1

2

INDEX
SR. NO. DESCRIPTION PAGE NO.
1.
CHAPTER-I
Introduction & Background
3
2.
CHAPTER-2
Geology and Reserves
6
3.
CHAPTER-3
Quarrying
8
4.
CHAPTER-4
Mining Plant--Crushing Plant
26
5.
CHAPTER-5
Machinery & Equipment
43
6.
CHAPTER-6
Costs
48





3
CHAPTER-1
Introduction & Background
M/S Apex Industries (Pvt.) Ltd. House No 32 Street 55 I-9/4 Islamabad have been granted
PL for 168.469 acres for marble-hard limestone near Markandi District Abbotabad for value
addition to sell as Slab/Plates/Granule/Powder/ gravel as a feed to the mega projects in the
pipeline in the surrounding. The applicant has a long experience in Mining/ quarrying in
various regions and carry a good track record.
The applied for area falls on Topo sheet F-43/8 near Markandi on the western bank of River
Jhelum upstream Kohala. The Marble-Hard limestone formation is the extension of Margala
Formation.
The area falls on the boundary of KPK, Punjab and AJK. The major market in the
surroundings falls within AJK. The tempo of development and coming up of new projects
require marble hard limestone in various forms. Currently this material is being supplied
from Texila which is far away and expensive. The project will provide quality material to
the surroundings at cost effective rates.




4

The area is accessible from Islamabad via Murree to Kohala and to a branch road leading to
site. From Kohala the entire developing territories of AJK can be met with very conveniently
the project being at a central location. The Kohala hydral power, a mega project sponsored
by the Saudia Arabia for the establishment of a university are the potential sources for
marketing.

The perception of the applicant is in line with the National Development Program of this
region. The upcoming new Dams, Universities, roads and expressed way are the major intake
of the quality Marble/limestone. The project planning matrix explains the project from
perception to deliverable ends will take approximately half year and needs a careful and
candid handling at all stages with zero delays. The location of the area on satellite images
are also annexed for better understanding.



5


The topography of the area shows a rolling terrain like that of Potohar. As seen on the part
plan drawn on the topo sheet
Points Northing Easting
A 1211460 3551010
B 11460 51606
C 10232 51742
D 10232 51010
Total Area 168.469 Acers

The applicant undertook pre-feasibility study and found a potential market for quality
Marble/Hard-limestone gravels of different sizes for feed to the Public Works Department.
The quality of limestone, its hardness is the same as that of Margallah limestone which is
being extracted from Texila bye pass. The extractions of stone in Texila bye pass is subjected
to the various litigations and are not likely to enjoy the restraint free working owing to geo-
political hostile environments. The applied for area is timely proposition to save the market
supplies from starvation.


6
CHAPTER-2
Geology and Reserves
Geology
The limestone in this range belongs to lackhart limestone formation. The sequence also
reveals to other formations i.e. Chichali formation and Samana Suc formation. The
escarpments consist of lithology and are not homogenous in its formation and are not strong
as such. These inclined rocks are naturally weathered and exposes boulders at certain
locations. The area is geologically is matter of interest where minor and major faults created
in network of displacement and dislocation in a crises cross manners. At certain point shale
is intercalated which provides gliding plain to the limestone. The addition of moisture through
rains catalyze this phenomenon.
Limestone Deposit
The limestone deposit has a good quality material which can feed in the construction of an
airport and high quality roads. The area is 500 acres sufficient to the life of the plant. The
geology of the area had already been described above.
Sedimentation
The rain water brings some sediment load in the natural water channels and also in the plain
areas.



7
RESERVES CALCULATIONS OF LEASE 168.469 ACRES


PARAMETERS UNITS VALUES
I ACRE SQ.YDS 4840
1 ACRE SQ METERS 4467
1 METER. THICK ROCK VOLUME 4467
AVG THICKNESS/HEIGHT M 10
WT. OF LIME STONE/CU.M TONS 2.08
LIME STONE-GEO RES/ACRE TONS 92913.6
LEASE HOLD ACRES 168.469
LESS GEO. LOSSES % 5
AREA FOR MINEABILITY AC RES 160.0456
MINEABLE RESERVES TONES
1487040
8
AVG .PLANNED OUT PUT/YR TONS 450000
LIFE OF QUARRY AT CPL YRS 33.04535



8
CHAPTER-3
Quarrying
Extraction Technology
Overburden removal
Overburden in hard rock quarries may include soil, sub-soil, unconsolidated younger rock
formations, other contaminating rock bodies, and/or weathered materials. Unconsolidated
overburden may be removed using excavators; wheeled loading shovels or hydraulic back-
hoe excavators. Consolidated overburden may require blasting before it can be removed.
Overburden removal at sand and gravel operations has a greater emphasis on the reuse of
overburden material as part of the ongoing restoration process. For further details on
restoration. Overburden usually consists of soil, peat or glacial till; the thickness can range
from less than 1 m to about 15 m. Overburden to mineral ratios are also highly variable and,
although it is commonly quoted that they should not exceed 2:1, higher ratios are worked
where the mineral is of good quality.
Wherever possible, overburden material is directly reused in site restoration; where this is not
possible it is transported to a suitable site specified in the planning permission. Soils and
sub-soils are carefully stripped using specially equipped hydraulic backhoe excavators and
stored in special storage bunds. They require careful handling and storage if their physical
structure and chemical characteristics are to be preserved. For this reason different layers
within the soil are stored separately from each other so that they may be re-laid sequentially
during restoration. Where possible soils will be directly placed onto previously worked out
areas as part of progressive restoration.



9
Drilling and primary fragmentation
Drilling and blasting is carried out to fracture the rock to enable mechanical excavation. For
further details on blasting, it is normally essential in hard rock quarries; holes are drilled
behind the working face and filled with an explosive. When detonated, the rock is broken
into manageable fragments to be taken away for further crushing and processing. Drilling
and blasting is rare at sand and gravel operations; it is sometimes required prior to the
excavation of more consolidated materials.
The most common blasting agent is ANFO, a mixture of ammonium nitrate (fertilizer) and
fuel oil. Laser profiling may be used to characterize the quarry face before blasting so that the
exact quantity of explosive is used. Blasting agents are often brought to site in separate form
and mixed when inserted into the hole; often by specialist contractors. Use of blasting agents
and explosives in quarries is regulated by the Quarries (Explosives) Regulations 1988. Poor
blasting significantly increases production costs, it is therefore designed to obtain optimum
fragmentation reducing the need for secondary breakage without producing excessive quarry
fines (material finer than 4 mm).




10


During hard rock blast
Electronic detonators allow blasts to be triggered sequentially to minimize vibration. Careful
design of the delay between blasts (the blast sequence) mean that the pressure waves from
each blast interfere with each other and reduce vibration. The amount of explosive used in a
blast is carefully measured to reduce the risk of fly rock (pieces of material that are thrown
clear of the blast site).



11
There is a trade-off between blasting costs and crushing costs; if large rock pieces are
produced by blasting the cost of crushing will be increased. Oversize rock slows the loading
process and may exceed the maximum size set for the primary crusher, leading to reduced
efficiency. It may also increase the maintenance costs for both loading and crushing
equipment. Blasting generally tends to be optimized according to handling and crusher
efficiency criteria. A recent project Less Fines Production in Aggregate and Industrial
Minerals Industry examined the potential for reducing the amount of fines resulting from
blasting in quarries via the use of new blasting methodologies.
Through careful control of hole location, depth, detonation sequence and timing the blasting
process can be optimized in terms of cost and minimizing environmental and social impacts.
The energy released when the explosive is detonated does not only go toward breaking the
rock; some energy is lost via heat, sound (as noise), displacement and ground shaking
(vibration).
In order to use appropriate quantity of explosives and to follow the proper drilling and
blasting techniques please follow the guidelines in the enclosed annexures at the end of this
Chapter.
Exploitation Mining of Limestone
The reassessment about geological and mineable reserves will lay the foundation of project
life as well as production planning parameters if need be explored drilling at few locations
could be adopted to see the trend of the deposits below the ground level.
Thereafter, the quarry design shall follow the following sequence of operations:
Development of access road to the top
Leveling at the top to undertake bench formation below
Selection of drilling machine most probably 96mm dia
Selection of the hole depth most likely upto 10m
The width of the bench shall be 2 the height of the bench which will be governed
by the drilling hole depth



12
The production planning will determine the number of wholes to be drilled in one
blasting whether to meet weekly demand or by weekly demand
The standard method of charging the hole with appropriate explosive density shall
be used in order to increase the yield of rocks more than 4 tons per kg of explosive
The standard and scientific method shall be utilized for keeping the distances the
width of the burden and the hole spacing as well as number of holes in one line
Wabocard shall be used in conjunction with relays where considered expedient
Before undertaking the full operations of quarries the rip rape blasting test shall
be carried to find over 85% of the fragmentation within the acceptable range of
the crusher so as to avoid secondary blasting
The transportation of excavated materials shall be done through trucks / dumpers to
the crushing plant
The crush material shall be screened for different fractions meet the market
demands
The loading at the materials at quarries shall be through a shover loader and self
dumping at crushing units
Due regard shall be given to safety parameters at quarrying and plant operations



13
ANNEXURES ON GUIDELINES ON DRILLING AND BLASTING
FOR TRENCHES AND BENCHES




14






15











16








17












18






19






20





21














22







23








24




25





26
CHAPTER- 4
Mining Plant--Crushing Plant
Production Good Practice

Ideally, a quarry will sell everything that is extracted and processed. In the past, quarries
produced a range of single-size aggregate products up to 40 mm in size. However, the trend
for highly specified aggregate has meant that products have become increasingly finer.
Currently, many quarries do not produce significant quantities of aggregate coarser than 20
mm; it is not unusual for material coarser than 10 mm to be stockpiled and re-crushed on
demand. Decreasing the top size of aggregate produced has had an inverse effect on the
proportion of fines produced; a 40 mm top size results in 5-10% fines, 20 mm top size results
in 15-20% fines and 10 mm top size results in 35-40% fines. This represents up to an eight-
fold increase in fines production.
The amount of fines produced increases as material progresses from primary to secondary
and subsequent stages. The amount of fines arising from the primary crushing stage is



27
strongly influenced by the blasting process; if rock can be removed without blasting this will
reduce the amount of fines produced. The amount of fines generated during blasting may be
as high as 20%. Table indicates the fines content generated at each stage of the crushing
process; the proportion of fines produced varies with the type of rock and also the type of
crusher used.
NB Fines = quarry fines; the proportion of quarry fines produced is attributed to specific
crushers.
Crushing plant technology
Crushing is carried out to produce particles of a given size distribution and particle shape. The
most common types used are compression crushers and impact crushers. Many crushers also
incorporate a component of abrasion and attrition which leads to the production of fine
material. The physical and mechanical properties of a rock govern the way it breaks apart.
Brittle minerals with inelastic behaviour will fracture when subjected

Production Technology Table
Quarry fines produced in hard rock aggregate operations



Production Stage Rock type
Proportion of fines in the crusher
product (weight %)
3 - 6% (Jaw) to 10 - 15% (Gyratory) 6 -
7% (Jaw) to 20% (Impact) 1 - 2% (Jaw)
to 15 - 20% (Jaw & Gyratory)
0 - 23% (Cone)
15 - 25% (Cone) to <30% (Impact) 10 -
15% (Cone)
5 - 30% (Cone) to 40% (Impact) <20%
(Impact) to 40% (Hammer mill) ~15%
(Cone) to 40% (Impact)
Igneous + Metamorphic
Primary crushing Limestone
Sandstone
Secondary crushing
Tertiary crushing
(and subsequent stages)
Igneous + Metamorphic
Limestone
Sandstone
Igneous + Metamorphic
Limestone
Sandstone



28
to sufficient stress; the presence of cracks or flaws in the crystalline matrix of the mineral
will act to concentrate stress, resulting in crack propagation and ultimately fracturing. Some
minerals display elastic behaviour, whereby stress is absorbed by distortion of the crystal
matrix without fracturing. Fracturing preferentially occurs along cleavage planes, grain
boundaries, laminations, bedding planes, foliation, joints and other planes of weakness.
Compressive crushing produces material that consists of two distinct size ranges; coarse
particles formed by tensile fracturing and fine particles formed by compressive fracturing.
Impact crushing produces material with a uniform particle shape and size. Crushing is usually
performed dry and in several stages.
The energy used by crushing equipment causes distortion and fracturing, which creates new
surfaces. The amount of energy used to create these new surfaces is approximately 2% of
that used in the crushing process; the remainder is lost as sound, heat and vibration. Crushing
of brittle material uses less energy than crushing of elastic material; the latter may change
shape rather than fracture. Comminution theories used to determine the amount of energy
required for crushing often assume brittle behaviour.
Crushers applying a steady continuous compressive stress, such as roll crushers, which are
not ideally suited to the minerals industry, consume the lowest energy per unit volume. Jaw,
gyratory and cone crushers consume the most energy, and impact crushers are intermediate
consumers. The selection of a crusher is made by considering the type of material to be
crushed, the feed size, throughput, the required product size and quality, the product's
commercial value, as well as the capital cost, power requirements, operational costs and
environmental restrictions relating to the crusher. There is a direct correlation between the
Bond Work Index and the capital investment required; the harder the rock the more crushing
stages and/ or larger equipment is required. A crusher that is ideally suited technically may
not be the best choice when economic factors are brought into play. Also, the performance
of a crusher will be reliant upon the crushing plant which it is part of; therefore it is important
that decisions regarding new equipment are made after crushing trials using the largest
practical volumes of the material to be worked.



29

Crusher throughput capacity is typically quoted in tonnes per hour (tph). The nature of
crushing is essentially volumetric and capacity figures typically refer to rocks with a bulk
density of 1600 kilograms per cubic metre (kg/m
3
). The product yield is more important than
the throughput capacity; 100 tph of crushed material with 30% oversize only results in 70
tph of product, whereas a crusher that produces 85 tph of crushed material with 5% oversize
results in 80 tph of product.
Jaw crusher good practice
Overview
A jaw crusher consists of two metal plates that crush material as they close together. As a
compression crusher, they generally produce the coarsest material; this is due to the
preferential breakage of rocks along inherent lines of weakness. Jaw crushers are mainly
used in primary crushing as a means of preparing rock for subsequent processing stages;
they are rarely used as secondary crushers (where they are used to boost primary





Bond Work Index (Wi, kWh per tonne)
Mineral Work Index (Wi) Mineral Work Index (Wi)
3.4
Barite 4.7 - 6.9 Glass


15.1 - 16
Basalt 17.0 - 22.5 Granite


9.0 - 12.8
Cement clinker 14.8 Limestone
148.0
Coal 12.5 - 13.0 Mica


13.6 - 14.1
Dolomite 9.0 - 12.4 Quartz


9.6
Feldspar 12.8 Quartzite





30
production capacity). Some sand and gravel plants use granulators (a squat form of jaw
crusher) for crushing cobbles.
Jaw crushers do not produce a large proportion of quarry fines (material <4 mm) material;
at a closed side setting (CSS) of 40 mm a jaw crusher will produce less than 10% of quarry
fines and at a CSS of 200 mm it produces less than 1%.
Key finding
Jaw crushers are mainly used in primary crushing where the amount of fines produced is
typically less than 5%; any attempts to minimize fines production at this stage will have little
effect on the total fines arising as most are produced in the secondary and tertiary stages.
Feed
Jaw crushers are routinely choke fed as this maximizes production capacity and ensures that
particles are uniformly broken. It promotes stone-on-stone crushing which breaks up flaky
or slabby particles; this probably results in a higher proportion of fines than if operated under
non-choke conditions. Reduction in fines produced could be achieved by trickle feeding
material into the jaw crusher; however this would have an adverse effect on particle shape
and also it would reduce throughput capacity. Ideally, the feed rate should not be switched
from choke to non-choke, as this would have a knock-on effect on the down-stream secondary
processing plant. In practice, many jaw crushers are fed in this intermittent fashion due to
gaps in the delivery of feed material from the quarry. Jaw crusher feed is pre-screened using
a grizzly -screen prior to crushing; this is in order to remove material finer than the closed
side setting.
Key finding
In practice, many jaw crushers are not fed to their design capacity; this is because the
subsequent processing plant does not have sufficient capacity to handle the volume of
material that would be produced if the jaw crusher were working to capacity.



31
Crusher setting
Ideally, the reduction ratio of a jaw crusher should be 6:1; this is calculated as the ratio
between the particle size of the feed (the F80 is used, this is the particle size at which 80%
is finer than the top size of the feed) and the particle-size of the product. The finer the closed
side setting (CSS) the greater the proportion of fines produced. The closed side setting of a
jaw crusher is constrained by the need to maintain the nip angle within a narrow range
(typically 19 to 23
o
); too large an angle causes boiling in the crushing chamber (this is where
the jaw plates cannot grip onto the rock and it keeps slipping up and down).
Key finding
Increasing the CSS in an attempt to reduce the amount of fines produced may have the
opposite effect; it would lead to a greater proportion of oversize material, which would need
re-crushing and would ultimately lead to a higher proportion of fines being produced.
The settings on a jaw crusher are more designed for producing material for secondary
crushing. The best particle shape is typically found in material that is approximately the same
size as the closed side setting. Smaller sizes will contain a higher proportion of elongated
particles because they have passed through the crusher without being touched. Larger sizes
will also contain a higher proportion of elongated particles because long and narrow pieces
have also passed through the crusher without being touched. This indicates that the closed side
setting is best set to the size of the main product required to give the best results.




32
Crushing plant, you can also say it aggregate plant, or quarry plant, includes vibrating feeder,
jaw crusher, impact crusher, vibrating screen, belt conveyor and centrally electric controlling
system, etc. The designed capacity is from 50t/h to 500t/h. To meet customers specific
requirement, we can also add other equipments such as cone crusher, dust catcher on the
production line.
Process of Crushing Plant:
Big materials are fed to the jaw crusher evenly and gradually by vibrating feeder through a
hopper for primary crushing. After first crush, the material will transferred to impact crusher
by belt conveyor for secondary crush; the crushed materials will then transferred to vibrating
screen for separating. After separating, the parts that can meet standard will be transferred
away as final products, while the other parts will be returned to impact crusher, thus forming
a closed circuit. Size of final products can be combined and graded according to customers
specific requirement. We can also equip dust catcher system to protect environment.
Crushing Machine--Jaw Crusher




33
Crushing Machine--Impact Crusher
Primary Impact Crusher
The product grading from an impact crusher will change throughout the life of the wearing
parts particularly the impact hammers or blow bars. As the profile of the hammer changes with
increasing wear, the product grading becomes coarser. Many modern impact crusher
installations have a variable speed drive arrangement that allows an increase in the rotor
speed to compensate for wear on the impact hammers.
Open discharge arrangements in impact crushers rely on retention of the rock within the
crushing chamber. This is achieved by reducing the gap between the rotor hammers (crushing
members) and the impact curtain.
Key finding
Decreasing the gap between the hammers and impact curtain increases particle retention in
the chamber. This increases the size reduction ratio; however it also reduces throughput
capacity and increases fines production.
Closed discharge arrangements rely on a series of grids to retain the material within the
crushing chamber; these are generally not adjustable. Decreasing the size of the grid
apertures has the effect of increasing the residence times of material in the crushing chamber.
This increases the size reduction ratio; however it also reduces throughput capacity and
increases fines production.




34

Impact crushers are successfully crushing a wide range of materials such as limestone,
dolomite, gravel, basalt, copper reverts, concrete and asphalt. Whether you need a portable,
stationary impact crushing plant, we have the optimum, innovative solution for your specific
needs.
They are primary and secondary impact crushing plants. The impact crusher shown left in this
modern aggregate processing installation is a highly popular plant for secondary crushing
applications. It is a brute of a crusher that handles concrete full of rebar, asphalt and other
debris to produce highly saleable materials.
Crushing Machine--Cone Crusher




35
cone crushers are the best available choice for the aggregate and mining market. They feature
a unique combination of crusher speed, throw and cavity design. With these benefits, our
cone crushers provide unbeatable performance in primary or secondary application.
Cone crushers perform well in crushing various kinds of ores and rocks of medium or above
medium hardness. It has the advantages of stable structure, high efficiency and long lifetime.
Because we adopt energy saving technologies, the cone crushers consume less energy
compared with other brands. The particular design ensures continuous operation.
1. Due to easy to operate, the cone crusher can be easily integrated to automation system,
as a result the overall efficiency can be increased dramatically.
2. The spring safety system of crusher acts as an overloading protection system that allows
metals to pass through the crushing chamber so as not to damage the cone crusher. The safety
system uses dry oil and water as two kinds of sealed formation to make plaster powder and
engine oil separated to make sure reliable performance. So the life time is longer, and then
the whole cost is reduced.
3. The cone crushers are suitable to crush medium size, fine and ultra fine powders
depending on the different type.
Crushing Machine--HPC Cone Crusher
Key finding
Cone crushers are mainly used in secondary and tertiary roles, therefore attempts to minimize
fines production will have a greater effect on the overall production of fines compared to
attempts at minimizing fines production by primary gyratory or jaw crushers.



36
Feed
Uniform distribution of feed material around the cone crusher inlet is good practice as it
allows production of a consistent product and consistent operation of the crusher. Choke
feeding is important for cone crushers as it maintains a good particle shape by facilitating an
inter-particle crushing action; trickle feeding is not a sensible option as it increases the
proportion of flaky material in the crusher product.
Key finding
Pre-screening of the feed to remove the fines, especially in tertiary crushing is good practice;
it helps to avoid packing of material in the chamber and maintain an effective crushing action.
It is advisable to maintain approximately 10-15% of material finer than the closed side setting
in the feed to assist crushing action. Pre-screening to remove 6-10mm aggregate from the
feed should be avoided as void space in the chamber results in an increased proportion of
flaky material in the product.




37

HP Series high efficiency Hydraulic Pressure Cone Crusher is a world-level cone crusher
developed from the up-to-the-minute technology of Germany. The cone crusher not only
improves the production capacity and crushing efficiency, but also widen the applying area,
the hardness of materials range from limestone to basalt. It has a second-to-none crushing
performance in the work of medium-size crushing, fine crushing and super fine crushing.
The crusher is the improved type of spring cone crusher and can be used to replace ordinary
hydraulic pressure cone crusher in the line of mining and construction. It is the most ideal
equipment for large stone crushing factory and mining industry.
HP Series high efficiency Hydraulic pressure Cone Crusher has a better performance
compared with spring cone crusher and ordinary Hydraulic pressure Cone Crusher:
1. A high crushing ratio and production efficiency. The connection of higher turning speed
and stroke makes the rated power and passing capacity improved greatly and the crushing
ratio and capacity increased.
2. Less spare part consuming and low operation cost advanced crushing principal and
technical data, reliable operation and low operation cost. All parts of the crusher have anti-
wearing protection, which can make the life time of spare parts increased by 30%



38
and the maintenance costs decreased to the lowest. The crusher avoids the disadvantages of
impact crusher like low average crushing ratio, large energy consumption, fast abrasion of
hammer, impact plate and lining board.
3. between-layer pressuring crushing and better finished product shape.
The crusher adopts between-layer pressuring crushing principal and the suited turning speed,
not the traditional single particle crushing principal. The special crushing cavity can makes
the crusher crush materials selectively, thus the proportion of fine product and products of
cubic shape be increased distinctly and products of lump size decreased by a large extent.
4. Hydraulic pressure protection and hydraulic pressure cavity clearing, high
automatization and less stop production and repairing time.
The discharge opening adjusted by hydraulic pressure and overload protection makes
performance of the crusher increased by a large extent, the maintenance and operation easier,
the repairing time shorter; the bidirectional metal releasing hydraulic pressure vat makes slab
pass through crushing cavity; the crusher can discharges materials automatically when the
hydraulic pressure works under the conditions of iron passing and instantaneous overloading,
thus there is no trouble of stopping the crusher to discharge materials by hand.
5. Thin oil lubrication makes the life time increased.
Unique design of thin oil lubrication system prolongs life time of the crusher, high
performance and not touchable labyrinth airproof part blocks off the dust and remove the
common disorders like the mixture of oil and water in spring cone crusher.
6. Manifold crushing cavity
It is only need to change fixed cone lining board and movable cone lining board; the type of
crushing cavity can be changed from standard coarse cavity to short head fine cavity, which
can meet various kinds of need.



39
7. Easy maintenance and operation.
All parts of HP cone crusher can be assembled, disassembled and repaired from the top and
side part, including the fixed cone and movable cone. For the changing no need to
disassemble the crusher body and fasten the bolts. Hydraulic motor makes the performance
of crusher better.
8. The crusher can provide customers a higher capacity, better product shape, and easy be
operated
Primary Gyratory Crusher
Crusher settings
The liner profiles are designed for a range of product sizes from extra coarse (EC) to extra
fine (EF); the EF liner profile will result in the highest fines proportion for a given cone
crusher.
Key finding
The finer the closed side setting the greater the proportion of fines produced.
Monitoring the crushing force, as registered through the load on the crusher motors and also
the pressure on the hydraulic mantle adjustment mechanism, will give forewarning of crusher
packing problems before they become too acute.
Impact crusher good practice
Overview
Impact crushers consist of a set of hammers that crush material as they spin within a crushing
chamber. Impact crushers tend to be used where shape is a critical requirement and the feed
material is not very abrasive. The crushing action of an impact crusher breaks a rock along
natural cleavage planes giving rise to good product quality in terms of shape. The quality of
these products makes them ideal for use in highly specified roadstone and concrete aggregate
applications.



40
Key finding
Improvement in product particle shape comes at the price of producing excessive fines.
Stone CrusherVertical Shaft Impact (VSI) Crusher
Feed arrangement
It is vitally important that the feed arrangement to an impact crusher ensures an even
distribution of feed material across the full width of the rotor. This will allow for even
distribution of energy into the feed material and uniform wear patterns ensuring consistent
product gradation and power consumption.
Crusher settings
Size reduction in an impact crusher relies on energy being imparted into the rock from the
rotor. This initial impact is responsible for more than 60% of the crushing action with the
remainder being made up of impact against an adjustable breaker bar and a small amount of
inter-particle collision.
Key finding
Size reduction is directly proportional to the rotor speed; it largely dictates the amount of
fines produced. Slower rotor speeds can be used as a means of reducing the amount of fines
produced but may result in a product with a less desirable particle shape. Slower rotor
speeds are preferable as a means of minimizing the amount of wear on crusher components.




41
Vertical Shaft Impact Crusher is the most advanced impact crusher in modern world. It
introduces high quality roller bearing like Sweden SKF and America TIMKEN, which ensure
the smooth running of main unit. Hydraulic system used in upper cap, it is easy and
convenient to maintenance and replace spare parts. The feeding is the sole patent of the
manufacturer for using central feeding and central feeding with cascade feeding, the feeding
method can change as per needed so as to satisfy customers different request.
1. Advanced double pump oil lubrication system minimize the maintenance frequency
2. High precision roller bearing, smooth main unit running, and long service time
3. Hydraulic lift cap, easy and convenient replacement and maintenance
4. Over vibration alarm system
5. Special dustproof seal system, outside powder is prevented from entering oil mouth
6. Unique feeding method (change between central feeding and central feeding with cascade
feeding make rock on rock and rock on iron possible, both crushing and shaping are
achieved.
7. Particular material throw head design and reasonable material selection prolong the
service time.
Roll crushers
Roll crushers have limited application in the quarrying industry, aside from their use in
limestone operations; this is largely because of their low throughput. They tend to be used
for sedimentary, friable rock and wet or sticky materials that jaw or gyratory crushers struggle
to process. These crushers use a combination of impact, shear and compression to break up
the feed material; they can be subdivided into sledging or slugger rolls, and crushing rolls.
Sledging or slugger rolls have either a single or double-roll construction. A single-roll
sledging crusher consists of a heavy roll with rows of teeth (or picks) that are used to grip the
rock and feed it into the crushing chamber. Facing the roll is a breaker plate; the



42
distance between this plate and the roll is the crusher setting. A two-roll slugger crusher
consists of two toothed rolls. A mineral sizer is similar to a two-roll slugger but with more
pronounced teeth that are staggered on the contra-rotating rolls; this helps to increase the
capacity by allowing the passage of undersize material and enabling a relatively high
reduction ratio. Crushing rolls consist of double, contra-rotating rolls that act primarily as
compressive crushers; they are especially used for friable, non-abrasive material.



43
CHAPTER 5
Machinery & Equipment
The mineral granted caries a nomenclature of marble (hard limestone). This type of deposits has multi faces uses
including slaps, tiles, crush and powder. The machinery will be selected keeping in view the demands. Basically the
machinery for gravel making including crushers, conveyors, bins, shaking screens etc. are locally fabricated and
will be added in 3 phases. Each unit is estimated to provide a crushing capacity of 500 tons in 16 hours. The
machinery components and other support services needed have been included in the following paragraphs:

UNIT-1



Sr. No.
ITEMS
Sr. No.
ITEMS
1 Hopper Feeder 16 Hopper Rora (Stone)
2
Jaw Crasher Parker 24 x 36
17 Conveyor Mix No.2, 24
x 110 (3000)
3 Conveyor No.1, 36 x
50 (3500)
18
Hopper Mix
4 Conveyor No.2, 30 x
64 (3500)
19
Hopper Bajar(Stone)
5 Double Hopper
Feeder
20 Screen 16x 6
6
JawCrasher9x36
21
Motor Machine No.1,
80~HP
7
JawCrusher9x36
22
Motor Machine No.2,
70~HP
8 Conveyor No.3, 30 x
87 (3500)
23 Motor Machine No.3,
75~HP
9 Back Conveyor 24 x 91
(3000)
24 Motor MachineNo.l,30~
HP
10 Conveyor Rora (Stone'
24x82 3000
25 Motor Machine No.1,
25~HP
11 Conveyor Bajar (Stone
24x95 3000
26 Motor Machine No.1,
20~HP
12 Conveyors Bajar
(Stone 24 x 8213000
27 Motor Machine No.1,
15~HP
13 Conveyor Wastage of
Stone 21 x 63 (3000)
28 Electric Panel Room
14 Back Loading
Conveyor
29 Transform 400~KV A
with accessories
15 Conveyor Rora Stone
No.2, 22 x 75 (3000)





44


UNIT 2

Sr. No. Part i cul ars

Sr. No. Part i cul ars
1
Machine No.1, 21 x 36

19
Loading Conveyor
Bajar (Stone) 24 x
75 (3000)
2
Machine No.2, 7 x 48

20
Loading Conveyor
s / 4 24 x 75 (3000)
3,
Machine No.3, 7 x 48

21
Loading Conveyor
1/2 24x75
(3000)
4
Back Machine 6 x 30

22
Loading Conveyor
3/8 24x75
(3000)
5 Rol1ar 22 x 24 23 Hopper No.1,
6 Screen 16 x 51/4

24
Double Hopper Feeder
with. 02Nos
7
Conveyor No.1, 30 x81

25
Hopper of
Wastage of Stone
8
Conveyor No.2, 30 x 69


26 Small Hopper
9
Conveyor No.3,30
x94

27
Motor No.1,
Machine 100~HP
10
Conveyor 18 x 30
84

28 Motor 80~HP
11
Conveyor 11/2 20
x 75

29
Back Motor 6O~HP
12
Conveyor 1/2" 18
x 116

30
Motor Rolla 6O~
HP
13
Conveyor 3/ 16 x
121

31
Screen Motor 25~
HP
14
Conveyor 2/818 x
103,

32
Motor 20~HP
15
Back Conveyor 18
x95

33
Motor 15~HP
16
Back Rolar 21 x
60 (3000).

34
Motor 20~HP
17
Wastage of Stone
Conveyor 18 x
80,(3000)

35
Motor 15 HP
18
Back Hopper
Wastage of Stone

36
Electric Panel



45
Unit No. 3

Sr. No. Part i cul ars

Sr. No. Part i cul ars
1
Machine No.1, 21 x 36

19
Loading' Conveyor
Bajar (Stone) 24 x
75 (3000)
2
Machine No.2, 7 x 48

20
Loading Conveyor
s / 4 24 x 75 (3000)
3,
Machine No.3, 7 x 48

21
Lo~Conveyor 1/2
24 x 75 (3000)
4
Back Machine 6 x 30

22
Loading Conveyor
3/8 24x75
(3000)
5 Rol1ar 22x24 23 Hopper No.1,
6 Screen 16 x 51/4

24
Double Hopper
with. 02Nos
Feeder
7
Conveyor No.1, 30 x 81

25
Hopper of
Wastage of Stone
8
Conveyor No.2, 30
x 69

26 Small Hopper
9
Conveyor No. 3, 30
x94

27
Motor No.1,
Machine 100~HP
10
Conveyor

18 x
84

28 Motor 8o~HP
11
Conveyor.11/2 20
x 75

29
Back Motor60~HP
12
Conveyor 1/2" 18
x116

30
Motor Rollar 6O~
HP
13
Conveyor 3/ 16
121

31
Screen Motor 25~
HP
14
Conveyor 2/818
103,

32 Motor 20~HP
15
Back Conveyor 18
x95

33 Motor 15~HP
16
Back Rollar 2 21 x
60 (3000).

34
Motor 20~HP
17
Wastage of Stone
Conveyor 18 x
80,(3000)

35
Motor 15 HP
18
Back Hopper
Wastage of Stone

36 Electric Panel






46
MINE DEVELOPMENT\
DETAIL OF MINING MACHINERY & TRANSPORTATION
Drilling Rig
Back Hose
Shovel Loader
Dumpers
Pickup



LAND AND BUILDING


ITEMS
Land
Office Guestroom Kitchen
Crusher workshop, room, bath, store
Canteen Block, Generator Room, Bath, Porch, Guard rom
Control Room Bath Room
Servant Quarters
Welding Workshop, Verandah
Tractor Workshop, Room
Loader Workshop, Verandah, Tyre Shop
Residences
Services Station Diesel Store Petrol Pump
residences
Ramp Wastage of stone





47
47
Staf f & Servi ces

Sr. No. Cl assi f i cati on Nos.
1. Mining Advisor/Managing Director 01
2. Quarry Manager 01
3. Shift Incharge 03
4. Crusher Operators 06
5. Drilling Supervisor 01
6. Heavy Machinery Operators 06
7. Mechanic 01
8. Electrician 01
9. Welder 01
10. Helper 06
11. Driver 03
12. Support Services 06
13. Explosive Magazine Incharge 01
14. Store Keeper 01
15. Manager Accounts 01
16. Procurement Manager 01
17. Manager Administration/Camp Incharge 01

Note: In case of any major breakdown repair shall be carried out by out sourcing.
Similarly, the Mine Surveyor will be out source.



48
CHAPTER-6

COSTS

Machinery & Equipment as well as their cost component are based on the current market rates on delivery of machinery & equipment at site.







49
49






50
50




51

CHAPTER-7
PROJECT PLANNING MATRIX
PPM KOHALA PROJECT-TIME IN WEEKS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Team Building
Company Formation
PREFEASIBILITY STUDIES CONCEPTUAL BASE AFFIRMATION
RESOURCE MOBILIZATION
APPOINTMENT OF CONSULTANTS FEASIBILITY STUDIES
AVAILABLE
Reconfirmation of Lease Order
LEASE DEMARCATION ACCESS ROADS COMPLETED
EXPLORATORY DRILLING COMPLETED RESERVES FIRMED
UP MACHINERY/EQUIPMENT ORDERED
LAND DEVELOPMENT
INFRA STRUCTURE DEVELOPMENT
CIVIL WORKS START MACHINERY EQUIPMENT INSTALLED
QUARRY DEVELOPMENT COMPLETED
PLANT COMMISSIONS




52
52

CONCLUSION
The project costs have been carefully placed and with the investment of 1.45 m$ the
payback period is about one year which is recommended to be established and
implemented.



(Muhammad Khalid Pervaiz)



5/10/12 Details
1/1 regsys.fbr.gov.pk/Registration/searchDetail.aspx?rand=0.2145164345856756&crup=4516667#
Print Back
Taxpayer Online Verification
Date : 10-05-2012
Time : 11:20:02
NTN/FTN 3975940-7 Category COMPANY
Name APEX INDUSTRIES (PRIVATE) LIMITED

Business/Branches Sr. Business/Branch Name
1. A PEX I NDUSTRI ES (PRI V A TE) LI MI TED

Principal Business Activity OTHER MINING AND QUARRYING N.E.C.

Business Nature SERVICE PROVIDER
Registered For INCOME TAX w.e.f 09-May-2012
Income Tax office RTO ISLAMABAD


PL-Marble (202)/2012 DateL.:. b /2013
GOVERNMENTOFKHYBERPUKHTOONKHW
DIRECTORATE GENERAL MINES AND MINERAL D ELOPMENT
/
MINERAL DEVELOPMENT WING
To \
Mr.Gul Asghar Khan S/0 FAteh Khan
For M/S Apex Industries (Pvt) Ltd
House No.32 Street No.55, G-9/4
Islamabad.
Subject:- GRANT OF PROSPECTING LICENSE FOR MARBLE OVER AN AREA OF
168.469 ACRES NEAR VILLAGE MARKANDI DISTRICT ABBOTTABAD.
In the continuation of this Directorate Allotment Letter of even number dated 16/0112013
on the subject noted above, and as you have complied with the requirements thereof and demarcation of
the above area has been carried out /completed and the Prospecting Scheme/Development scheme
submitted by you has been provisionally approved, you are therefore ,provisionally permitted to start
Prospecting/Mining operations in the subject area on the following conditions:-
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
That before commencement of any operation in the said area, you will as required under
clause 28 of the 3rd schedule-VI annexed to the Khyber Pakhtunkhwa Mining concession
Rule 2005communicate to this Directorate and Assistant Director/Mineral Development
Officer /Royalty Inspector Mineral Development Abbottabad the name and address of the
Manager Resident in the locality of the side area under whose supervision such operations
are to be carried out.
That you will furnish this Directorate/ Assistant Director, Mineral Development, Mineral
Development Officer/Royalty Inspector Mineral Development Abbottabad . With the
monthly production/Disposal returns on the prescribed form specimen attached herewith so
as to reach regularly by 7th of each month at the latest. In case there is no production in a
particular month a Nil report may be sent explaining the reason thereof. In case of non-
submission of monthly return action under rule (65)2 of the Khyber Pakhtunkhwa Mining
Concession Rules 2005 shall be taken.
That you will report without delay to the Licensing Authority the discovery of any other
mineral for which you don' t hold a prospecting license/mining lease of such mineral
bearing strata or archeological discovery or treasuries.
That you will continue to observe and abide by the other terms and conditions as
communicated in the allotment letter referred to above.
That you will abide by all rules and regulations with regard to the labor and inspection of
mines as directed by the Chief Inspector of Mines Khyber Pakhtunkhwa from time to time.
That you will submit a revised Prospecting/Development Scheme in the light of
information gathered during your two years operation, in case as an other renewal of the
prospecting license/mining lease is warranted.
That if ,the demarcation of the area and the pillars fixed by you are found incorrect and the
pillars shifted from the appropriate place on the ground at the time of verification of this
Directorate you will have to pay survey Fee ofRs.7,000 (Rupee Seven Thousand onl y) in
that case for another demarcation.
(viii) That if at any time during checking by an authorized officer of this Directorate it has been
found that the staff mentioned in the prospecting Scheme/Development Scheme have not
been employed or the machinery proposed for excavation is not installed at site, this
Directorate will take action against you as permissible under the K.P.K.Mining Concession
Rules, 2005, which may result in the cancellation of your Prospecting license/Mining lease.
Any change of employment on machinery must be intimated to update from prospecting
scheme and office for proper monitoring of your operation.
(ix) That you will prepare and maintain an up to-date layout and working plans at mine site for
inspection purpose in accordance with rule 82 of Khyber Pakhtunkhwa Mining Concession
Rule, 2005
(x) This permission unless earlier withdrawn shall be valid up to 15/01 /2015
(xi) That you will issue authenticated challan to each Truck/Trolly loaded from area The
Challan book shall be authenticated from the undersigned or any other officer authorized in
this behalf. The Mineral transported without valid challan shall be considered as un-
authorized and action shall be taken against you as punishable under Khyber Pakhtunkhwa
Mining Concession Rule 2005.
(xii) That you will abide by law regulation as well as honor the instructions of new
policy/procedure circulated vide Dire letter o. SO-Adnm (M&M)3-148/09 dated
1 ih November,2009.
Assistant Director (T, lznical) Mineral Dev,
Abbottabad
Endst.No ........ ./MDW/AD/ PL-Marble (202)/2012 Dated /2013
----
Copy to:-
1. The Director General Mines and Mineral Khyber Pakhtunkhwa Peshawar. H/Qrs Office
allotment letter dated: 16/ 112013 demarcation certificate along with prospecting scheme are
enclosed for information please.
2. The Chieflnspector of Mines K.P.K Peshawar for information please
3. The Deputy Commissioner Abbottabad for information pleases.
4. The Senior Inspector of Mines Hazara Division for information.
5. The Assistant Commissioner Abbottabad for information
6. Central Statistical Officer Government of Pakistan Islamabad.
7. Assistant Director Royalty Branch Headquarter Office Peshawar.
8. Miscellaneous file (Concession Branch).(2)/2011
Assistant Di ector (Technical) Mineral Dev,
Abbottabad