6 WEEKS REPORT - 03

INDEX NO - 200803T
NAME - V.Anoshan
COMPANY - Bogala Graphite Lanka PLC SUBMIT
DATE - 09/04/2024
Work done during the third 6 week period
During the past 6 weeks, I had the valuable opportunity to work at the Bogala Graphite Mining Lanka PLC
processing plant. This report will provide a comprehensive overview of my experiences and insights gained
while working in various sections of the processing plant. The processing plant is a complex facility
comprising several units, each playing a crucial role in the overall graphite processing operations. The
sections covered in this report include the Trommel Plant, Froth Flotation Plant, Dewatering System, Ball
Mill, K&B Plant, Dispersion Plant, and Laboratory.

Trommel Plant
The Trommel Plant serves as a vital component in the graphite processing operations, specifically focusing
on particle size separation. This section involves key stages such as input handling, size reduction,
Trommel sieve separation, hand sorting, and output handling. The Trommel Plant plays a critical role in
efficiently separating graphite particles into different sizes, contributing to the overall processing
efficiency.

Last week, I worked at the Trommel Plant, an integral part of our graphite processing operations. The
operation of the Trommel Plant involves several key stages.

Input Handling

Graphite output from underground wagons is initially separated based on color tags. These sorted
graphite pieces are then fed into a vibrated bin, which allows for controlled output.

Size Reduction

The graphite particles undergo size reduction using a jaw crusher. Different sizes of plates can be used to
adjust the output particle size according to requirements. Once crushed, the graphite is transferred to the
next stage via a conveyor belt and bucket elevator.

Jaw crusher Plates, used to jaw crusher output Bucket elevator

Trommel Sieve Separation

The crushed graphite is then fed into a Trommel, which is essentially a cylindrical drum-shaped mesh
screen. As the drum rotates, smaller particles pass through the mesh screens, while larger particles
continue along the drum until they exit at the other end. This process effectively separates the graphite
into three different sizes of particles

 Tub Dust - Particles less than 25mm

 2 OL - Particles between 25mm and 35mm
 1 OL - Particles greater than 35mm

Trommel plant Trommel output Bins

Output Handling

The Tub Dust and 2 OL graphite particles are transferred to the Froth Flotation and K&B plants based on
specific requirements. Meanwhile, the 1 OL graphite is directed to the hand sorting section.

Hand sorting Hand sorting output collected in big bags

Hand Sorting

At the hand sorting section, operators meticulously separate the 1 OL graphite into four sections based
on graphite percentage.

 99-97%
 92-90%
 65-60%
 Stone %
The Trommel Plant plays a critical role in ensuring the efficient separation of graphite particles,
contributing to the overall quality and processing efficiency of our operations.
Floatation plant
The primary objective of this plant is to separate graphite particles from the gangue and enhance the
purity of the graphite concentrate. The process encompasses four key stages grinding, froth flotation,
dewatering, and drying.

Grinding

This initial step involves crushing and grinding the graphite to achieve improved liberation of the particles.
The plant employs a combination of a ball mill and two vertical mills to achieve this. The reduction in
particle size facilitates the exposure of graphite particles for subsequent flotation.

The grinding process involves both a wet ball mill mechanism and vertical mills. The ball mill utilizes steel
balls of varying sizes to reduce particle size up to 400 microns, while the vertical mills further refine the
particles to sizes ranging from 100 to 200 microns, using small ceramics balls as grinding material.

Additionally, spiral classification is employed to separate fine and larger particles, ensuring the desired
purity and quality of the graphite concentrate.

Vertical mill Ball mill Spiral classifier

Ceramics balls Steel ball

Froth Flotation

In this crucial process, air bubbles are introduced into a conditioned slurry, selectively attaching to
hydrophobic graphite particles while leaving hydrophilic impurities behind. This selective attachment
forms a froth on the surface of the flotation cell. Various units, including Rougher, Scavenger, and cleaning
units, are utilized to separate and extract the graphite particles from the froth. The addition of EKOFOL
aids in the selective attachment of graphite particles to the air bubbles.

Dewatering

Following flotation, the resulting graphite slurry contains excess water, which is removed through
centrifugation. This process applies centrifugal forces to separate water from the graphite solids,
facilitating the elimination of excess moisture.

Drying

To further reduce moisture content, a triplex dryer is employed to ensure the collected graphite
concentrate is thoroughly dried.
Dewatering System of Flotation Plant
I worked at the Dewatering System maintenance work of the Flotation Plant, a critical component in the
graphite processing process. This system plays a vital role in separating water from the graphite slurry,
ensuring the production of high-quality graphite concentrate.

The dewatering system employs two types of centrifuges: the Bag Lifting Centrifuge and the Bottom
Discharge Centrifuge. The operation of the dewatering system involves several key mechanisms

Feeding

The graphite slurry, obtained from the aggregation tank, is fed into the centrifuge bowl through the top
inlet. This process is typically automated, triggered when the slurry level in the tank reaches a
predetermined point. A double diaphragm pump is utilized to ensure a consistent and controlled feed of
the graphite slurry into the dewatering machine.

Spinning

Once the graphite slurry is introduced into the centrifuge bowl, the machine is set in motion, and the
bowl's rotation speed gradually increases, reaching up to 900 RPM. This rapid rotation generates
centrifugal force, causing the heavier solid particles to migrate towards the outer wall of the centrifuge
bowl. Simultaneously, the filter cloth allows water to pass through while retaining the solid particles. The
separated water, or filtrate, is discharged through the filtrate outlet for further dewatering.

Scraping

During the centrifugation process, the solid particles accumulate on the inner walls of the bowl, forming
a compact cake. In the bottom discharge centrifuge machine, a scraping mechanism is employed to gently
loosen the cake from the bowl walls. This scraping action ensures efficient separation and facilitates the
subsequent discharge of the solid cake.

Discharging

Once the solid cake is adequately scraped from the bowl walls, the bottom valve is activated to discharge
the cake. Careful control is exercised to prevent any water from passing through this valve. The discharged
solid cake is then collected in a bin for further processing, typically drying.

The entire dewatering process is meticulously controlled and automated, allowing for precise adjustments
to optimize separation efficiency and achieve the desired quality of the graphite concentrate.
Features of the dewatering centrifugal system

1. The centrifuge adopts frequency motor driving and full-automatic repetitive operation. During the
automatic repetitive operations, the optimized operation is realized through frequency step-less speed
control so that the requirements of low-speed discharging are met.

2. The centrifuge adopts dynamic or regenerative breaking to achieve obvious efficiency effects.

3. The electric control is realized by PLC. Time setting can be carried out for all working procedures and
the real-time working status of each procedure can be displayed on the operation screen.

4. Product contact parts of the centrifuge are made of austenitic stainless steel (according to users'
requirements) to ensure cleanliness and sanitation during the production process.

5. The structure of the centrifuge adopts a compact structure and stable running.

6. Higher production capacity, automation, and speed, better separation efficiency, and lower noise, and
labor intensity.

Wilfly table
At the flotation plant, wilfley table used to separate rangala mines graphite. Wilfley table works based on
density differentiation.

Rotex plant
I worked at the Rotex plant, which specializes in sieving very fine particle sizes. The plant utilizes a
efficiency sieve system comprising two sieve plates, each equipped with small sieves labeled as number
100, 80, and 50. One of the primary functions of the Rotex plant is to separate outputs from froth flotation
and ball mill processes. Through this sieve, the plant effectively segregates particles based on their sizes.

The plant produces three distinct types of outputs, which are carefully collected and packaged in bags for
further processing or distribution. The efficiency and precision of the sieve system play a crucial role in
maintaining the quality and consistency of the plant's outputs.
K & B plant
At the K&B plant, the focus lies on particle size reduction and sieving processes. Roller crushers play a key
role in reducing particle size, while larger vibrated screens are employed to precisely separate particles
according to customer specifications.

The process begins with Trommel mill 1 ol and 2 ol output graphite particles fed into a large bin, followed
by size reduction using jaw crushers. Subsequently, the particles are conveyed to the vibrated screen
section via conveyor belt and bucket elevator. At the top of the plant, four sieves (numbered 4, 8, 10, and
40) are utilized to separate particles into five distinct types. 5 types of particles are separated from sieve
screens. Three types of particles are collected as output, while the remaining two types are directed to
roller crushers for further grinding. After grinding, these particles are returned to the sieves via the bucket
elevator. Given the dry nature of the plant, dust collectors are strategically placed at each processing
section to efficiently collect dust particles, ensuring a clean and safe working environment.

Roller crusher

K&B Plant sieves

Ball mill
The ball mill at the Branwell plant serves the crucial function of reducing particle size in a dry environment.
Utilizing steel balls as grinding material, it efficiently breaks down particles to the desired size.

Particles are fed into the ball mill from a bin via a small conveyor belt. The resulting output is then directed
to an air classifier, which segregates finer particles from larger (heavier ones). The heavier particles are
recycled back into the ball mill for further grinding, while the finer particles move on to the air pulsar. In
the air pulsar, grinded fine particles and collected dust particle transfer to the mixture. This mixture then
proceeds to the packing plant, where it is blended and packaged into paper bags and larger bags for
distribution.
Water plays a crucial role in maintaining the temperature of the plant motors, with a designed water
circulation path ensuring efficient heat absorption throughout the system. This helps to safeguard the
equipment and maintain optimal operating conditions.

Packing plant Air pulsar

Dispersion plant
The dispersion plant at Bogala Graphite Mine is a crucial component of the processing facility, tasked with
the production of dispersion products. These dispersion products are essential for various industrial
applications.

The primary objective of the dispersion plant is to execute a standardized procedure to manufacture
dispersion products efficiently. This process involves precise measurements and mixing of raw materials
according to specified instructions.

The formation of a dispersion product could include components such as Aquapowder, water with a
specified additive concentration (e.g., 0.1% proxel), biocide (e.g., Mergak K20 at 0.2% concentration), and
antifoamer. These components are carefully weighed and combined in predetermined proportions to
ensure the desired properties of the final dispersion product.

Once all components are added, they undergo a meticulous mixing process to achieve uniform dispersion
and desired consistency. Quality control measures are implemented at the final output.

Mixing motor Mixing tank Final product tank

Laboratory
During my visit to the laboratory, I had the opportunity to engage actively with various tools and
equipment essential for the analytical and processing tasks. Throughout my time in the laboratory, I
explored and familiarized myself with instruments, such as moister analyzer, electrically heat furnace,
analytical balance, desiccator and ceramic crucible. Muffle furnace, tapping machine, Ford (Din) cup, Scott
volume meter and sieve machine. Each serving a specific purpose in the processing operations.

Moister analyzer Analytical balance Desiccator Sieve machine

In conclusion, my experience at the Bogala Graphite Mining Lanka PLC processing plant has provided
valuable insights into the operations and processes involved in graphite processing. Each section of the
processing plant plays a unique and critical role in ensuring the efficiency, quality, and purity of the final
graphite products.