to the three drop points (vibrio
feeders) as they arrive already having been reduced in size. 3Main coal is reduced by the feeder
breaker underground. The chaba plants have jaw crushers and double roll crushers which reduce
the coal sizes. A jaw crusher unit has been added to the plant to process the coal from JKL.

ROM has three main purposes that are:

55
 1. Storage – if the plant is not running, due to a breakdown or undergoing maintenance
services on Fridays. As a result, the Run off mine then serves as a storage facility.
2. Blending - This is usually practiced based on the requirements of the customer. Blending
helps to ensure that no coal is thrown away if it is out of spec. If the coal is out of spec, it
can be blended with another coal grade and in the process, the coal is brought within
spec. An example of a blending practice at the plant is the NPD stockpiles usually
purchased by Zesa Munyati.
3. Steady feed – A steady feed to the plant avoids equipment choking, loss of production
hours and plant under utilization. Vibrio feeders are made use of. They help to achieve a
steady feed to the plant.

4.4.3 Plant Feeding

The plant as already stated above has coal stockpiled at the ROM at different loci depending on
where the coal is mined from. This also determines how the coal is fed into the plant. Long back
coal from the mines used to arrive at the plant using a series of WPC conveyors but they have
since been abandoned. The conveyors would join a system of conveyors at the plant from PC1 to
PC4 (PC for primary crusher) which fed the ROM jus above the vibrio feeders. Currently
though, haulage trucks are responsible for filling up the ROM and coal from 3Main and Chaba is
stockpiled jus above the 3 drop points. Currently on feeder number 2 is working and present the
first feed entry point to the plant. The feeders vibrate in the process drawing coal to fall into the
tunnel underneath the ROM. The coal is received by the conveyor belt, PC5. The conveyor belt
is fitted with a weight meter to determine the tonnage of the plant as it runs. A dust fan is also
fitted in the tunnel to extract all the dust from the coal. The second feed entry point is via the jaw
crusher. The jaw crusher processes coal from the open cast mine (JKL) thereby reducing its size
to about 100mm. This is dependent on the customer specifications and the gap of the jaws can be
adjusted accordingly to achieve a wide spectrum of products as is desired. From the crusher, the
coal passes a couple of conveyors where it finally joins the PC5 conveyor belts. From PC5, the
coal is deposited to PC6. There is an electromagnet that is fitted jus above the PC6 conveyor belt
to trap any metallic contamination as the coal passes the magnet. PC6 is also fitted with two dust
extraction units as well as a scalping screen and a crusher. All these are currently down at the
plant therefore the coal goes through the Shute to PC7. From PC7 to coal is deposited to WS26

56
(WS for wet screen). From WS26 it is fed to WS1. WS1 then directly feeds to the IFE Feeder
bunkers with a total capacity of about 900 tons. Currently only one bunker is operational and it is
bunker number 1. From below the bunker, the wet screening section operations begin.

57
4.4.4SCREENING

4.4.4.1 WET SCREENING

Fig 2.1 wet screen section flow sheet.

From the Scalping screen on PC6 through the rolls crusher (non operational currently) the coal is
collected in the PC7 conveyor belt which deposits its coal to WS26. WS26 connects to WS1 and
this signifies the start of the wet screening. WS1 empties its coal into the three feeder bunkers
(only one operational currently). The purpose of the bins is to provide a steady flow of coal to
the screens. Only one bunker (number 1) is operational currently. From the bunker the coal is
dropped via a Shute to the flood box. Here water from 28 cone (clean) and 48 cone (slimy) are
introduced into the IFE lines. There are three IFE lines, each with a triplet of screens making a
total of nine screens to minimize production hours lost due to the breakdown of any IFE line.
Currently however only line one is operational. The introduced of the water serves to force any
duffy coal adhering to the surfaces of the bigger coal grades. Adequate water should be added
with water from 48 cone (dirty) being introduced first followed by fresh water from 28 cone
(fresh water) introduced a few centimeters away. The purpose of the 28 cone water is to rinse the

58
coal that has been washed by the dirty 48 cone water. The right amount should be added so that
instead of trapping the duffy coal on the surfaces, the inadequate water might have the
undesirable effect of making the coal stick on the other grades’ surfaces thereby compromising
the separation.

Each IFE line has 3 decks, a top deck, middle deck and a bottom deck. The top deck is a double
screened deck with screen sizes of 30mm at the top and 10mm at the bottom. It has two products,
duff and peas. The duff being -10mm races down through the top deck to be collected at the
desliming screens. After desliming, the duff is collected on WS2 to WS2A for loading via the
wagons or it is collected via the WS11 conveyor to the NPD stockpile. The peas being -30mm
+10mm enter the top screen but not the bottom screen. The overflow of the bottom screen is
deposited to WS3. This conveyor is reversible and can ferry the peas to the loading wagons point
or if there aren’t any orders, empty into the WS21 belt to WS21A then to the peas stockpile for
storage. The peas can also be deposited to WS11 which deposits to the CP1A conveyor belt then
to the CP1 conveyor with empties at the NPD stockpile. The overflow of the top deck goes to the
middle deck. These are particles that are +30mm. The middle deck has only one screen, the
40mm screen and any material below 40mm any above 30mm (nuts), is collected on the WS4
conveyor belt below the screen. The belt is reversible and can take the nuts to the loading points
or to the NPD stockpile via WS11 to CP1A to CP1. The overflow of the middle deck is collected
on the bottom double deck. At the top of the deck is a 100mm screen. Below is a 50mm screen.
Small cobbles being +40mm but -50mm, go through both screens and are collected on WS5.
These are transferred to WS11 and ferried to the NPD stockpiles. The overflow of the 50mm
screen (large cobbles) is collected onto the WS7 conveyor belt. From the WS7 belt, it empties to
WS15 then 16 and finally 17 for loading. Both 16 and 17 are in the dry screen section. The
overflow of the 100mm screen (rounds) collects on WS8. From WS8 it is transferred to WS9
then to WS14 then 17A where it is deposited for loading. Belts 14 and 17A are in the dry screen
section.

4.4.4.2 DRY SCREENING

The dry screening section is largely for quality control. This is where most of the shale is
removed from the coal by experienced shale hand pickers. For the rounds, they enter the dry

59
screen section conveyor 14 then to 17A. Along the line of production, a couple of hand pickers
remove the shale from the rounds and place it into shale conveyor 1. The large cobbles enter via
15 then 16 then 17. Along the production line, there are three shale pickers which remove shale
from the conveyor belts to the shale conveyor. The rounds and large cobbles conveyors move
very slowly so as to allow the workers to efficiently remove all the waste material. WS17 has a
flopper gate such that if there are no wagons to load the large cobbles, the gate opens and feeds
to WS18. From WS18 the coal is transported to the secondary crusher (Schumer crusher) which
crushes the large cobbles into small cobbles. These collect on WS19 then WS20 then WS25 then
WS26 and finally WS1 which empties into the feeder bunkers.

4.4.4.3 FACTORS AFFECTING SCREEN EFFICIENCY

 Slope of the screen – the slope of the screen is important at it influences the residence
time of the particles. If the angle of slope is big, undersize material can even pass the
screen without being removed due to the reduced probability of interacting with the
apertures. The bigger the angle, the faster the particles will cascade through the screen
without being attended to. This reduces the efficiency of the screen
 Feed rate – the rate at which the coal is fed into the IFE lines is critical to the efficiency
of the screens. If the feed rate is high then the residence time of the particles will be low
and effective separation is thus compromised.
 Bed depth – The particles charged onto the screens should be a monolayer of particles
such that every particle is given an equal chance of interacting with the apertures of the
screen. The bigger the depth then the lower the efficiency as the probability of undersize
particles reporting in the oversize zone is increased.
 Screen Blinding - near size material can blind the screen and reduce the effective area for
separation of the screens. This in turn reduces the efficiency of the screens for separation.
 Damaged screens – damaged screens can lead to material reporting to the wrong product
collection zone.
 Moisture content – the amount of water needs to be balanced so as to avoid small
particles adhering to the bigger particles and reporting to the oversize zone along with the
small particles on their surfaces.

60
  Vibrations – the amount of vibration the particles are exposed to will increase or the
decrease the chances of a particle interacting with the screen apertures.
 Particle geometry – the geometry of the particles is also important in the efficiency of the
screens. An undersize material can report to the oversize zone due to the orientation of
the particle as it interacts with the screen apertures.

4.4.5 COAL GRADES AT THE CPP

There are six coal grades that are produced at the Coal Preparation plant. These are given below
along with their size specifications:

1. Duff – -10mm +0.5mm

2. Peas – -30mm +10mm
3. Nuts – -40mm +30mm
4. Small cobbles – -50mm +40mm
5. Large cobbles – -100mm +50mm
6. Rounds – -150mm +100mm

Coal fines are also produced at the plant thickener and these have a size range of ±0.5mm.

61
 4.4.6 WATER CIRCULATION SYSTEM

Fig 3.1 Coal Preparation plant water circulation system

The Coal Preparation plant is a water intensive plant and a steady supply of water to the plant as
well as water recycling mechanisms need to be in place. The steady supply of water is provided
from the Lwendulu dam. The water in the dam is from the Zesa cooling plants. The water is
pumped from Lwendulu dam to the Jacaranda dam. The Jacaranda dam is the plant’s reservoir
and is just a stone’s throw away from the plant. The dam has two pumps, pump one and pump
two, though currently only one of the pumps is functional. The pumps would normally pump the
water from the Jacaranda dam to the 28 sump and the 28 Cone with pump one pumping to the
sump and pump two to the 28 cone. Currently pumping to the 28 cone is down as the pump is not
functional. So the 28 cone is solely filled by water from the thickener. Any water that overflows
from the cone is redirected to the 28 sump below by an overflow pipe such that two delivery
pipes fill the sump (from Jacaranda and the overflow pipe). The water from the 28 cone is the

62
plant’s only source of fresh water. The water from 28 cone flows to the wet screen section by
gravity where it is used to wash the coal being screened. The water from the 28 sump is pumped
by a low level pump to the 48 sump. The water enters the sump via a launder. The water, being
“fresh” water serves to dilute the slurry water that is in the 48 sump. The sump has two
circulating pumps that provide a circulatory motion to the murky water to help agitate and mix it
evenly. Currently though only circulating pump 49 is operational and pump 48 is under
breakdown. After the slurry water from the sump has been diluted it is pumped to the 48 cone.
From the cone, some of the water flows to the wet screens to wash the coal while some flows by
gravity to the slurry tank. At the slurry tank there are two slurry pumps, though one is
operational currently. The main function of the pump is to pump water to the header tank. The
slurry overflow is channeled back to the 48sump. At the header tank the water flows to the
thickener due to gravity. The water first arrives at the floatation tank before it is channeled to the
thickener. At the floatation tank there is a floatation pump that pumps the feed water to the
second hydrocyclone. The hydrocyclone underflow goes through the dewatering screens and the
water seeps through to the dewatering under pan while the overflow collects on the tailings
conveyor and straight to the stockpile. The dewatering under pan water is then directed to the
thickener main launder. The hydrocyclone overflow is directed to the main launder and into the
thickener.

Before the slurry water from the 48 cone goes to the thickener, fresh water is introduced into the
system via a 4 inch pipe that cleans the piping to avoid pipe blockages due to the slurry water.
Another thing to note is that the water level in both cones should always be the same. This is
ensured by a balancing pipe that stretches from the 28 cone to the 48 cone. If the water level in
the 28 cone is lower, water moves from the 48 cone to the 28 cone. The flow of water is due to
the difference in water pressure between the two cones. Any water that is lost in the circulation
due to pipe leakages or cone overflows is redirected via a system of canals to a low level sump.
From the sump, the water is pumped to the 28 sump. This reduces the amount of water lost
within the system.

4.4.7 THICKENER
The thickener at the HCCL has a capacity of 3250m 3 and a diameter of 40m with a 2.7m dam
depth.

63
Fig 3.2 A diagrammatic representation of a typical thickener.

Fig 3.3 Water flow at the HCCL Thickener.

Dirty water from the plant collects in the 48 cone. The water flows by gravity to the slurry tank.
It is then pumped to the header tank from the slurry tank. The water then flows to the floatation
tank at the thickener via gravity. The feed water is then pumped to the hydrocyclone (number 2).
The overflow from the hydrocyclone collects on the thickener main launder. The underflow is
passed through the dewatering screens and excess water collects on the under pan. From the

64
under pan it is directed to the main launder. The flocculating agent is then added just before the
water enters the dam. The agent is added at a rate of 5”30 (5litres every 30 seconds). The water
then enters the main dam. The flocculation agent serves to help clarify the water by clumping the
fines together. This gives them weight and they settle at the bottom of the tank leaving clarified
water at the top. The clarified water overflows and collects in the thickener catch box. From the
catch box the water is pumped by the overflow pump to the 28 cone. Underflow slurry is pumped
to the hydrocyclone (number one). The overflow from the cyclone enters the main launder while
the underflow passes through the dewatering screens. Water from the dewatering screens collects
in the under pan then it is directed to the main launder back to the thickener. The underflow is
pumped to the slurry dams for ten minutes every two hours to manage the bed level of the
thickener.

4.4.7.1 PARAMETERS
There are a number of parameters that govern the operation of the thickener. These are namely
the bed level, thickener overflow specific gravity, thickener underflow specific gravity and the
traction drive amperage.

4.4.7.1.1 BED LEVEL

The bed level of the thickener is critical in the operation of the thickener. The maximum bed
level of the thickener is 225cm. The level of the thickener should never exceed or reach this
height. If this level is reached, it leads to the sliming of the dam. To maintain the bed level, the
thickener attendant increases the pumping time of the slurry to the dams as well as increasing the
flocculent dosage.

4.4.7.1.2 THICKENER UNDERFLOW

The specific gravity of the sludge that settles at the bottom of the dam is crucial in its operation.
It has been determined that the specific gravity of the underflow should never exceed or reach
117 as this will lead to the traction drive jamming underflow piping being blocked. To avoid that
occurring, the pumping time to the slurry dams is increased when the underflow density
approaches this figure. Moreover the flocculent dosage is reduced to reduce the number of fines
that settle at the bottom.

65
4.4.7.1.3 THICKENER OVERFLOW
The water that overflows at the tops of the dam should never exceed a specific gravity of 107.
Since this water is the one that is pumped to the 28 cone as the clarified water for re use, it is
important that is almost as clear as the thickener can clarify it. If the density of the overflow
water reaches this level then it will compromise the quality of the graded coal, especially the
peas. Moreover it leads to the loss of fine magnetite which is quite expensive since it also
supplies the heavy medium separation unit.

4.4.7.1.4 TRACTION DRIVE

The traction drive amperage should never reach or exceed 7.5 amperes. This will lead to the
traction drive jamming. All of this is dependent on the thickener underflow specific gravity.

66
 4.4.8 SLURRY DAMS
These are man-made dams that receives slurry from the thickener through a canal, they are
created so as to trap coal fines which are suspended in water. Currently HCCL has eight slurry
dams and only four of its dams are operational. These are dam 5, 6, 7 and 8. Slurry dams are
used for separating coal fines from water and for storing coal fines.

Slurry from the thickener is pumped to the slurry dams at a rate of once after every two hours.
Each pumping is done for a period of ten minutes. A canal is utilized to channel slurry to the
dams. The slurry passes through a screen that restricts large foreign particles to pass through
(thus plastics and containers). From the screen the slurry comes to where there are two gates one
for the sump way and the other for the bypass. A single slide gate is opened at a time. This is
archived by opening the particular gate with route required and closing the other. For normal
operations the sump way slide gate will be open and the bypass sliding gate is closed. Whereas
the bypass gate is opened and sump way gate is closed when sump is under cleaning or
renovations or pump is under repairs. The sump is a large concrete tank built on ground level
and it has two suction pipes mounted at the bottom of it.

Two suction pumps are connected on the other end of the suction pipes. These pumps draw
slurry from the sump and pump it to the slurry dams through a delivery pipe. However there is a
T junction connection on the delivery pipe just after the pump and both of its ends have valves.
One at the end of the T junction is for delivery to the dam, whereas the other returns water back
to the sump for agitation. Agitation is required in the sump, due to that slurry settles quickly in
the sump. Pumps are run one at a time, while the other is on standby. This is archived by
selecting particular pump to be running using a control switch. This control switch has three
positions of selection and these are pump 1, off and pump 2. However there is one pump
available, hence in case of a breakdown there is no standby pump and the bypass slide gate will
have to be opened. This allows the maintenance team to work on pump.

The upstream method is the lowest initial cost and most popular design for a raised tailings
embankment in low risk seismic areas. One of the reasons for this is mainly due to the minimal

67
amount of fill material required for initial construction and subsequent rising which normally
consists entirely of the coarse fraction of the tailings. Construction of an upstream designed
embankment starts with a starter dyke foundation. Pane stocks inlets are created at the area
which is of the lowest gradient and they are connected to a pane-stock concrete pipe which lies
below the dam, it runs from that point to the main canal.

The tailings are discharged from the top of the dam crest creating a beach and this is occurs by
natural segregation of coarse material settles closest to the spigot and the fines furthest away, this
creates a beach of coal fines that becomes the foundation for future embankment raises. Due to
this the dam slopes from the embankment (the area with the embankment being of higher
gradient than the rest of the dam). The water finds its way into the pane-stock inlet and it drops
into the pane-stock concrete pipe due to gravity. The pane-stock inlet is made from concrete
rings that are placed one on top of the other; these play a roll of filtering off the coal fines from
the water. The level of the dam rises from the dam wall to the pane-stock inlet. As the level of
the coal fine raises the pane-stock inlet is raised by adding a concrete rings. When the discharge
area is now level with the starter dyke (embankment rise), excavators are used to build an
embankment rise on top of the previous starter dyke.

However dams made from this method have a tendency of failing due to a static/transient load
induced liquefaction flow slide event. This is not surprising considering the low relative density
of the tailings and the potential for water mismanagement to generate high saturation of the
embankment and subsequently creating liquefaction induced flows of the tailings.

Water that drops in the pane-stock pipe gravitates to the main canal. This main canal receives
water from all slurry dams and delivers it to the clay pits. There are three clay pits and the water
from the main canal flows from pit to pit. At the exit of the last clay pit there is a concrete slab
where samples taken for tests of checking acid contented this is done at the main lab. Water in
the last clay pit is said to be neutral (pH 7).

68
5.0 RESEARCH WORK CONDUCTED

INVESTIGATING THE INDEPENDENT FACTORS THAT AFFECT JIG PERFORMANCE TOWARDS

OPTIMIZING JIG PERFORMANCE AND THE BENEFICIATION OF THE TAILINGS WASTE DUMP.

5.1 Introduction
The Hwange Colliery Company Limited Jig and Floatation Plant was initially built to process the
coking coal fines dump near the Coal Processing Plant in a joint venture with the South Mining
Company. The plant initially had a jig plant coupled with two floatation cells. The objective of
the plant was to increase the coking coal reserves for the HCCL battery and the HCGC battery
by blending the processed fines dump with the product from the jigs plant so as to increase the
coking coal which was in great demand. The plant ended up operating as the company’s sole
coal washing plant after the Heavy medium separation plant at the Coal Preparation Plant broke
down. Thus it currently is responsible for the washing of all stocks that the company needs
washed. Primarily though its main purpose is the washing of coking coal (duff and peas). With
the floatation cells having been by-passed due to lack of repair, the company isn’t processing
fines as initially projected but rather coking coal with an ash conformity of 10% or less. This
projects then looks at the efficiency of the plant in producing a coal product of that ash content
while producing a tailings waste stockpile that has an ash content greater than 50%, all this at a
recovery percentage of eighty five. Factors that affect the plant from achieving its objectives are
then investigated.

Problem Background
The tailings of the jig plant have, of late been presenting a problem as to where they should be
stockpiled. Moving them to be disposed of as waste presents the company with unnecessary
transportation costs for a product which won’t benefit the company. Taking into account the fact
that the coal is brought to the plant from the mine which first transports it to Chaba then to the
plant, an issue of double handling then becomes a huge problem. A profitable solution has to be
sort. A solution that benefits the company rather than be an expense to the company. Considering
the product produced, there have been queries as to the consistency of the Jig plant in producing
quality product on a daily basis. Taking into consideration the fact that the coal belt is not a
constant in terms of its properties, then this inconsistency in the plant’s processing abilities

69
presents a huge problem. Taking into account the fact that the desired end product is a constant
i.e. the product ash content should always be less than 10%, it is paramount that there be an
investigation into the factors that may affect the jig performance with the optimization of plant
recovery in mind.

Problem Statement
The plant is highly inconsistent in terms of performance and the double handling of coal
(disposal of tailings) is a serious issue that needs attention.

Aim
To optimize plant recovery as well explore the beneficiation of the tailings waste as HPS for
supply to the ZPC Hwange power generation plant rather than being disposed.

Objectives
To produce coking coal with the below specifications on a regular basis:

 Product ash of less than 10%

 Plant recovery of 85%
 Waste ash of at least 50%
 Minimize waste generated so than no clean coal reports to the waste dump.

Assumptions
 Bed levels are not set at their optimum.
 Feed particles fed to the plant are -30mm +0.5mm
 Number of strokes in the jig are not at their optimum.
 The jig compartments are overloaded with a wide range of particles.
 JKL coal is the only coal being processed at the plant.

70
Justification
The data provided by the Coal Global Report and the KPI data for the month of August show a
developing trend at the Jigs and Floatation plant. There has been a large amount of downtime
lately which has led to a sharp decline in the amount of coal processed. This, coupled with a
sudden decrease in the ash content of the tailings are cause for concern as this implies that, of the
little coal that has been processed for August, some of it has been lost as tailings to further
compound the losses experienced. Thus, if the waste tailings are of adequate or at least close to
the quality of power coal, they can be blended and sold as power coal to minimize costs.

Methodology
In carrying out this research, data from the Coal Global report for the Jigs and Floatation plant as
well as KPI for the Jigs and Floatation plant for the month of August was analyzed and then
compared with the key parameters that govern the operation of the Jig and Floatation plant.
These parameters include:

 The feed, product and waste ash content.

 Plant recovery
 Feed particle size.

71
Research findings
Table 5.1 Jig Performance Analysis

Date Jig Feed Jig Jig Waste Jig Size Size (duff)
Ash Product Ash Recovery (Peas)
Ash
3 Aug 15 10 17.1 29.6 5.9 94.1
10 Aug 11.3 8.6 33.6 89.4 47.8 52.2
11 Aug 12.5 9.2 45.6 90.90 46.8 53.2
12 Aug 12.3 9.2 50.7 92.5 43.3 56.7
13 Aug 10.8 10 47.4 97.9 45 55
14 Aug 13.2 9.3 35.1 84.7 39.1 60.9
15 Aug 14.2 8.0 37.7 79.1 63.2 36.8
17 Aug 11 7.7 34.4 87.8 49.5 50.5
18 Aug 11.7 8.3 42 90.1 35.7 64.3
19 Aug 12.6 9.4 27 81.8 61.9 38.1
20 Aug 13 8.3 29.6 77.9 47 53
21 Aug 12 7.5 44.7 87.8 51.4 48.6
22 Aug 14.1 8.5 36.2 79.8 82.1 17.9
25 Aug 11.5 8.1 35.2 87.6 76.4 23.6
Average 12.5 8.7 36.9 82.6 50.35
49.65
Minimum 10.8 7.5 17.1 29.6 5.9 17.9
Maximum 15 10 50.7 97.9 82.1 94.1

72
 120

100

80

60

40

20

0
28-Jul 2-Aug 7-Aug 12-Aug 17-Aug 22-Aug 27-Aug

Jig Feed Ash Jig Product Ash Jig Waste Ash

Jig Recovery Size (Peas) Size (duff)

Fig 5.1 Jig Performance Analysis

The independent factors affecting jig performance that have been of notable interest in this
research are the following: the feed ash content, the size range fed (ratio of blending) and the
downtime of the plant. The data from the Coal Global Report and the KPI data for the month of
August has been used to determine these for the month and graphs plotted to investigate their
relation, if any to the plant recovery and the product ash. A trend in the waste ash is also
analyzed solely from Table 5.1 and conclusions reached as to the suitability of the waste being
used as power coal to minimize transport costs when being handled simply as waste for disposal.
This data is also inter-related to the plant recovery to determine the effect, if any, of the ash
content of the waste product on the plant recovery.

Comments

73
 1. Feed Ash

The feed ash data from the Coal Global Report has been plotted graphical and its variance as
the progresses compared with that of the plant recovery and the product ash.

a) Feed Ash vs Recovery – notably from the comparison of the two graphs in Fig 5.1in
hindsight, there is really no correlation between the two. But a certain trend begins to
develop if closer detail is given to the performance of the plant on a particular day in
comparison with the next day the plant is run. An example would be (15 and 17) and (22
and 25). From these two scenarios it can be clearly seen that the plant recovery increases
with a decrease in the feed ash percentage. This vindicates the limitations of the jig plant
in dealing with feeds of a high ash content and underlines the need for the plant to be
supplied with coal of 15% and below for an economic recovery.
b) Feed Ash vs Product Ash – save for a few discrepancies here and there, it is clear from
fig 5.1 that there is an existing relationship between the feed ash content and the product
ash content. From the comparisons, it is apparent that an increase in the feed ash will
result in a subsequent increase in the product ash content. This highlights the effect of the
feed ash on the performance of the jig plant. The performance of the plant in relation to
the final product’s ash content is dependent on the feed ash content of the feed fed that
particular day.
2. Downtime
The Jig and floatation plant was bedeviled by various plant stops that resulted in
significant amounts of production hours lost for the month of August. Below is a table
showing the downtime experienced by the plant for the days the plant managed to run.

Table 5.2 Downtime for the month of August

Date Downtime
3 Aug 14.7
10 Aug 18.8
11 Aug 17.8
12 Aug 19.9
13 Aug 19.3

74
14 Aug 18.9
15 Aug 20.8
17 Aug 14.4
18 Aug 17.5
19 Aug 18.7
20 Aug 18.5
21 Aug 13.8
22 Aug 22.5
25 Aug 16.4
Average 18
Minimum 13.8
Maximum 22.5
a) Downtime vs Product Ash – The graph below shows the relation, if any, between the
downtime and the product ash. From the graph there isn’t really any relation between the
two properties. However analysis of the peaks of the graph will show a trend between the
two. Analysis of the peaks will show that the if there is more down time, the product ash
will correspondingly be high as well. The explanation could be that since the plant would
have been run for a shorter time, would not have reached its normalisation threshold. This
is usually achieved after a couple of hours running and the plant lab analyst doing quality
analysis that will determine factors such as the bed level and feed rate for the type of coal

75
 being attended to that particular day.

25
Downtime vs Product Ash

20

15

10

0
28-Jul 2-Aug 7-Aug 12-Aug 17-Aug 22-Aug 27-Aug

Downtime Jig Product Ash

Fig 5.2 Graph showing the relationship between downtime and the product ash.
b) Downtime vs Recovery - The graph below shows the relation, if any, between the
downtime and the recovery. From the graph, in hindsight there really isn’t any
relationship between the two however analyzing the peaks and dips of the graphs we can
observe a trend of sorts. A decrease in the downtime of the plant results in an increase in
the plant recovery which logically makes sense. The less time the plant spends lying idle,
the more valuable material is recovered!

76
 Downtime vs Recovery
120

100

80

60

40

20

0
28-Jul 2-Aug 7-Aug 12-Aug 17-Aug 22-Aug 27-Aug

Downtime Jig Recovery

Fig 5.3 Graph showing the relationship between downtime and the recovery.
3. Feed Size
The plant receives both duff (-10mm) and peas (-30mm +10mm) from Chaba for
processing these days. Rarely is 3Main coal being processed at the plant because of its
high ash content so the plant handles JKL coal. The peas and duff are usually run
simultaneously, blended in no respective blending ratio by the loader that feeds the vibrio
feeder at the mouth of the plant. This then leads to an inconsistency of results but
however it is a necessary evil as a compromise of sorts is reached when blending is done.
However the perfect blending ratio for optimizing performance has to be determined so
as to increase the productivity of the plant. Profitability afterall is the primary goal of the
company and product consistency is as close a guarantee to customers’ confidence as it is
to assured profits.
From Table 5.1, it can be seen that the highest recovery is achieved on the 13th of August
at a blending ratio of the peas:duff of 45:55 or put simply 1:1.22. The company should try
to operate within that range of limitation. Before this can be taken into account as the

77
truth however, we investigate if there really is any relationship between feed size and the
recovery as well as the product ash.
a) Feed size vs Product Ash – from the graph below, there really isn’t any relationship
between the feed size and the product ash. As the blending ratios fluctuate with duff
beginning as the most frequent until it becomes the least frequent coal grade, there
isnt any significant change in the product ash showing the independency of the
parameter to feed size. This therefore means that the duff and peas can be mixed
anyhow without compromising the product ash content that is required (10% and
below).

Feed Size vs Product ash

100
90
80
70
60
50
40
30
20
10
0
28-Jul 2-Aug 7-Aug 12-Aug 17-Aug 22-Aug 27-Aug

Jig Product Ash Size (Peas) Size (duff)

Fig 5.4 Graph showing the relationship between feed size and the product ash

b) Feed Size vs Recovery – from the graph below it is apparent that as the blending
ratios differ, the recovery is also affected as a result. A couple of recovery peaks
depict the corresponding blending ratio for the peas and duff to achieve that particular
set value. The highest recovery of the plant (97.9%) is obtained when the blending
ratio is 1:1.2 (peas to duff). An almost 1:1 mixing ratio on the 17th of August yields a
recovery of 87.8 which is still well above the 85% product recovery stipulation of the
plant. The graph also gives information as to what blending ratios should not be
attempted as they reduce the plant recovery to below the required 85%.

78
 Feed Size vs Recovery
120

100

80

60

40

20

0
28-Jul 2-Aug 7-Aug 12-Aug 17-Aug 22-Aug 27-Aug

Jig Recovery Size (Peas) Size (duff)

Fig 5.5 Graph showing the relationship between feed size and the recovery.

Waste

When analyzing the waste data from table 5.1, there is a discontinuity in the data that does not
truly give a constant ash content of the waste. Some days the ash content is as low as 17.1 while
in some days as high as 50.7. thus the data does not give us a concrete and finally answer as to
how to deal with the waste. The suggestion would therefore be to deal with the waste as per its
daily generation. If the waste is around 30% and below, then the waste can be blended with HPS
(Hwange Power Coal) and sold to ZPC Hwange rather than be disposed off. Waste disposals of
about 50% and above should be considered as waste and treated as suc unfortunately. However
anything between 30-50% shows that clean coal is being washed to the waste as the plant
requires a waste ash content of 50% and above. In such instances, when there is no coal at the
ROM, such waste should be run, if it is significant in quantity and any lost clean coal thus
recovered.

79
 Waste ash vs Recovery
120

100

80

60

40

20

0
28-Jul 2-Aug 7-Aug 12-Aug 17-Aug 22-Aug 27-Aug

Jig Recovery Jig Waste Ash

Fig 5.6 Graph showing the relationship between the waste ash and the recovery.

From the graph it is apparent that as the waste ash content increases, the recovery of the plant
also increases, and when it decreases the recovery also declines which means in that regard, the
jig plant is operating as is required getting rid of the waste while increasing the recovery.

Other factors that affect Jig Performance

 Bed level – the jig bed level is crucial to the operation of the jig plant. As already
illustrated in section [4.3 JIGS AND FLOATATION PLANT], the level of the bed can
determine whether clean coal is lost as waste or waste reports to the products side and
contaminate the product.
 Number of strokes – the number of pulsations (and their length) from the introduction of
compressed air allows for proper stratification of the bed as well as the size of material it
will be able to handle.
 Feed rate – the rate at which the coal is fed into the jig beds is important depending on
the size of material to be processed and should be adjusted accordingly.
 Amount of water – the amount of water fed into the plant, for transporting the coal as
well as acting as a medium are important for the performance of the jig.

All these factors are dependent on the plant attendants and are subject to change at any given
time, usually as a result of the quality analysis of the product, waste and feed at the plant
laboratory.

80
Conclusion
The three questions that need to be asked at the end of this investigation are:

 Does the feed ash affect jig performance and how?

 Does the feed size affect jig performance and how?
 Does downtime affect jig performance and how?
 Can the tailings waste at the Jigs plant be used for beneficiation by selling the waste as
HPS?

From the Coal Global Report and the KPI data for August, we can conclude the following:

1) The feed size affects the performance of the jig plant and care has to be taken during the
blending process so as to optimize plant performance. A blending ratio of 1:1.22 duff to
peas achieves the highest recovery.
2) From the Coal global data and the KPI data we can safely conclude that the feed ash
affects the plant performance. The higher the feed ash is, the higher product ash will be
and thus shows the limitations of the jig plant and its narrow range of operation in terms
of the feed ash that it can handle while meeting its required product specifications.
3) Downtime data in relation to plant performance then depends on the definition of the
clarity of the term “performance”. From the data provided, it is quite inconclusive how
this factor affects performance but the more time spent with the plant lying idle, the more
the running costs there will be and the “economic” performance of the plant is
compromised.
4) The waste generated is inconsistent in terms of its ash content thus we cannot definitively
reach a conclusion on any action that can and needs to be taken.

Recommendations

 Waste at the plant should be dealt with as per daily generation and regular monitoring of
the waste ash content helps to monitor the recovery of the plant.
 The plant should operate within the optimum blending process, which in this
investigation is determined as 1:1.22 peas to duff which has a recovery of 97.9%.
 The company should operate or at least try to operate within the optimum design
specifications of the plant. By-passing of the floatation cells is a blunder that is costly
than when operational. (no processing of coal fines as this was the initial plant objective)
 Set performance targets and their corresponding controls should be clearly set out for the
operators and attendants as a guiding principle.
 The plant should only process coal from open cast as it isn’t very efficient in the
processing of coking coal with ash levels close to and higher than 15%. That is its major
limitation and attention should be given to that avoid compromising it performance

81
 Regular maintenance checks could help alleviate the problem of downtime rather than
having plant service on Thursdays only. Though this is done to reduce the production
time that will be lost, from the onset of things it is clear that this has actually led to more
downtime with conveyor belts regularly undergoing mechanical failure in the process
compromising the quality of the product due to spillages etc.

82
6.0 Hwange Colliery Company Limited Training Program
Chaba Plant A and Plant B 1 month
The student should know;
 Basic flow sheet
 Operation of dry screens
Dry Screen  Quality control practices
 Production capacity Production foreman
 Standard operation procedures
 Dry screen products
Plant Metallurgist
 Safety, Health and
Environmental issues
 Emergency procedures

Washing Plant Wet Screen plant Production foreman 1 month

 Basic flow sheet
 Operation of wet screens
 Quality control practices Plant Metallurgist
 Production capacity
 Standard operation
procedures
 Dry screen products
 Safety, Health and
Environmental issues
 Emergency procedures

Jig and Flotation

 Stockpile and Jig pits

handling
 Reagent handling and use
 Knowledge of all products
 Material flow sheet
 Operation of Jigs
 Operation of Flotation cells
 Slime beneficiation plant
 Control systems in place
 Pumping system in place
 Standard operation procedures
 Safety, Health and
Environmental issues
Waste Thickener and Water Management 2 weeks
Management
 Density control/tailings

83
 disposal
 Equipment design and Production foreman
capacity
 Flocculation and bed level
control
 Water balance of the Wet
Screening plant
 Standard procedures
 Safety, Health and
Environmental issues
 Emergency procedures
Slurry Dams and Waste
Management Plant Metallurgist
2 weeks
 Slurry disposal system
 Type of the Slurry dams
 Effluent water management
 Overall plant water balance
 Waste dump rehabilitation
 Safety, Health and
Environmental issues
 Emergency procedures

Product Handling Basic product handling 1 month

 Stockpile management
 Wagon loading
 Standard procedures
 Safety, Health and
Environment issues Production foreman
 Emergency procedures

Rail Traffic Plant Metallurgist

 Rail Transport system
 Operation of Locomotives
 Logistics of all rail traffic

84