WAGON TIPPLER

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 Presentation Outline
 Introduction

 Railway Siding

 Bauxite Handling Plant

Coal Handling Plant

Critical Equipment – Wagon Tippler

 Hammer Mill Plant 2

 Process Flow of Plant

Mines Alumina Tippler

Coal 10,00,000 MT/Annum Bauxite
21,86,000 MT/Annum
Steam &
Boiler and Power
Alumina Plant
Co Generation
Alumina

Reduction Plant
Final Primary Metal
Product
Marketing Fabrication Plant

Customer
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 INTRODUCTION
 Raw materials - bauxite, coal, caustic,
furnace oil, C.P coke comes through
railway siding.

Organization structure of Department

Alumina Tippler & H/Mill

Railway siding Bauxite Coal Hammer Mill

Handling Plant handling Plant

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 INTRODUCTION
The overall functioning of Alumina
Tippler can be broadly divided in to 4 major Sections :
( A) Shunting & Weighment

( Railway section )

(B) Bauxite Unloading, Screening & Primary

Crushing ( Bauxite Handling Plant)

(C) Coal Unloading, Screening & Primary

Crushing ( Coal Handling Plant)

(D) Bauxite Screening, Secondary

Crushing & Stockpiling

( Hammer Mill area)

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 Railway Siding
Major equipments in Railway siding
 04 nos Diesel Locomotive SAN make 400 HP
 11.5 KM Railway Track
 01 no In-Motion weigh bridge
 Raw materials - coal ,bauxite

 1 rake = 59 wagons

 Weighing of wagons/raw materials

 Speed of wagons: 6-7 km/hr

 7 hours free time allotted by railway for rake unloading.

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 Working of Railway Siding

 Receiving of different Raw materials in

rakes thru Indian Railways (1 rake = 59

wagons, 3850 Tons)

 Air releasing of rakes/Wagons

 Part shunting of Wagons 10/12 wagons per

lot thru Hindalco 400 HP D/Loco

 Weighing of wagons/raw materials thru

in motion Weighing scale for gross weight

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 Railway Siding
 Placement of Different material Wagons at

different unloading station

 Shunting of empty wagons to drawn out

line by weighing thru in motion weighing

scale for tare weight.

 Final D/Out of empty wagons for rake formation

 7 hours allotted by railway for rake unloading

process.

The demurrage is charged

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@ Rs 8850 per Hour per Rake.
Wagon Tippler
Capacity 600 TPH
Reclaim #4
Hopper Hopper
BC1142
AF AF

BC11AY0002
1
BC11816

Reclaim #1
BC11AY0017
VGF BC11AY0016 BC1007

BC11AY0012

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BC11AY0015 BC1001

BC11AY0019

BC11AY0051
D/Gate & Chute
BC Belt Conveyor
Cone Crusher

Stock Pile/ Reclaim BC11AY0053 BC11AY0054

AF Apron Feeder
VGF Vibrating Grizzly Feeder
Spreader Conveyor
Reclaim #2 Reclaim #3 Made by KKSingh
Bauxite Handling Plant & Its Major Equipment
Wagon tippler 82.5 Ton 1 No.

Hopper 150 Ton 2 nos.

Apron Feeder 350 TPH 2 nos.

Belt Conveyor over size

(+ 75 to 350 mm) 4 nos.

VGF 250 TPH 1 no.

Cone Crusher 150 & 300 TPH

Conveyor belt Under size (-75 mm) 14 nos.

Stock 10
Wagon Tippler Plant Capacity =600 TPH
At Boiler & Cogen plant
requirement of coal is
around 2800 MT/Day.
BMS Impactor
Aprox 10,00,000 MT
VGF
Coal /Annum
3 Way Gate

Screen Screen

Stock Pile
+25mm -75
mm
Stock Pile
- 25 mm & +75 11
mm
 Coal Handling Plant & Its Major Equipment
Wagon tippler 82.5 Ton 1 No.
Hopper 150 Ton 2 nos.

Apron Feeder 250 TPH 2 nos.

Belt Conveyor over size

(+ 100 to 500 mm) 4 nos.

VGF 250 TPH 1 no.

Impactor @ 300 TPH

Conveyor belt Under size (-100 mm) 08 nos.

Vibrating Screen 250 TPH 2 nos.

Stock 12
Specifications of Wagon Tippler

Name Rotary rail car dumper/1135

Year of installation 1967

Manufacturer Heyl & Patterson (USA)

Capacity/speed 82. 5 MT/9 - 10 wagons per hr

Material handled Bauxite

Clamping mechanism Hydraulic cylinder

Hydraulic oil pressure 300 psi

Drive motor power/speed 50 HP/1000 rpm

Motor type 415V, 50Hz

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Working of Wagon Tippler
(B) Unloading & Crushing
• Weighed wagons are placed on WAGON TIPPLER
(This equipment unloads the Box N (open on top)
wagon by tippling to 160 deg rotation) for unloading
of materials
• The Wagon Tippler unloads 8 –9 wagons / Hour into
an underground 150 Ton capacity hopper. The
Bauxite is retrieved from the hopper at @ 550 TPH by
2 nos Apron Feeder, conveyed and Crushed
From (-) 350mm to (-) 75mm size as per customer
requirement.

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 Working of Wagon Tippler

Hydraulic unit

Hydraulic Cylinder & pipe line 15

Hydraulic Jacks
Working of Wagon Tippler

Main drive unit End drive unit

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 Hopper and Apron Feeder
 Materials unloaded to hopper

Conical in shape

Materials dropped in zig-zag

fashion to reduce the direct
impact load on Apron Feeder.

 Apron Feeder is made of Mn

steel
Properties: rubbing
life

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 Apron Feeder
 Apron Feeders are usually installed under a hopper or bin

 Apron feeder machines can be found in mining operations

 USED FOR EXTRACTING MATERIAL FROM STORAGE HOPPER

 DELIVERING IT AT CONTROLLED RATE TO THE DOWN-STREAM CONVEYOR

 OPTIMAL OVERLAPPING OF THE PANS IS PROVIDED SO THAT THERE

IS NO LEAKAGE OF MATERIAL FROM THE FEEDER.

 THE FEEDER HAS DESIGNED TO WITHSTAND IMPACT LOAD

RESULTING FROM LARGE SIZED LUMPS FALLING INTO THE HOPPER.

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 Apron Feeder
Working principle of Apron Feeder – VFD (variable
frequency drives) where speed of motor is varied
that helps:
 To optimize the feed rate
Frequency is set depending upon the size of
bauxite and coal fed.

Size Freq.

Fine 50%

5-6 inch 65%

13 inch 80%

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 Belt Conveyor
• Designed according to lump size.
• Made of rubber on nylon.
• Nylon ply provides strengthening and Rubber
gives cushioning effect .

Top Middle Bottom Belt Grade

layer layer layer
(Rubbe (Nylon (Rubber)
r) ply)
Bauxit 7 5 ply 4 mm M 24 (High Tensile
e& mm strength, superior in
Coal abrasion & cut resistance

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Belt Conveyor accessories
Types of pulleys attached to belt conveyor:
Head pulley
Snub pulley
Bend pulley
Tail pulley
Rollers attached:
Transaction roller
Impact roller
 Troughing roller
 Return roller
 Self aligned Roller
Safety attachment
Zero Speed switch
Pull cord switch
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 VGF (Vibrating Grizzly Feeder)

 vibrating grizzly is used to separate under size feed material prior to

the primary crushing.

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 Bauxite Crushing Unit
After VGF, oversized materials are passed to crushing
unit.
Feed plate helps distribution of material uniformly before
sending to crushing unit.
Cone crusher breaks the material by squeezing action
provided by eccentrically gyrating spindle.
Reduction of bauxite is from 8-10 inches to 3-4 inches.

Material Crushing Unit Input Out put

Bauxite Cone crusher 300 to 350 - 75 mm

mm
Coal Impactor 500 mm -100 mm

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Cone Crusher
Bauxite crushing
350 mm to -75 mm

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 Impact Crusher (Coal Impactor)
The material to be reduced is feed into hopper from which, it
falls directly in to the center of impactor impeller rotating at
high speed. The material is then uniformly jlug outwards by
centrifugal force. The rotating speed of the impeller assembly
along with the precision speed and angles outwards and
forwards against the stationary. Other flying particles. Each
impact reduces the material further. The plates are position at
sufficient distance from the rotating impeller to allow free
body impacting. The resulting fragmented cubical product is
discharged by gravity. Output gradation within limits can be
controlled by varying these two factors (1) impeller speed (2)
the feed material characteristic. The impactor gives superior
cubical shape product with excellent gradation at reduced
horse power with low maintenance cost.
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 Impact Crusher (Impactor)

Impactor for Coal crushing

500 mm to -100 mm

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 Vibrating Screen for Coal
 Screening is an important operation in
mineral dressing for the preparation of
the feed material to the next process.

 Types and Sizes:

Screen is in Single, Double and Triple
deck Vibrating screen with size of the
deck from 600 mm, 900 mm, 1200 mm
and 1500 mm width.

 Capacity: Capacity of the screening

machine is variable depending on the
following factors,
Throughput.
Bulk density of the material.
Mesh size of the separation.
Particle size distribution of the feed.
Moisture content.
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 Stock
The -3 inch (-75 mm) sized
Bauxite material moves to
stock through conveyor belt
after Screening & Crushing.
1 month Bauxite stock
165000 MT is necessary for
smooth functioning of plant.

The -4 inch (- 100 mm) sized

Coal material moves to stock
through conveyor belt after
Screening & Crushing.
1 month Coal stock 105000
MT is necessary for smooth
functioning of plant.
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 Hammer Mill
RAW MATERIAL BAUXITE
SECONDARY CRUSHING
FROM -75 TO -12 MM

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Line diagram of Bxt stock pile for H Mill Secondary crushing

Ball Mill 1 BC-1008 & 1109

Hammer Mill
#1&2 Reclaim # 1
Ball Mill 2
Capacity 50,000 Ton
Ball Mill 3
BC-19 & 53

Hammer Mill Reclaim # 2 New

Ball Mill 4 #3&4 Capacity 50,000 Ton Stock
Ball Mill 7 Pile
BC-51 & 54
Ball Mill 5 Hammer Mill Capacity
#5&6 Reclaim # 3 75,000 ton
Ball Mill 6 Capacity 50,000 Ton

BC-1002
Hammer Mill
Ball Mill 8 # 7 Reclaim # 4 30
Capacity 20,000 Ton
There are Four Hammer Mill circuits :-

Hammer Mill # 1 & 2 : 110 & 70 TPH

Hammer Mill # 3 & 4 : 110 TPH

Hammer Mill # 5 & 6 : 150 TPH

Hammer Mill # 7 : 110 TPH

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 #1 #2 #3 #4 #5 #6 #7
Capacity 100 70 110 110 150 150 110
(Running)
TPH
Motor H.P. 150 150 180 150 270 270 150
No. of 27 78 45 27 80 80 21
Hammer
s
No. of 15-17 12- 13 15- 64 64 36
Cage 14 17
Bars
Screen Vibra Fix Vibr Vibr Vibr Vibr Vibr
Type ting ed ating ating ating ating ating
Day Bin 470 610 1200 1200 470 - -
capacity
Tons
Hammer 5 5 14 5 16 16 5
Weight(Kgs
.)
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 Equipments in Hammer Mill
• Reclaim & Emergency feeder
• Hammer Mill Feed Conveyor
• Magnet & Metal detector on Conveyor
• Vibrating Screen
• Hammer Mills
• Hammer Mill discharge Conveyor
• Sump Pumps in Tunnel
• Dust Collector (Bag Filters)
• Weight-o-meter on Hammer mills
Discharge Conveyor
• Air Blasters

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Hammer mill
Hammers are mounted
on rotating shaft that
swing on the ends of the
cross .
Material fed through
hopper gets impacted
that gets shredded &
expelled through screens
in the drum of a selected
size.
Material finally gets
crushed to 0.5 inch size.

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Thank You