MALAYAN COLLEGES LAGUNA
MITL COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING
2T 2020-2021, JANUARY 30, 2021
ME116P - INDUSTRIAL PLANT ENGINEERING
DESIGN PROBLEM
A proposed gold mining operation to be located in the island province of
Masbate will contain an ore mill and concentrator plant, a compressed air plant, and a
diesel-electric power plant. The mine is expected to have an average output of 240(a) MT
per 24 hours of ore containing 1.20(b) % gold which is raised from an underground
mining operation of 220(c) meters below by an air operated hoist. The plant will be
located 940(d) meters above sea level where all equipment will be located near the mine
site except those that will be used in the mining operations. The industrial diesel power
plant will be designed to supply the power requirements of all motor driven mechanical
equipment in the mill complex and an additional 75(e) % of power load will be allocated
for the lighting needs of the offices, housing units, shops, and other auxiliary services.
The following services by the plant are to be provided:
I. Mining Operations
1. Air Operated Rock Drills – 5(f) units, 760(g) kPag, and 6.25(h) m3/min free air capacity
with 80(i) % capacity factor.
2. Air Operated Sinking Pumps – 5(j) units, 760(g) kPag, and 6.20(k) m3/min free air
capacity.
3. Air Operated Mine Hoists – 2(l) units, 760(g) kPag, and 12.0(m) m3/min free air capacity,
hoisting cage is 200(n) kg, and car is 150(o) kg and is loaded with 500(p) kg of ore per haul
at 6.5(q) m/s2 acceleration from 220(c) m depth.
4. Blowers – 2(r) units, identical curved blades, 3.00(s) m3/min capacity at given altitude,
and 125(t) mm water gage static pressure.
II. Compressed Air Plant
Air compressors are to be reciprocating type, horizontal, double-acting, 2 stages,
water cooled, 840(u) kPag pressure with inter-cooler and after-cooler. Air receivers should
be provided each unit with minimum number of safety valves.
III. Industrial Power Plant
Diesel generating units whose capacities should be sufficient to supply all power
and lighting load of the complex. Provide sufficient running and stand by reserve for
dependable and continuous mine operations. Cooling tower should be designed with
sufficient capacity and size to handle both diesel and compressor cooling.
IV. Mine Concentrator Plant
1. Blake and Jaw Crushers – 1(v) unit, non-choking type, and minimum discharge is 75
mm diameter at a capacity sufficient to process mine output of 240(a) MT per 24 hours.
Specify motor rating and rpm for bulk density of 1800 kg/m3.
2. Ball Mills – Specify number of units required with output through 100 mesh screen.
Calculate the power required.
3. Belt Conveyors
a. Horizontal – 2 units at 15(w) MT/hr, 1800 kg/m3 bulk density, length of conveyor is 30(x)
m, speed at 35 m/min.
b. Inclined – 3 units at 10(y) MT/hr, conveyor length is 20(z) m, rise of 8 m, and speed of 45
m/min.
Design Requirements
1. Calculate the free air requirements of all compressed air consuming tools at the given
altitude. Tabulate summary of results.
2. Calculate the bore and stroke, the power requirement, and the number of units of air
compressor. Specify the standard size of the compressor from the catalogue.
3. Design the compressed air receiving tank system to be provided to each compressor unit.
Specify the standard size of the air receiver tank and the number of safety valves required
for each air receiver tank unit. Lay-out the compressed air system and the compressed-air
piping distribution system of the plant together with the necessary pipe fittings. Size the
compressed-air piping distribution system.
4. Design and / or select the air blowers and calculate their power requirements. Specify the
air blower standard size from the catalogue.
5. Design and / or select the crusher ball mills and the belt conveyors. Specify the standard
equipment size from the catalogue.
6. Design a natural draft (atmospheric type) cooling tower system for atmospheric condition
at the given altitude and a wet bulb temperature of 5°C. Specify the standard equipment
size from the catalogue.
7. Design the industrial diesel power plant system and determine the number of diesel
generating units. Specify the standard equipment size from the catalogue.
8. Design and / or select the wire ropes required. Use adequate factor of safety as provided
for by a standard machine design textbook or handbook. Specify the standard equipment
size from the catalogue.
9. Design and / or select the V – belt drive system for the compressor at a motor speed of
1200 rpm. Specify the standard equipment size from the catalogue.
10. Prepare all detailed computations and engineering economic analysis, technical drawings,
accompanied with a project summary, letter of transmittal, acknowledgement, table of
contents, brief introduction on gold mine site background, design problem statement,
references, and other requirements for a standard engineering report.
