www.isrinfomedia.comVOL. 49 NO. 07 DECEMBER 2005 ISSN 0578-7661

A PUBLICATION OF ISR INFOMEDIA LIMITEDMAHANTI MEDIA GROUP

HARI MACHINES LIMITEDRegd. Office & Works :- Rajgangpur - 770 017 (Orissa) India. Phone : 91-6624-220-141/161, Fax : 91-6624-220-151

Email : hml@harimachines.in, Website : http:/www.harimachines.comKolkata Office :- 12C, Stephen House, 4 B.B.D. Bag, Kolkata - 700 001, India. Phone : 91-33-2248-7612 / 4451

Fax : 91-33-2248-7155, Email - hmlkol@harimachines.in

Iron Ore beneficiationplant in WHYALLA, Australiasupplied by Allmineral

ISO : 9001

A G L O B A L P U B L I C A T I O N O N S T E E L & H E A V Y E N G I N E E R I N G

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Hari Machines Ltd (HML) belongs to the Dalmia group of industries that has OCL India Ltd as itsflagship company. The group has interests in cement, refractory, steel, sponge iron, mining, industrialmachines & equipments, computer software, travel and investments.

HML is catering to the needs of various core sector industries for the last three & half decades bysupplying them world class heavy industrial machinery and equipment. Consistency in maintaininginternational quality standards, reliable after sales service and customer satisfaction has earned thecompany repute and respect among industrial giants at home and abroad. HML is committed in carryingthe torch forward to new destination and achievements.

Hari Machines Ltd has many firsts to its credit

l Counter Current Intensive mixer – Horizontal & Inclined

l Friction Screw Press (400T & 800T) with complete automation and PLC control.

l Electric Arc furnace of 100 tonnes per batch hot metal carrying capacity for Jindal Steel & PowerLtd, Raigarh (designed by SMS Demag).

l Gunning machines

l Gunning Manipulators (360 degrees shooter gun) for refractory applications.

l Planetary mixer for refractory applications industry

The above equipment have regularly being upgraded with new and better performing features. Manyof these have enabled import substitution.

Reaching out to global customers (Exports):

l Major equipment for Vertical roller mills for AKIJ, Bangladesh based on the design of LoescheIndia.

l Friction Screw Press for Refractory applications to Bangladesh

l Cold Rolling Mill equipment to KYCR Bangladesh based on the design of SMS Demag.

l Friction Screw Press (400T) for Refractory applications to China.

l Counter Current Mixers to Bangladesh

l 16 nos Pinch Roll stands for Iskenderun Steel plant, Turkey through HEC, Ranchi as per the design of Tiazpromashexport, USSR.

HML serving the core sectors withworld class machinery & equipment

HML Administrative Building

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l Impact crusher, Screening & Grinding unit to BST, Thailand

l Counter Current Intensive mixer, Friction Screw Press, Jaw Crusher, Impact Mill, Saudi Arabia.

Milestones 1971 - 2005

v 1971 - Establishment of HML

v 1976 - Manufacture of Hydraulic Toggle press in collaboration with Friedrich Horn of West Germany.

v 1982 - Design, manufacture & supply of first Friction Screw Press 400T.

v 1987 - Supply of Rolling Mill equipment (about 700 MT) for Visakhapatnam Steel Plant throughMecon as per the design of SMS Schloesmann Simag of Germany

v 1992 - Design & manufacture of first Counter Current Intensive Mixer 500 kgs.

v 1994 - Design & manufacture of Friction Screw Press 800T., with automatic operation hydraulicbrake, outside ejection, PLC control and vacuum pressing.

v 1997 - ISO 9001 certification

v 1998 - Development of Gunning machine and Gunning manipulator 360 degrees shooter gun for gunning applications in major steel plants.

v 1999 - Started manufacturing & supply of sponge iron equipment.

v 2001 - Supplied Friction Screw Press (400T) to China.

v 2002 - Development and supply of Counter Current Intensive mixer 1000kgs per batch to Tata Refractories Ltd, Belpahar.

v 2003 - Exported Friction Screw Press to Sri Lanka

v 2004 - Transformation of HML to a heavy manufacturing shop.

Supplied mechanical equipmentfor 100 tons per batch Electric Arc furnace to JSPL, Raigarh based on the design of SMS Demag.

v 2005 - Supplied major equipment for Vertical Roller Mills for Cement plants like OCL, DCBLincluding AKIJ, Bangladesh based on the design of Loesche.

- Manufacturing of AOD converter for Alloy Steel Plant,Durgapur based on the design of SMS Demag.

- Manufacturing of Lime Kiln as per design of FFE Minerals.

Setting our eyes on new horizons in termsof tremendous opportunity in the field ofmineral processing, HML has spread its wingsto touch new spheres in mineral crushing andbeneficiation by forging foreign alliances withDBT Mineral Processing GmbH, Germanyand Allmineral GmbH, Germany and USArespectively.

HML’s dedicated pursuit towards development and keeping in line with the technological advancementhas resulted in entering into a technical assistance agreement with Allmineral, GmbH, Germany to takegiant strides into the horizons of Mineral upgradation. Allmineral is one of the World leaders in thefield of mineral beneficiation with successful installations at Australia, Africa, Spain USA, Russia,Europe, U.K. etc. They have developed a number of patented machines which have proven themselvesworldwide in a variety of beneficiation processes for raw and waste materials (Iron Ore dumps). Now,HML and Allmineral shall together focus to provide complete solutions for mineral upgradation tocustomers in India.

HML & Allmineral (Germany & USA)join hands to provide complete solutionsfor mineral beneficiation in India

For many years, it has become apparent that coal, asprimary energy and Iron Ore , as primary raw materialfor steel, are playing an increasingly important role inthe industrial scenario. Apart from these, there are otherapplications like sand/gravel, rubble, contaminated soils,metal-slag, non ferrous minerals, diamonds, salt andothers.

These beneficiation systems are technically designedprocesses making the intelligent use of the laws of physicsand natural elements of air and water. Based on theanalysis of raw materials, designing low cost and tailormade solutions to beneficiate the mined raw material toa marketable/ usable product in the industries shall beprovided to our customers. The products are Allair, Alljig and Allflux systems and their detailedinformation is provided below.

ALLAIR - Dry Process (For coal beneficiation only) – This technology is air-pulsed jig which is bestsuited for areas where water is scarce and also where customers are particularly interested in keepingwater contamination to a minimum. Since it uses no water and processes solely using air, it has a distinctadvantage of not adding an undesirable increase in moisture content which is normally associated withwet processes. Typically in a Sponge Iron unit where minimum moisture addition is sought in the cleancoal and the rejects could be used in the power generation through AFBC boilers, this jigging machinewould be preferred by customers. To add to these features it’s fully automatic operation with analogmeasurement of bed depth, low capital investment and low operating costs makes the Allair a veryinteresting proposition for the customers.

Modular Beneficiation Plant

Colcarbon ColumbiaHard coal benefication

1 x 50 t|h 20 - 0 mm1 x allair® G 4 x 8

start up March 2004

SAMCA SpainLignite benefication

12 x 50 t|h 30 - 0 mm12 x allair® G 4 x 8 start up November 2004

Ladle Transfer Car for ESSAR Steel, Hazira

2000 TPD Cement Vertical Roller Mill equipment for AKIJ, Bangladesh

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l Impact crusher, Screening & Grinding unit to BST, Thailand

l Counter Current Intensive mixer, Friction Screw Press, Jaw Crusher, Impact Mill, Saudi Arabia.

Milestones 1971 - 2005

v 1971 - Establishment of HML

v 1976 - Manufacture of Hydraulic Toggle press in collaboration with Friedrich Horn of West Germany.

v 1982 - Design, manufacture & supply of first Friction Screw Press 400T.

v 1987 - Supply of Rolling Mill equipment (about 700 MT) for Visakhapatnam Steel Plant throughMecon as per the design of SMS Schloesmann Simag of Germany

v 1992 - Design & manufacture of first Counter Current Intensive Mixer 500 kgs.

v 1994 - Design & manufacture of Friction Screw Press 800T., with automatic operation hydraulicbrake, outside ejection, PLC control and vacuum pressing.

v 1997 - ISO 9001 certification

v 1998 - Development of Gunning machine and Gunning manipulator 360 degrees shooter gun for gunning applications in major steel plants.

v 1999 - Started manufacturing & supply of sponge iron equipment.

v 2001 - Supplied Friction Screw Press (400T) to China.

v 2002 - Development and supply of Counter Current Intensive mixer 1000kgs per batch to Tata Refractories Ltd, Belpahar.

v 2003 - Exported Friction Screw Press to Sri Lanka

v 2004 - Transformation of HML to a heavy manufacturing shop.

Supplied mechanical equipmentfor 100 tons per batch Electric Arc furnace to JSPL, Raigarh based on the design of SMS Demag.

v 2005 - Supplied major equipment for Vertical Roller Mills for Cement plants like OCL, DCBLincluding AKIJ, Bangladesh based on the design of Loesche.

- Manufacturing of AOD converter for Alloy Steel Plant,Durgapur based on the design of SMS Demag.

- Manufacturing of Lime Kiln as per design of FFE Minerals.

Setting our eyes on new horizons in termsof tremendous opportunity in the field ofmineral processing, HML has spread its wingsto touch new spheres in mineral crushing andbeneficiation by forging foreign alliances withDBT Mineral Processing GmbH, Germanyand Allmineral GmbH, Germany and USArespectively.

HML’s dedicated pursuit towards development and keeping in line with the technological advancementhas resulted in entering into a technical assistance agreement with Allmineral, GmbH, Germany to takegiant strides into the horizons of Mineral upgradation. Allmineral is one of the World leaders in thefield of mineral beneficiation with successful installations at Australia, Africa, Spain USA, Russia,Europe, U.K. etc. They have developed a number of patented machines which have proven themselvesworldwide in a variety of beneficiation processes for raw and waste materials (Iron Ore dumps). Now,HML and Allmineral shall together focus to provide complete solutions for mineral upgradation tocustomers in India.

HML & Allmineral (Germany & USA)join hands to provide complete solutionsfor mineral beneficiation in India

For many years, it has become apparent that coal, asprimary energy and Iron Ore , as primary raw materialfor steel, are playing an increasingly important role inthe industrial scenario. Apart from these, there are otherapplications like sand/gravel, rubble, contaminated soils,metal-slag, non ferrous minerals, diamonds, salt andothers.

These beneficiation systems are technically designedprocesses making the intelligent use of the laws of physicsand natural elements of air and water. Based on theanalysis of raw materials, designing low cost and tailormade solutions to beneficiate the mined raw material toa marketable/ usable product in the industries shall beprovided to our customers. The products are Allair, Alljig and Allflux systems and their detailedinformation is provided below.

ALLAIR - Dry Process (For coal beneficiation only) – This technology is air-pulsed jig which is bestsuited for areas where water is scarce and also where customers are particularly interested in keepingwater contamination to a minimum. Since it uses no water and processes solely using air, it has a distinctadvantage of not adding an undesirable increase in moisture content which is normally associated withwet processes. Typically in a Sponge Iron unit where minimum moisture addition is sought in the cleancoal and the rejects could be used in the power generation through AFBC boilers, this jigging machinewould be preferred by customers. To add to these features it’s fully automatic operation with analogmeasurement of bed depth, low capital investment and low operating costs makes the Allair a veryinteresting proposition for the customers.

Modular Beneficiation Plant

Colcarbon ColumbiaHard coal benefication

1 x 50 t|h 20 - 0 mm1 x allair® G 4 x 8

start up March 2004

SAMCA SpainLignite benefication

12 x 50 t|h 30 - 0 mm12 x allair® G 4 x 8 start up November 2004

Ladle Transfer Car for ESSAR Steel, Hazira

2000 TPD Cement Vertical Roller Mill equipment for AKIJ, Bangladesh

S U P P L E M E N T

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ALLJIG - Wet Process (For Coal and Iron Orebeneficiation) – This technology is based on theseparation of minerals in the jigging machines wouldstratify in pulsating water. The upward and downwardcurrents fluidize and compact the grains into relativelyhomogenous layers. Low density pieces stratify on thesurface, while specifically heavy grains settle on thelower bed. The most precise stratification of the particlesare achieved by the optimization of the frequency andamplitude of water pulsation according to the feedcharacteristics. These machines are air pulsed to achievenearly wear-free and so the stroke-motion could beadjusted within wide parameters during operation witheasy operation and control design features. The laterallypulsed jig guarantees an all time physical stable systemwith less energy consumption, maintenance and wear.The distinct advantages of the PLC based analoguemeasured discharge control :

# direct setting of target value (layer thickness) on the operator panel.

# absolute measurement and indicating scale on theoperator panel.

# controller parameter setting (change) on operatorpanel.

# advanced dynamics in controller actions.

This machine is fully automatic with analogmeasurement of bed depth with a capacity tohandle feed size ranging from 1mm to 150mmwith throughput rates up to 700TPH.Allminerals have plants successfully runningall over the world.

The performance data of the beneficiationplant at Whayalla, Australia and KumbaResources at South Africa are worthmentioning which are given below.

ALLFLUX (For beneficiation of mineral fines) – This machine uses fluidized bed technology for theseparation and hydraulic classification of slurried fines for the production of three classified products.

The two-step process permits the handling of slurries without pre-thickening. The coarse and heavyparticles are separated in the coarse section. The discharge of coarser material out of the central hopperis automatically controlled by a density probe.

In the peripheral ring, called the fine section, the separation of light particles from the fines anddesliming takes place. Particles of a lower specific gravity than the fluidized bed will remain above thefluidized bed and will overflow with most of the process water to the overflow chute. It has the advantageof classifying, separating, thickening and desliming in one step. This machine is fully automatic withno moving parts and can take a feed of size ≤ 4mm with throughput rates of up to 2000cum/hr.

Jim Walter Resources Alabama , USACoal beneficiation

500 t|h 14 - 1 mmalljig® 2 x F - 2500 start up December 1989

York Canyon Mine New Mexico, USACoal beneficiation

alljig® 2 x G - 2500500 t|h 60 - 6 mmalljig® 2 x F - 2500450 t|h 6 - 0,15 mm

HWE - Australia Whyalla – South Australia Iron ore separation1 x 100 t|h 8 - 1 mm1 x alljig® F 2500 x 3000 start up September 20041 x 120 t|h 32 - 8 mm1 x alljig® G 2500 x 3000 start up September 2004

BHP - Australia Port Hedland – Western AustraliaIron ore separation2 x 150 t|h 8 - 1 mm2 x alljig® FUB 3000 x 4000 start up September 1996

Airjig at OCL

Airjig performance data at ocl (sponge iron works)

Source of Raw Yield of Ash % Ash %Raw Coal Coal Washed Clean Rejects

Ash % Coal Coal

Gopalpur - E 37.00 70.84 32.28 48.47Basundhara

Gopalpur - E 42.00 71.10 37.08 57.57Basundhara

Lilari - F 37.36 67.87 33.38 45.77Lilari

Talcher - E 39.16 81.99 35.35 56.97Ananta

Governments all over the world are continuing to place even more stringent limits on the release ofpollutants and thus Allair enjoys the principal advantage of being environmental friendly and offering adry processing system with a quantum improvement in separating efficiency without introducing a moisturepenalty to the clean coal product.

ALLAIR-FIRST TIME IN INDIA : HML has successfully supplied and commissioned a 50TPHcapacity Allair Jig for beneficiation of coal at OCL India Ltd, Sponge Iron Works, Orissa, in themonth of November, 2005.

alljig® Operation Results

Lump Iron Ore 8 - 32 mm Dump Processing Australia

Fe SiO2 Al2O3

Feed 54,0 - 58,0 5,5 - 11,0 2,5 - 4,0Concentrate 62,5 - 66,0 2,2 - 3,5 0,8 - 2,0Yield 80 - 85

alljig® Operation Results

Fine Iron Ore 1 - 8 mm Dump Processing Australia

Fe SiO2 Al2O3

Feed 50,0 - 55,0 6,5 - 11,0 4,0 - 8,0Concentrate 62,0 - 66,0 2,5 - 4,0 1,5 - 2,5Yield 60 - 70

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ALLJIG - Wet Process (For Coal and Iron Orebeneficiation) – This technology is based on theseparation of minerals in the jigging machines wouldstratify in pulsating water. The upward and downwardcurrents fluidize and compact the grains into relativelyhomogenous layers. Low density pieces stratify on thesurface, while specifically heavy grains settle on thelower bed. The most precise stratification of the particlesare achieved by the optimization of the frequency andamplitude of water pulsation according to the feedcharacteristics. These machines are air pulsed to achievenearly wear-free and so the stroke-motion could beadjusted within wide parameters during operation witheasy operation and control design features. The laterallypulsed jig guarantees an all time physical stable systemwith less energy consumption, maintenance and wear.The distinct advantages of the PLC based analoguemeasured discharge control :

# direct setting of target value (layer thickness) on the operator panel.

# absolute measurement and indicating scale on theoperator panel.

# controller parameter setting (change) on operatorpanel.

# advanced dynamics in controller actions.

This machine is fully automatic with analogmeasurement of bed depth with a capacity tohandle feed size ranging from 1mm to 150mmwith throughput rates up to 700TPH.Allminerals have plants successfully runningall over the world.

The performance data of the beneficiationplant at Whayalla, Australia and KumbaResources at South Africa are worthmentioning which are given below.

ALLFLUX (For beneficiation of mineral fines) – This machine uses fluidized bed technology for theseparation and hydraulic classification of slurried fines for the production of three classified products.

The two-step process permits the handling of slurries without pre-thickening. The coarse and heavyparticles are separated in the coarse section. The discharge of coarser material out of the central hopperis automatically controlled by a density probe.

In the peripheral ring, called the fine section, the separation of light particles from the fines anddesliming takes place. Particles of a lower specific gravity than the fluidized bed will remain above thefluidized bed and will overflow with most of the process water to the overflow chute. It has the advantageof classifying, separating, thickening and desliming in one step. This machine is fully automatic withno moving parts and can take a feed of size ≤ 4mm with throughput rates of up to 2000cum/hr.

Jim Walter Resources Alabama , USACoal beneficiation

500 t|h 14 - 1 mmalljig® 2 x F - 2500 start up December 1989

York Canyon Mine New Mexico, USACoal beneficiation

alljig® 2 x G - 2500500 t|h 60 - 6 mmalljig® 2 x F - 2500450 t|h 6 - 0,15 mm

HWE - Australia Whyalla – South Australia Iron ore separation1 x 100 t|h 8 - 1 mm1 x alljig® F 2500 x 3000 start up September 20041 x 120 t|h 32 - 8 mm1 x alljig® G 2500 x 3000 start up September 2004

BHP - Australia Port Hedland – Western AustraliaIron ore separation2 x 150 t|h 8 - 1 mm2 x alljig® FUB 3000 x 4000 start up September 1996

Airjig at OCL

Airjig performance data at ocl (sponge iron works)

Source of Raw Yield of Ash % Ash %Raw Coal Coal Washed Clean Rejects

Ash % Coal Coal

Gopalpur - E 37.00 70.84 32.28 48.47Basundhara

Gopalpur - E 42.00 71.10 37.08 57.57Basundhara

Lilari - F 37.36 67.87 33.38 45.77Lilari

Talcher - E 39.16 81.99 35.35 56.97Ananta

Governments all over the world are continuing to place even more stringent limits on the release ofpollutants and thus Allair enjoys the principal advantage of being environmental friendly and offering adry processing system with a quantum improvement in separating efficiency without introducing a moisturepenalty to the clean coal product.

ALLAIR-FIRST TIME IN INDIA : HML has successfully supplied and commissioned a 50TPHcapacity Allair Jig for beneficiation of coal at OCL India Ltd, Sponge Iron Works, Orissa, in themonth of November, 2005.

alljig® Operation Results

Lump Iron Ore 8 - 32 mm Dump Processing Australia

Fe SiO2 Al2O3

Feed 54,0 - 58,0 5,5 - 11,0 2,5 - 4,0Concentrate 62,5 - 66,0 2,2 - 3,5 0,8 - 2,0Yield 80 - 85

alljig® Operation Results

Fine Iron Ore 1 - 8 mm Dump Processing Australia

Fe SiO2 Al2O3

Feed 50,0 - 55,0 6,5 - 11,0 4,0 - 8,0Concentrate 62,0 - 66,0 2,5 - 4,0 1,5 - 2,5Yield 60 - 70

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HML have entered into a technicalassistance agreement with DBT MineralProcessing GmbH - The specialist forhorizontal crushing technology, formanufacturing and supply of Feederbreakers in India.

DBT Mineral Processing GmbH is acompany belonging to the renownedDBT group which is the member of theRAG group and a 100% subsidiary ofRAG Coal International AG. DBT is asupplier of complete system solutionsfor underground coal mining world wideand world market leader in the area oflong-wall equipment. DBT supplies thefull range of equipment from hydraulicshield supports, electro-hydrauliccontrols, conveyors, ploughs andshearers to crushers and transport &logistic solutions.

HML tie-up with DBT MineralProcessing, Germany - world leaders inthe field of horizontal crushing technology

Impact roll crusher for Gypsum suppliedto Platre Lambord, France

Impact roll crusher for Limestone suppliedto Global Stone, USA

Success for Allmineral – A groundbreaking contractAllmineral, has once again achieved success in the international market.

Kumba Resources Limited, the fourth biggest iron ore producer in the world

and biggest producer of iron ore in South Africa has contracted Allminerals

to supply 18 alljigs to Sishen Mine in the Northern Cape.

These jigs will form the nucleus of the Sishen Expansion Project for the

production of an additional 10 million tons of iron ore concentrate to increase

the export of iron ore from Sishen Mine, which at present is running at

24 million to 35 million tons per year. This project will contribute significantly

to the growth in the South African economy as iron ore is one of the top earners

of foreign exchange.

The DBT group’s leading position is the result of comprehensive experience gained over decades ofhigh innovative performance engineering for mutually complementary products and of an internationalnetwork of companies.

DBT mineral processing’s range of equipment include feeder breaker, impact roll crusher, horizontaljaw crusher & chain conveyor. Feeder breakers are primary crushers (pick mounted roll crushers integratedwith chain conveyors) for crushing run of mine minerals like coal, limestone, potash, rock, gypsum,

Allflux Plant at USA

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HML have entered into a technicalassistance agreement with DBT MineralProcessing GmbH - The specialist forhorizontal crushing technology, formanufacturing and supply of Feederbreakers in India.

DBT Mineral Processing GmbH is acompany belonging to the renownedDBT group which is the member of theRAG group and a 100% subsidiary ofRAG Coal International AG. DBT is asupplier of complete system solutionsfor underground coal mining world wideand world market leader in the area oflong-wall equipment. DBT supplies thefull range of equipment from hydraulicshield supports, electro-hydrauliccontrols, conveyors, ploughs andshearers to crushers and transport &logistic solutions.

HML tie-up with DBT MineralProcessing, Germany - world leaders inthe field of horizontal crushing technology

Impact roll crusher for Gypsum suppliedto Platre Lambord, France

Impact roll crusher for Limestone suppliedto Global Stone, USA

Success for Allmineral – A groundbreaking contractAllmineral, has once again achieved success in the international market.

Kumba Resources Limited, the fourth biggest iron ore producer in the world

and biggest producer of iron ore in South Africa has contracted Allminerals

to supply 18 alljigs to Sishen Mine in the Northern Cape.

These jigs will form the nucleus of the Sishen Expansion Project for the

production of an additional 10 million tons of iron ore concentrate to increase

the export of iron ore from Sishen Mine, which at present is running at

24 million to 35 million tons per year. This project will contribute significantly

to the growth in the South African economy as iron ore is one of the top earners

of foreign exchange.

The DBT group’s leading position is the result of comprehensive experience gained over decades ofhigh innovative performance engineering for mutually complementary products and of an internationalnetwork of companies.

DBT mineral processing’s range of equipment include feeder breaker, impact roll crusher, horizontaljaw crusher & chain conveyor. Feeder breakers are primary crushers (pick mounted roll crushers integratedwith chain conveyors) for crushing run of mine minerals like coal, limestone, potash, rock, gypsum,

Allflux Plant at USA

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“HML is all set with world class technologyto become a major player in mineralbeneficiation in India”

Considering the future growth plans in Power & Steel sectors in India, the main raw material i.e. coal& iron ore will be very vital with regards to quality & availability. Though India is self sufficient in termof non-coking coal & iron ore but most of the deposits are not of right grade. Therefore, beneficiationof low grade Coal & Iron ore will go a long way in augmenting the mineral availability and also sustainthe ecological balance in the long run. HML is geared up to execute turnkey projects. BOO (Build,Own,Operate) & BOOT (Build,Own,Operate,Transfer) solutions in mineral beneficiation.

l Do you feel there will be any major change in the overall markets for the products of yourcompany? How well equipped are you in terms of product diversification from the point of viewof your customers’ need?

S Mishra : Our existing markets will remain buoyant in near future. Additionally with mineralprocessing & beneficiation products in our bag, we will be targeting coal & iron ore mine as well as userindustries of these raw materials like cement, steel, sponge iron, power sector, etc.

The major deposits of coal & iron ore are located in Orissa, Jharkhand & Chattisgarh. These statesare also attracting most of the future capital investment (to the tune of 3 lac crores) with regard to steel& metallurgical based industries.

Therefore, we have a strategic locational advantage being close to our present as well as futurecustomers. HML has already developed the design capabilities for new product development. Thecomplete infrastructure to address to various needs including automation is present.

We are also continuously upgrading the manufacturing facilities and also that the existing facility iscapable to manufacture a varied product range i.e. crushing, grinding, mixing, pressing refractoryapplications, rolling mill equipments, continuous casting, pipe plant, blast furnace, VRM, Kilns & Coolersfor various applications.

We have a capable team of trained manpower to take care of all kinds of sourcing and manufacturingneeds.

l Who is your major customers’ base at present – both Indian and foreign? Tell us somethingabout the export sales of your company. Is there any alliance abroad and how do you visualize thecondition of the export market in the near future?

S Mishra : Over a period of time, we have been exporting equipment to nearby countries like SaudiArabia, Bangladesh, Sri Lanka, China and Thailand. These equipment were mainly refractory equipmentsuch as friction screw presses, mixers, crushing and grinding equipment.

Apart from the above, we have delivered Rolling mill equipment to Bangladesh based on SMS Demagdesign. Presently we shall be exporting Vertical roller mill equipment for cement plant to Bangladesh.

We have established marketing tie-ups abroad mainly for the refractory equimpment and are workingtowards achieving our future goals.

Mr. S. MishraGeneral Manager, Hari Machines Ltd.

l In terms of volume of sales, you have always achieved highertargets in the past. What is the target for the on going financial yearand what are your niche areas at present? In the near future, willthere be any major change in the market segments?

S Mishra : We are targeting a turnover of 500 crores by 2010 fromour present level of 100 crores. The steel, metallurgical & cement sectoris buoyant now and will grow continuously in future too.

HML has ventured into mineral beneficiation (the Sunrise industry)in technical assistance with Allmineral, Germany who are one of theworld leaders in the field of mineral beneficiation. The main applicationsare coal & iron ore.

Light compact design

Rotor Picks

petroleum coke, etc. down to asize suitable for continuoustransport and further processing.

Feeder breaker supplied byDBT have wide range ofcapacities up-to 2500 tons perhour. The machine comes withvarious design which can be usedas stationary, semi-mobile ormobile units. In some of thespecial design, the expensiveconcrete foundation is notrequired at all. For specificapplications without a feedinghopper, no expensive ramp isrequired to feed the crusher.

With the special design ofrotor, an output size as low asminus 100 mm can be obtainedin single stage of crushing only. Thus, secondary crushing is notnecessary thereby reducing thecapital and the operating cost ofthe machine. The integratedchain conveyor are robust and have chain breaking strength up-to 150 tons thereby reducing the frequentbreaking of chains.

The integral PLC system monitors and controls the crusher and conveyor drives, thus permitting theunmanned/remote control automatic operation of the crusher. Choking (plugging) is negated because,if there is an overload to the crusher, the simple reversal of the conveyor will clear the crusher, eliminatingthe need of lost time and labour intensive manual cleaning.

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“HML is all set with world class technologyto become a major player in mineralbeneficiation in India”

Considering the future growth plans in Power & Steel sectors in India, the main raw material i.e. coal& iron ore will be very vital with regards to quality & availability. Though India is self sufficient in termof non-coking coal & iron ore but most of the deposits are not of right grade. Therefore, beneficiationof low grade Coal & Iron ore will go a long way in augmenting the mineral availability and also sustainthe ecological balance in the long run. HML is geared up to execute turnkey projects. BOO (Build,Own,Operate) & BOOT (Build,Own,Operate,Transfer) solutions in mineral beneficiation.

l Do you feel there will be any major change in the overall markets for the products of yourcompany? How well equipped are you in terms of product diversification from the point of viewof your customers’ need?

S Mishra : Our existing markets will remain buoyant in near future. Additionally with mineralprocessing & beneficiation products in our bag, we will be targeting coal & iron ore mine as well as userindustries of these raw materials like cement, steel, sponge iron, power sector, etc.

The major deposits of coal & iron ore are located in Orissa, Jharkhand & Chattisgarh. These statesare also attracting most of the future capital investment (to the tune of 3 lac crores) with regard to steel& metallurgical based industries.

Therefore, we have a strategic locational advantage being close to our present as well as futurecustomers. HML has already developed the design capabilities for new product development. Thecomplete infrastructure to address to various needs including automation is present.

We are also continuously upgrading the manufacturing facilities and also that the existing facility iscapable to manufacture a varied product range i.e. crushing, grinding, mixing, pressing refractoryapplications, rolling mill equipments, continuous casting, pipe plant, blast furnace, VRM, Kilns & Coolersfor various applications.

We have a capable team of trained manpower to take care of all kinds of sourcing and manufacturingneeds.

l Who is your major customers’ base at present – both Indian and foreign? Tell us somethingabout the export sales of your company. Is there any alliance abroad and how do you visualize thecondition of the export market in the near future?

S Mishra : Over a period of time, we have been exporting equipment to nearby countries like SaudiArabia, Bangladesh, Sri Lanka, China and Thailand. These equipment were mainly refractory equipmentsuch as friction screw presses, mixers, crushing and grinding equipment.

Apart from the above, we have delivered Rolling mill equipment to Bangladesh based on SMS Demagdesign. Presently we shall be exporting Vertical roller mill equipment for cement plant to Bangladesh.

We have established marketing tie-ups abroad mainly for the refractory equimpment and are workingtowards achieving our future goals.

Mr. S. MishraGeneral Manager, Hari Machines Ltd.

l In terms of volume of sales, you have always achieved highertargets in the past. What is the target for the on going financial yearand what are your niche areas at present? In the near future, willthere be any major change in the market segments?

S Mishra : We are targeting a turnover of 500 crores by 2010 fromour present level of 100 crores. The steel, metallurgical & cement sectoris buoyant now and will grow continuously in future too.

HML has ventured into mineral beneficiation (the Sunrise industry)in technical assistance with Allmineral, Germany who are one of theworld leaders in the field of mineral beneficiation. The main applicationsare coal & iron ore.

Light compact design

Rotor Picks

petroleum coke, etc. down to asize suitable for continuoustransport and further processing.

Feeder breaker supplied byDBT have wide range ofcapacities up-to 2500 tons perhour. The machine comes withvarious design which can be usedas stationary, semi-mobile ormobile units. In some of thespecial design, the expensiveconcrete foundation is notrequired at all. For specificapplications without a feedinghopper, no expensive ramp isrequired to feed the crusher.

With the special design ofrotor, an output size as low asminus 100 mm can be obtainedin single stage of crushing only. Thus, secondary crushing is notnecessary thereby reducing thecapital and the operating cost ofthe machine. The integratedchain conveyor are robust and have chain breaking strength up-to 150 tons thereby reducing the frequentbreaking of chains.

The integral PLC system monitors and controls the crusher and conveyor drives, thus permitting theunmanned/remote control automatic operation of the crusher. Choking (plugging) is negated because,if there is an overload to the crusher, the simple reversal of the conveyor will clear the crusher, eliminatingthe need of lost time and labour intensive manual cleaning.

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l Different customers have different needs. How do you technically illustrate and rank thecustomers’ specific needs and demands in terms of the usability of your products? Is there any coreprocess that needs particular attention?

Dr. Breuer : Practically any beneficiation plant is tailormade for different capacities,different raw materials, different product specs, different site conditions. Although we are trying tostandardise plants and equipment in order to reduce costs, from experience we know every customerhas got special needs and we have to follow these requests. At the end, the customer will be successful,technically and economically, only, if technology and plant design guarantee product quality, high yieldsand low operation costs. And that´s our goal to provide the customer with the best technique availablefor the specific application with an optimized overall economy.

l What is the main technology behind the operations of AllJig? Please describe its mainapplication areas along with its advantages. How the operating parameters of AllJig jigging machinescold be optimized?

Dr. Breuer : Stratification of raw materials according to specific density by pulsating water andefficient separation of the stratified bed into a light and heavy fraction. Sounds easy, but there is sometechnology and a lot of experience with a wide variation of applications behind it. And always, a designthat allows for optimization of all relevant parameters in wide ranges for high specific throughputs athigh efficiencies, combined with constant and easy operation.

l What are the main areas where AllFlux could be usefully implemented? How does thissystem works and what are the advantages the customers’ can get out of it? How long this processhas been proved to the useful in the industry?

Dr. Breuer : Fine feed sizes, extremely high throughputs in a single unit of up to 2000 cum/h withup to 750 t/h solids, three products of different density resp. size out of one unit, that´s the basis for thesuccess with allflux since more than ten years now.

l The Allair Jig is mainly useful in coal beneficiation. What are its advantages? How beneficialcan this be in upgrading the coal and increasing its calorific value when it comes to be one of themajor inputs in power plants?

Dr. Breuer : It is well proven whether coal is upgraded by wet or dry technology, the reduction in ash,sulphur, mercury and other mineral contaminants while increasing the calorific value, benefit thecleanliness, efficiency and operating costs of power plants. Consuming high-ash and high-sulphur coalin the production of power contributes to pulverizer wear, boiler tube wear, slagging and fouling and lossof availability and loss of generation capacity.

Dry beneficiation of coal offers a number of unique advantages. Governments all over the world arecontinuing to place even more stringent limits on the release of pollutants from coal cleaning plants. Airjigging has an inherent advantage since it uses no process water. Also Allmineral provides fabric dustcollectors with all of our dry jigging plants, therefore dust pollution is essentially eliminated. Thus, oneof the principal advantages of the Allair Jig plant is environmental friendliness.

Dry cleaning does not introduce a moisture penalty to the clean coal product, which is particularlyimportant if the amount of improvement needed is minimal. The processing cost for upgrading coal with

“Our goal is toprovide the besttechnology forspecific application.”

Dr. - Ing. Heribert BreuerManaging DirectorAllmineral GmbH & Co. K. G, Germany

l Please elaborate the main areas of application for Mineral Beneficiation? What are its variousstages of the beneficiation process and what are its main utilities?

Dr. Heribert Breuer : The majority of mined mineral raw materials has to be beneficiated to meetthe demands of the users, steel mills and related producers of sponge iron etc., power stations, cokingplants, nonferrous metal producers. The core process of any beneficiation plant is the separation process,where differences in physical properties between the value mineral and the nonvalue associated minerals(gangue) are used. These differences may exist in density (gravity separation), magnetism (magneticseparation) or surface properties (flotation) for example.

Typically these mechanical processes are more economical than using low grade materials in thefollowing metallurgical applications. One of the most important separation processes is density separation,and that is the technology where allmineral is specialized in, from coarse to fine feed sizes, wet or dryprocesses.

l In case of Ore Beneficiation, how can the Allmineral’s AllJig, AllFlux and AllAir systemscan really be helpful in reducing the overall input cost after installation at the customers’ end inthe long run?

Dr. Breuer : Talking about ore beneficiation means wet processing, with alljig and allflux. In caseof iron ore a lot of mined ore has been dumped because of its low grade or certain parts of the deposithaven´t been mined , i.e. the existing resources have been used partially only. Allmineral technologiesoffer the possibility to produce high value products according to international specifications out of rawmaterials which were discarded up to now. A highly profitable and very ecological investment, generatingvalue out of “waste” and extending the life time of the resource.

Any beneficiation plant is tailormade for different

raw materials, different products specifications,

different site conditions, etc. Efforts are made

to standardize plants and equipment in order to

reduce cost. Customers have special needs and

that has to be followed up to their satisfaction

limits, says Dr. Heribert Breuer, in a close

interview with Iron & Steel Review.

S U P P L E M E N T

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l Different customers have different needs. How do you technically illustrate and rank thecustomers’ specific needs and demands in terms of the usability of your products? Is there any coreprocess that needs particular attention?

Dr. Breuer : Practically any beneficiation plant is tailormade for different capacities,different raw materials, different product specs, different site conditions. Although we are trying tostandardise plants and equipment in order to reduce costs, from experience we know every customerhas got special needs and we have to follow these requests. At the end, the customer will be successful,technically and economically, only, if technology and plant design guarantee product quality, high yieldsand low operation costs. And that´s our goal to provide the customer with the best technique availablefor the specific application with an optimized overall economy.

l What is the main technology behind the operations of AllJig? Please describe its mainapplication areas along with its advantages. How the operating parameters of AllJig jigging machinescold be optimized?

Dr. Breuer : Stratification of raw materials according to specific density by pulsating water andefficient separation of the stratified bed into a light and heavy fraction. Sounds easy, but there is sometechnology and a lot of experience with a wide variation of applications behind it. And always, a designthat allows for optimization of all relevant parameters in wide ranges for high specific throughputs athigh efficiencies, combined with constant and easy operation.

l What are the main areas where AllFlux could be usefully implemented? How does thissystem works and what are the advantages the customers’ can get out of it? How long this processhas been proved to the useful in the industry?

Dr. Breuer : Fine feed sizes, extremely high throughputs in a single unit of up to 2000 cum/h withup to 750 t/h solids, three products of different density resp. size out of one unit, that´s the basis for thesuccess with allflux since more than ten years now.

l The Allair Jig is mainly useful in coal beneficiation. What are its advantages? How beneficialcan this be in upgrading the coal and increasing its calorific value when it comes to be one of themajor inputs in power plants?

Dr. Breuer : It is well proven whether coal is upgraded by wet or dry technology, the reduction in ash,sulphur, mercury and other mineral contaminants while increasing the calorific value, benefit thecleanliness, efficiency and operating costs of power plants. Consuming high-ash and high-sulphur coalin the production of power contributes to pulverizer wear, boiler tube wear, slagging and fouling and lossof availability and loss of generation capacity.

Dry beneficiation of coal offers a number of unique advantages. Governments all over the world arecontinuing to place even more stringent limits on the release of pollutants from coal cleaning plants. Airjigging has an inherent advantage since it uses no process water. Also Allmineral provides fabric dustcollectors with all of our dry jigging plants, therefore dust pollution is essentially eliminated. Thus, oneof the principal advantages of the Allair Jig plant is environmental friendliness.

Dry cleaning does not introduce a moisture penalty to the clean coal product, which is particularlyimportant if the amount of improvement needed is minimal. The processing cost for upgrading coal with

“Our goal is toprovide the besttechnology forspecific application.”

Dr. - Ing. Heribert BreuerManaging DirectorAllmineral GmbH & Co. K. G, Germany

l Please elaborate the main areas of application for Mineral Beneficiation? What are its variousstages of the beneficiation process and what are its main utilities?

Dr. Heribert Breuer : The majority of mined mineral raw materials has to be beneficiated to meetthe demands of the users, steel mills and related producers of sponge iron etc., power stations, cokingplants, nonferrous metal producers. The core process of any beneficiation plant is the separation process,where differences in physical properties between the value mineral and the nonvalue associated minerals(gangue) are used. These differences may exist in density (gravity separation), magnetism (magneticseparation) or surface properties (flotation) for example.

Typically these mechanical processes are more economical than using low grade materials in thefollowing metallurgical applications. One of the most important separation processes is density separation,and that is the technology where allmineral is specialized in, from coarse to fine feed sizes, wet or dryprocesses.

l In case of Ore Beneficiation, how can the Allmineral’s AllJig, AllFlux and AllAir systemscan really be helpful in reducing the overall input cost after installation at the customers’ end inthe long run?

Dr. Breuer : Talking about ore beneficiation means wet processing, with alljig and allflux. In caseof iron ore a lot of mined ore has been dumped because of its low grade or certain parts of the deposithaven´t been mined , i.e. the existing resources have been used partially only. Allmineral technologiesoffer the possibility to produce high value products according to international specifications out of rawmaterials which were discarded up to now. A highly profitable and very ecological investment, generatingvalue out of “waste” and extending the life time of the resource.

Any beneficiation plant is tailormade for different

raw materials, different products specifications,

different site conditions, etc. Efforts are made

to standardize plants and equipment in order to

reduce cost. Customers have special needs and

that has to be followed up to their satisfaction

limits, says Dr. Heribert Breuer, in a close

interview with Iron & Steel Review.

S U P P L E M E N T

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dry technology is often quite low and further enhanced by the elimination of water treatment and finesdewatering and disposal. And, of course, there are many locations where water is scarce or extremelyexpensive. Dry processing for these applications is sometimes the only option, short of abandoning thereserve.

Most of these advantages are inherent with all dry processing technologies; and for many decades verylittle coal was improved with dry methods. The renewed interest in dry-cleaning in general, and the AllairJig in particular, is primarily due to improvements in performance. By optimizing the stratification offeed particles and introducing an automatic bed level control system, the Allair Jig offers mine operatorsa dry processing system with a quantum improvement in separating efficiency. Their coal can be upgraded,dry, without a severe penalty in yield. Coal producers in India will soon learn about the benefits of drycleaning with an Allair Jig; OCL already has one in operation at a DRI plant in Rajgangpur.

l (In terms of maintenance cost, how far the Allminerals systems could be beneficial to theuser industries?) Apart from steel and power, what are the other major industries these productscould be very useful in the country?

Dr. Breuer : Non ferrous metals like chromite or manganese ore, and aggregates for the concreteindustry, that´s by far the biggest market for our systems in Europe and the US now a days. High qualityaggregates, no contaminants, customized sands, that´s what demanded there and we can guarantee it.

l This is the first time that these types of systems are coming to India. What do you think,would be the keys to success in the country? Is there any particular strategy that you would liketo follow while marketing the products in the country?

Dr. Breuer : We are the leader in jigging technology, wet and dry, worldwide, i.e. with about 300installations in 15 years its proven technology. The biggest dry coal beneficiation plant in the world inTeruel/ Spain is equipped with 12 allair- airjigs for more than 600 tph capacity. Last but not least, therecent contract for the supply of 18 alljigs for iron ore upgrading at the new 16 million tons per yearSishen Expansion Plant of Kumba Resources in South Africa demonstrates our outstanding position.

The potentials for the allflux technique with more than 50 installations are looking brighter with anynew application, among others, 5 installations on iron ore in the last 3 years.

I´m sure that´s a good background, because the technology is the key, and solid references.

l You have a strong Indian partner who is an established name. To what extent this has helpedyou? What would be your target industries and how much business you would expect to generatein your first year of operation?

Dr. Breuer : It took a while before we decided to becoming active in India. But once we met themanagement of Hari Machines and Mr. Dalmia itself it became clear for us, these are the right partners.Now we have the appropriate basis to jointly develop business in India, with partners active in this kindof business for many years and a very good understanding for technical and market needs.

From experience we know it takes some time to generate business in a new market, but with theemerging Indian economy, best available technology background and the strong local partner we arevery optimistic to get the first contract in very short term and then it will start running.

ISO : 9001HARI MACHINES LIMITEDRegd. Office & Works :- Rajgangpur - 770 017 (Orissa) India. Phone : 91-6624-220-141/161, Fax : 91-6624-220-151

Email : hml@harimachines.in, Website : http:/www.harimachines.com

Kolkata Office :- 12C, Stephen House, 4 B.B.D. Bag, Kolkata - 700 001, India. Phone : 91-33-22487612/4451Fax : 91-33-2248-7155, Email - hmlkol@harimachines.in

Airjig Plant at Ohio, USA

Alljig Plant at Germany

Allflux Plant at USA

HARI MACHINES LIMITED