imyb2011_r&d

Indian Minerals Yearbook 2011

(Part- I)

50th Edition

RESEARCH & DEVELOPMENT

(ADVANCE RELEASE)

GOVERNMENT OF INDIA MINISTRY OF MINES

INDIAN BUREAU OF MINES

Indira Bhavan, Civil Lines, NAGPUR – 440 102

PHONE/FAX NO. +91712 - 2565471

PBX : +91712 - 2562649, 2560544, 2560648 E-MAIL : [email protected]

Website: www.ibm.gov.in

October 2012

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5 Research & Development

The Science and Technology programmes (S&T)of the Ministry of Mines, Government of India,

cover the disciplines of Geology, Exploration,Mining, Bioleaching, Beneficiation, Rock Mechanics,Ground Control and Non-ferrous Metallurgy andenvironmental issues related to mining andmetallurgy. During 2010-11, 2 meetings were held byProject Evaluation and Review Committee (PERC).Based on its scrutiny report, Standing ScientificAdvisory Group (SSAG) considered andrecommended for Grant-in-Aid under S & Tprogramme of the Ministry of Mines. The SSAGalso approved eight projects in the 41st meetingheld on 7 June 2011.

The highlights of work carried out during2010-11 by various research organisations andindustries relating to mineral beneficiation andmining & environment are given below:

1. BENEFICIATION1.1 Bauxite

Process Development to reduce iron frombauxite for preparation of calcined bauxite(IMMT):

The sponsor, M/s Gokul Minex Pvt. Ltd,

Ahmedabad, has plans to utilise the bauxite deposit of

Udgeri region in Kolhapur district of Maharashtra for

making calcined bauxite. The objective of the project

was to develop suitable process flow sheet for the

removal of iron from the bauxite, with Fe2O

3 content of

6-8% in the ROM sample, through roasting-magnetic

separation process to prepare the quality of bauxite

suitable for preparation of calcined bauxite. Various

process schemes for removal of iron to the desired level

were tried by treating raw bauxite by both dry and wet

magnetic separation. The investigation also includes

study on the effect of roasting of bauxite followed by

magnetic separation on iron removal to meet

specifications of calcined bauxite. The results of the

study indicated that it was possible to remove iron to

the desired level of less than 3.0% as Fe2O

3 in the non-

magnetic fraction at a yield of 38%. The final process

scheme developed recommends processing of raw

bauxite lumps through roasting followed by crushing

and dry high intensity magnetic separator (85 wt%) at

particles of -1 mm + 0.15 mm. The scheme minimises

energy and water requirements while economising the

processing costs.

1.2 Beach Sand

Studies on heavies from beach and dune sandsof South-eastern coast of India with specialre ference to recovery and in dep thcharacterisation of zircons (IMMT):

The main objective of the study was separation of

differenet heavies by using different physical

beneficiation techniques and characterisation of

heavies in beach sands with special reference to zircon.

Zircon (ZrSiO4) is found usually as a constituent in

heavy mineral sand assemblages which include ilmenite,

rutile, leucoxene, monazite and garnet in varying

proportions. Investigations were carried out to enrich

zircon from beach sands of Odisha coast. Recovered

zircons are used for making zircon bricks and are fired

at different temperatures in an industrial tunnel kiln.

Physical, chemical and thermo-mechanical properties

are evaluated. Mineralogical properties are correlated

with the thermo-mechanical properties. The developed

bricks were compared with the standards and found

suitable for refractory industrial applications.

Similar studies were carried out to recover zircons

from red sediment samples from Bad Lands topography

of Odisha (Basanputti village, Ganjam district) and

Andhra Pradesh (Srikakulam). Physical, chemical and

minerological properties were studied. The product

achieved from red sediment sands containing 95%

total heavy minerals (THM) through mineral

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separator indicated 94% recovery. A product obtained

by stage spirals containing 98.9% total heavy minerals

achieved 98.6% recovery. The THM achieved from

spiral concentrator was subjected to high tension roll

separator to recover titaniferrous minerals (ilmenite and

rutile).

1.3 Copper OreUpgradation of composite copper ore from

Banwas , Khetr i and Kol ihan Mines for

HCL(IBM):

A composite copper ore sample from Khetri,

Kolihan and Banwas mines was sent at RODL, IBM,

Ajmer with an objective to achieve a concentrate of

18-20% Cu with 90-92% recovery. The as received

composite sample assayed 0.96% Cu, 59.01% SiO2,

2.52% S, 12.82% Fe and 71.65% acid insolubles.

Flotation at 62.5% minus 200 mesh grind and subjecting

the rougher float to re-grinding and cleaning in three

stages yielded a concentrate assaying 24.26% Cu,

33.91% Fe and 5.95% acid insoluble with 90.8% copper

recovery (Wt% yield 3.6). The copper concentrate

meets all the specifications stipulated by HCL.

Upgradation of a Copper Ore (Core) sample from

Chittorgarh, Rajasthan for M/s MECL (IBM):

A core sample of copper ore from Wari Copper

Project, district Chittorgarh, Rajasthan was sent by

M/s MECL, Nagpur at RODL, IBM, Ajmer to establish

the amenability of the sample to produce a copper

concentrate suitable for Indian smelters. The as

received sample assayed 1.20% Cu, 46.71% SiO2, 7.65%

Fe(T) and 74.48% acid insolubles.

Flotation Test at 66.5% minus 200 mesh grind

could yield a concentrate assaying 20.94% Cu, 30.56%

Fe, 5.66% SiO2, 11.54% acid insolubles with 87.2%

copper recovery (wt% yield 4.9). The copper

concentrate meets the specifications stipulated by

M/s MECL.

1.4 GoldReovery of Gold from Bhukia (East) Block,

Banswara, Rajasthan for MECL, Nagpur (IBM):

A gold ore from Bhukia (East) Block, Banswara

district, Rajasthan sent by MECL Ltd, Nagpur

contained 2 g/t gold and 51.0 g/t silver with other major

constituents assaying 29.66% SiO2, 25.92% Fe

2O

3,

8.94% CaO, 11.88% S(T), 4.34% MgO, 3.13% Na2O and

6.86% LOI. The sample was sent at RODL,IBM,

Bengaluru with an objective to optimise a process for

gold recovery. By employing bottle role cyanidation,

cyanide leach concentrate with 96% Au and 40% Ag

values could be extracted by cyanide leaching followed

by Carbon – In – Leach (CIL) process. The

consumption of sodium cyanide would be 2.72 kg per

tonne. The results achieved appear to be encouraging.

1.5 Iron Ore

Bench Scale Beneficiation studies on Iron OreFines Sample from Ghatkuri Iron Ore mines forM/s Orissa Manganese & Minerals Limited(IBM):

An Iron ore fine sample was received in theModern Mineral Processing Laboratory and Pilot Plant,IBM, Nagpur from Ghatkuri iron ore mines, Odisha forcarrying out bench scale beneficiation studies and todevelop a process flow sheet, for producing an ironconcentrate with maximum grade and recovery.

The as received sample assayed 51.13% Fe(T),12.75% SiO

2, 6.53% Al

2O

3, 0.23% CaO, 0.01% MgO,

0.05% P, 0.41% TiO2, 0.06% Mn and 5.48% LOI.

Tabling on as received sample reduced to all -65mesh could produce table concentrate assaying 63.90%Fe(T), 2.87% SiO

2, 2.36% Al

2O

3 & 2.68% LOI with weight

percent yield of 23.4 & Fe(T) recovery of 29.2%.

Composite of table concentrate & table middlingcould produce table concentrate assaying 60.85% Fe(T),5.04% SiO

2, 3.76% Al

2O

3 & 3.82% LOI with overall

weight per cent yield of 48.5% & overall Fe(T) recovery57.7%.

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Stub cyclone of the as received sample reduced toall -100 mesh yielded a concentrate (Underflow)assaying 58.23% Fe(T), 6.55% SiO

2, 3.90% Al

2O

3 and

3.75% LOI with weight per cent yield of 68.5% & Fe(T)recovery of 78.0%.

Wet High Intensity Magnetic Separation (20,000gauss) on Stub Cyclone Underflow (concentrate) couldproduce a concentrate (magnetic) assaying 62.98%Fe(T), 3.00% SiO

2, 2.73% Al

2O

3 and 2.70% LOI with

overall weight per cent yield of 53.8% (overall Fe(T)recovery of 66.2%).

The above concentrate produced may find utilityin iron & steel industry after pelletisation.

Beneficiation studies of BHQ ore by magneticseparation techniques to prepare pellet gradeconcentrate (IMMT):

Considering the availability of huge resources ofbanded iron ores in our country, IMMT, Bhubaneswarhas explored the possibility of producing suitable ironconcentrate for pellet making from these lean ores. Asthe high grade ores are dwindling sharply and to meetthe future needs of iron and steel industries, it isessential to develop a cost effective process for thebeneficiation of lean ores like BHQ to produce qualityiron concentrate. In this connection, MSPL Limited,Karnataka has come forward to set up a commercialbeneficiation plant to produce an iron concentratesuitable for the iron and steel making. The lean gradeBHQ ore sample received from MSPL contains ~38.0%Fe and 42% SiO

2. The mineralogical finding of the

sample indicated that the sample contains hematite,magnetite and quartz as major minerals and theliberation of these minerals is around 75 microns. Thebeneficiation studies consisting mainly of sizereduction followed by low and high intensity magneticseparation have indicated that an iron concentrate with64% Fe at 40% yield could be obtained. Alternateprocess flow sheets with different combinations havebeen suggested to recover the iron values suitable forpellet making.

Beneficiation of iron ore fines for Finex processof iron making (IMMT):

The objective of the studies was to develop asuitable beneficiation scheme to upgrade the low grade

iron ore fines (-10.0 mm) to generate concentrate forFinex process of iron making. The low grade iron orefines sample on an average contained 58.4% Fe, 4.3%SiO

2 and 4.7% Al

2O

3. The various minerals associated

in this ore are hematite, vitreous goethite, ochreousgoethite, gibbsite, kaolinite and quartz. The averagehematite content in the bulk sample is 46.30%. Variousbeneficiation techniques such as scrubbing, jigging,spiraling and magnetic separation have been used torecover the iron values. Different alternative flow-sheets have been suggested to recover the iron valuessuitable for Finex process for steel making. Theinvestigations have indicated that iron concentrate with64% Fe at 69% yield could be obtained by combinationof screening, jigging hydro-cyclone and magneticseparation techniques. The settling studies of bothconcentrate and tailings and the mineralogical findingsof the sample are also incorporated in the report.

Beneficiation of low grade iron ore fines to producequality concentrate (IMMT):

The main objective of the studies was to develop a

suitable beneficiation scheme to beneficiate low grade

siliceous iron ore fines (-10.0 mm) with 50-52% Fe to

prepare quality raw material for sintering and

pelletisation and to suggest optimum flow sheet which

can generate concentrate with more than 60-63% Fe

with appreciable yields & recoveries for both the

purposes. Detailed characterisation and beneficiation

studies were carried out on low-grade siliceous iron

ore of C.N. Halli sector containing around 50% Fe and

limited studies were carried on low grade iron ore of

BBH Chitradurga with 51.0% Fe. The characterisation

studies of C.N. Halli sample indicated the presence of

hematite as major mineral with minor amount of goethite,

limonite and quartz. The low grade iron ore of BBH

showed the presence of manganese minerals. The

optimum liberation of both the samples was found to

be below 150 micron. Beneficiation studies were carried

out by conventional beneficiation techniques such as

scrubbing, hydrocyclone, spiral, magnetic separation

by WHIMS/HGMS and their combinations. Different

schemes have been suggested to get a good grade and

yield by adopting classification, jigging, magnetic

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separation. The other combination yielded higher Fe

content with low weight recoveries.

Development of Commercial Flow sheet forBeneficiation of Low Grade Ore Fines forPelletisation (IMMT):

Three types of low grade fine samples having below

10 mm size particles were received. Detailed size and

chemical analysis and mineralogical studies were carried

out. Two of these samples contained 55-56% Fe. After

beneficiation, the grade of concentrate could be

improved to 63-64% with yield of 65-67% using

combination of gravity and magnetic separation

processes including the desliming of the ore by

scrubbing at the beginning. Another sample contained

61.89% Fe. After beneficiation, the grade of concentrate

could be improved to 65-65.5% with yield of 81-82%.

Processing of Low Grade Iron Ore Resources(NML):

A CSIR network research programme was

undertaken at CSIR-NML, Jamshedpur with IMMT,

Bhubneswar as the nodal laboratory NEIST, Jorhat

and CEERI, Pilani as participating laboratories towards

developing technology for gainful utilisation of low

grade iron ores, through systematic studies involving

characterisation, beneficiation and agglomeration.

Low grade iron ore samples were collected from

Gua and Meghtaburu mines of SAIL and a low grade

siliceous iron ore sample from Goa. Detailed

charcterisation and beneficiation studies involving

gravity, magnetic and flotation techniques were carried

out on low grade iron ore and the flowsheet was

developed which indicated an overall yield of about

75% inclusive of sinter fines with +63% Fe and pellet

fines of 65% Fe. A product with +63% Fe and 5.8%

SiO2 is obtainabale from BHQ from Meghahatuburu

through WHIMS and flotation. The flowsheet

developed for iron ore samples from Goa indicated that

a sinter fines of +63% Fe and a pellet fines with 65% Fe

is obtainable through jigging, spiralling, hydrocyclone

and WHIMS.

Studies were carried out on sintering of concentrate

obtained from processing of dump fines sample from

Gua. The effect of process variables namely basicity,

bed height, vertical speed of sintering (VSS), MgO

content of sinter, on the productivity and quality

parameters of sinter was investigated. The study

shows that an acceptable RDI of 28% could be achieved

at 2.6 sinter basicity and at lower bed height. Coke

breeze at 5% of the raw mix and moisture content in

between 5.5% to 5.8% seems to be optimum for an

acceptable strength (TI) of siner and in relation to RDI

of sitner.

Beneficiation of a low grade iron ore samplefrom Thakurani Iron Ore Mines, Noamundi,District West Singhbhum, Jharkhand (IBM):

A low grade iron ore sample from Thakurani Iron

Ore Mines, Noamundi, District West Singhbhum,

Jharkhand was received through IBM, Kolkata office

at Modern Mineral Processing Laboratory and Pilot

Plant, IBM, Nagpur for conducting bench scale

beneficiation studies.

The as received sample assayed 37.33% Fe(T),

0.13% FeO, 45.43% SiO2, 0.40% Al

2O

3, 0.046% CaO,

0.004% MgO, 0.018% TiO2 and 0.30% LOI.

By adopting gravity concentration, the composite

table concentrate (Conc. I + Conc.II) obtained at minus

150 mesh size assayed 59.50% Fe(T) & 13.73% SiO2

with 43.2% Fe(T) recovery(Wt% yield 43.2).

The upgradation of low grade iron ore to 59.50%

Fe(T) from 37.33% Fe(T) is appreciable. This

concentrate may find application in iron industry after

blending.

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Baseline audit (Phase I) of M/s BMM Ispat Ltdof an iron ore processing plant, Danapur,Karnataka (IBM):

M/s. BMM Ispat Ltd is operating an iron orebeneficiation plant at Danapur, Hospet, Bellary District,Karnataka using sub-grade iron ores of the region.BMM observed that the concentrate productivity andrecovery were below design levels. Based on the in-plant technical auditing studies carried out by RODL,IBM, Bengaluru, the throughput of the plant wasincreased from 120 TPH to 162 TPH i.e. 35% increasefrom baseline data. Also the iron ore recovery wasincreased from 75 to 82% and the tailing losses reducedfrom 47.68% to 40.62% Fe. The studies helped in costbenefit i.e. approx. 10% reduction in operating cost.

Upgradation of Iron Ore sample from BBHMines for M/s Voltas Limited, Bengaluru (IBM):

An iron ore sample from BBH Mines, BheemaSamudra, Chitradurga, Karnataka was received atRODL, IBM, Bengaluru so as to upgrade iron contenteconomically. Various beneficiation techniquesincluding washing and screening, scrubbing and sizing,gravity separation, magnetic separation and reductionroasting followed by magnetic separation were adoptedto upgrade iron content.

As received sample assaying 52.11% Fe(T), 7.16%SiO

2, 3.16% Al

2O

3, 5.33% Mn was upgraded to a

concentrate assaying 60.30% Fe(T), 4.99% SiO2 and

4.09% Mn with 87.0% recovery( Wt% yield 75.2) byreduction roasting at -48 mesh followed by magneticseparation. The concentrate obtained finds industrialapplication after blending.

Beneficiation of Composite iron ore sample fromBellary dis tr ic t , Karnataka of M/s AllumPrashanth, Mine Owner, Bengaluru (IBM):

A composite iron ore sample from Bellary district,Karnataka was sent by M/s Allum Prashanth, MineOwner, Bengaluru for beneficiation studies at RODL,Bengaluru to develop the flow sheet so as to achievea iron concentrate assaying Fe >65% with maximumrecovery.

The as received sample assayed 36.31% Fe(T),5.08% FeO, 42.70% SiO

2, 0.40% Al

2O

3, 0.84% CaO, 1.44%

MgO and 0.16% LOI.

The beneficiation flow sheet comprised followingroutes for obtaining desired iron concentrate:

(a) Tabling of the as received sample groundto all minus 200 mesh yielded an ironconcentrate assaying 67.84% Fe(T),2.99% SiO

2 and 0.18% Al

2O

3 with Fe(T)

recovery of 72.2% (wt % yield 38.1).

(b) Alternative route is that minus 200 meshsample when subjected to tablingfollowed by ferrous wheel magneticseparation, the combination of table andcleaner magnetic concentrate yielded aconcentrate assaying 65.25% Fe(T),9.47% FeO, 7.01% SiO

2 and 0.18% Al

2O

3

with Fe(T) recovery of 83.9% (Wt% yield46.0).

The above concentrates may find application inpelletisation.

Upgradation of low grade Iron Ore fines to Pelletgrade concentrate (IBM):

A low grade iron ore fines sample from BarbilRegion, Odisha was sent by M/s Jaganathpur SteelLimited, Ranchi, Jharkhand at RODL, IBM, Bengaluruwith an objective to evolve a flow sheet to produce apellet grade concentrate. The as received sampleassayed 58.15% Fe(T), 7.05% SiO

2, 4.39% Al

2O

3, 0.07%

Mn, 0.05% CaO and 4.30% LOI. By adopting gravityseparation after grinding at 95% minus 50 mesh in rodmill a concentrate assaying 65.83% Fe(T), 1.83% SiO

2,

1.37% Al2O

3, 0.05% Mn with 62.5% Fe(T) recovery with

Wt% yield of 55.5 could be obtained. The concentratemeets the specifications of the party.

1.6 Limestone

Beneficiation studies on a limestone samplefrom Sahedpur, d is t r ic t Morena (MP) forM/s Abhijeet Cement Ltd, Nagpur (IBM):

The limestone sample from M/s Abhijeet CementsLtd, Nagpur was sent at Modern Mineral ProcessingLaboratory and Pilot Plant, IBM, Nagpur to develop asuitable process flow sheet to produce a concentrate,which may find application in cement industry.

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The as received sample assayed 42.12% CaO, 1.83%Fe

2O

3, 14.83% SiO

2, 3.88% Al

2O

3, 0.63% MgO, 0.26%

TiO2, 1.43% K

2O, 0.21% Na

2O and 34.50% LOI .

(a) By adopting dry screening at -40mm size aconcentrate of -40+4mm fraction assaying44.10% CaO, 1.47% Fe

2O

3, 13.28% SiO

2, 3.0%

Al2O

3, 0.56% MgO and 35.49% LOI with

wt% yield of 88.8 and CaO recovery of 90.5%could be obtained.

(b) By adopting flotation route at a grind of87.2% -200 mesh a concentrate assaying48.11% CaO, 1.12% Fe

2O

3, 8.31% SiO

2, 2.80%

Al2O

3, 0.43% MgO and 36.59% LOI with

wt% yield 71.7 and CaO recovery of 80.9%could be obtained.

The concentrate produced above meets thespecification stipulated by the party for utilisation as asweetener in cement making.

Bench scale beneficiation studies on Limestonesample from M/s Prism Cement Limestone MinesLtd, Satna, M.P. (IBM):

A limestone sample assaying 35.47% CaO, 22.41%SiO

2, 2.21% Fe

2O

3, 3.81% Al

2O

3, 2.27% MgO and 31.52%

LOI was sent at Modern Mineral Processing Laboratoryand Pilot Plant, IBM, Nagpur by M/s Prism CementLimestone Mines Ltd, district Satna, Madhya Pradeshwith an objective to develop a flow sheet to produce aconcentrate suitable for user industry.

By adopting flotation route a limestoneconcentrate assaying 45.87% CaO, 9.83% SiO

2, 1.39%

Fe2O

3, 2.02% Al

2O

3, 1.60% MgO, 0.09% TiO

2, 0.42%

K2O, 0.3% Na

2O and 38.09% LOI with 80.1% CaO

recovery (wt% yield of 62.2) could be obtained.

The concentrate obtained above meets thespecifications stipulated by the party.

Beneficiation Studies of Lean grade Limestonefor Removal of Silica (IMMT):

The limestone sample roughtly contain ~44.5 -45.3% CaO and 13.5-14.3% SiO

2 as the major chemical

constituents. The alumina, magnesia and iron contentin the given sample are present in very lowconcentrations. The sample consists of calcite (CaCO

3)

and quartz (SiO2) as major mineral phases. The objective

of the project was to enhance the CaO value and reducethe silica content of the sample through physicalbeneficiation techniques. Several studies weretherefore undertaken by both dry and wet beneficiationtechniques to achieve the objective. Froth flotationtechnique was found to be the most suitable method toenhance the CaO content after grinding the material tobelow 50 micron size. The results of the flotation studieshave indicated that it is possible to achieve aconcentrate of 48.4% CaO at 71.5% yield using oleicacid as the collector, MIBC as the frother and sodiumsilicate as the dispersing reagent. The silica content inthe beneficiated concentrate could be brought downto below 7%. Although the calcium component of thesample is very finely disseminated, it was possible toachieve the desired concentrate after fine grindingfollowed by one or two stages of cleaning. Theinvestigations on the commercial grade reagents werealso proved to be efficient to float the calcite valuespresent in the sample.

Synthetic Flux for Basic Oxygen Steel Makingthrough Micro-pelletisation and Sintering ofWaste Oxides (NML):

Ultrafine waste oxides generated in steel plant weresubjeted to micro-pelletisation followed by sinteringto develop a CaO-FeOx type pre-fused flux materialthrough an innovative way. The developed flux materialdissolves in hot metal bath at faster rate owing to itslow softening point and favourable chemistry formingbasic and oxidising slag. The material will findapplication in BOF steel making for faster refining andpartial replacement of high melting lump lime.

1.7 Manganese Ore

Beneficiation of low grade manganese ore bywet high intensity magnetic separator (IMMT):

The objective of the project for Tata Steel wasto carry out beneficiation studies of low gradeferrugenous manganese ore of Joda region toreduce iron content to improve Mn/Fe ratio. Fourdifferent types of samples were subjected toWHIMS at 14000 Gauss & 10000 Gauss to separateiron rich minerals. The Mn/Fe ratio could beincreased to 1.5 to 3 with Mn content 35-42% bythis technique.

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1.8 Nickel

Enrichment of Nickel in Chromite OverburdenMaterials by dry beneficiation (IMMT):

Chromite Overburden Material from differentmining sites of Sukinda was collected for drybeneficiation studies. As received ChromiteOverburden sample was size analysed for both wetand dry process to f ind ou t the n icke lconcentration. The material was subjected to stagecrushing using jaw crusher, roll crusher, where itwas crushed to below 2 mm size. The overburdensample was subjected to VSK separator forseparation of coarse and fine fractions. The effectof different operating parameters, viz, cage wheelspeed (rpm) and vibrating tube feed (rpm) werestudied at constant air rate. The feed sample ofCOB containing 0.9% Ni has been enriched to0.95% Ni in -45 microns fraction.

1.9 Platinum Group Elements

Waste to Wealth: Noble metal Platinum GroupElements recovery from low grade chromite oresof Odisha (IMMT):

Platinum group elements are very rare in nature

and their occurrence is also very limited. In India, Boula

Nausahi Igneous complex is the only proven PGE

deposit but with a very low tenor. In this set up, PGE

occurs in oxide (chromite) and sulfide (Cu-Fe-S) facies

as very tiny grains of around 20 micron. Recovery of

PGE of such fineness from the host rocks is a very

challenging task. The major focus of research will be (i)

Recovery of PGE values from the low tenor hosts by

adopting suitable beneficiation tests and (ii)

Development of process flow sheet for recovery of PGE

from Indian ores.

Throughout the world, PGE are recovered by a

combination of different beneficiation techniques such

as gravity and flotation depending on the nature of

association, mineralogy and size of PGE phases. The

PGE mineralisation at BNIC is totally different from most

of the PGE deposits of world in (i) PGE are very fine (ii)

PGE are present as inclusions & exsolution in the host

chromite and Cu-Fe-S (iii) and very complex geological

set up of this deposit. So the methods adopted

elsewhere are not be suitable for processing this ore.

For the first time an attempt will be made to recover

PGE from the low grade Indian chromite ores.

1.10 Quartzite

Recovery of f loa t g lass concentra te f romQuartzite sample, Pohara, Bhandara district,Maharashtra (IBM):

A quartzite sample from Gadpendri (east),

district Bhandara, Maharashtra, assaying 97.99% SiO2,

0.68% Fe2O

3, 0.60% Al

2O

3, 0.05% CaO, 0.01% MgO,

0.09% K2O, 0.07% TiO

2 & 0.11% LOI was sent by M/s

Maharashtra State Mining Corporation Ltd, Nagpur at

the Modern Mineral Processing Laboratory and Pilot

Plant, IBM, Nagpur. The objective of the investigation

was to produce a quartzite concentrate suitable for use

in the float glass industry. After scrubbing followed

by wet high intensity magnetic separation, the

composite concentrate (-30 + 70 mesh and -70 + 120

mesh) non-magnetic assaying 99.16% SiO2, 0.13%

Fe2O

3, 0.25% Al

2O

3 and 0.11% LOI with 63.5% silica

recovery (wt% yield 62.7) could be obtained. The

composite concentrate meets the specifications

stipulated by the party.

1.11 Rock Phosphate

Upgradation of sub-grade Rock Phosphatesample for M/s RSMM Ltd, Rajasthan (IBM):

A sub-grade rock phosphate sample from

Jhamarkotra Mines, Rajasthan was sent by RSMM Ltd

with an objective to develop a flow sheet to obtain

phosphate concentrate which may be used in fertilizer

industry. The as received sample assayed 13.43% P2O

5,

49.48% SiO2, 5.66% Fe

2O

3, 6.87% Al

2O

3, 20.13% CaO,

0.46% MgO and 2.68% LOI. By adopting flotation route

a phosphate concentrate assaying 32.02% P2O

5, 13.33%

SiO2, 3.22% Fe

2O

3, 1.25% Al

2O

3, 14.22% acid insolubles

with P2O

5 recovery of 81.9% and weight % yield of 33.8

could be obtained. This concentrate may find

application in fertilizer industry.

5-9


Upgradation of low grade Rock Phosphate fromHirapur for M/s Madhya Bharat Agro ProductsLtd, Madhya Pradesh (IBM):

A low grade rock phosphate sample from Hirapurmines, Madhya Pradesh sent by Madhya Bharat AgroProducts Ltd. At Modern Mineral ProcessingLaboratory and Pilot Plant, IBM, Nagpur assayed15.66% P

2O

5, 43.46% SiO

2, 8.54% Fe

2O

3, 5.19% Al

2O

3

and 2.02% LOI.By adopting flotation route, a phosphate

concentrate assaying 34.28% P2O

5, 47.9% CaO, 7.79%

SiO2, 1.23% Al

2O

3 with P

2O

5 recovery of 58.2% (Wt%

yield 26.3) could be obtained.

The concentrate obtained meets the specificationsstipulated by the party.

Development of process flow sheet for RockPhosphate from Jhamarkotra for RSMML,Udaipur (IBM):

A rock phosphate sample from Jhamarkotra, districtUdaipur, Rajasthan sent by RSMM Ltd at RODL, IBM,Bengaluru with an objective to

1) Upgrade the ore to +32% P2O

5 by ore

dressing techniques with maximumpossible P

2O

5 recovery.

2) Develop a process flow sheet keeping inview the present unit operation atRSMML.

3) Optimise and to reduce the reagentconsumption.

The as received sample assayed 14.20% P2O

5,

36.91% CaO, 11.12% MgO, 0.54% Fe2O

3, 2.98% SiO

2. A

composite phosphate concentrate assaying 33.57%

P2O

5, 1.42% MgO, 7.11% SiO

2, was obtained with 83.5%

P2O

5 recovery (wt% yield 35.6) by adopting flotation

route. The concentrate obtained meets the requirement

as stipulated by the party. Also, for obtaining same

grade and recovery of phosphate concentrate the

throughput can be improved by increasing the pulp

density of feed to 50% solids from the initial 34% solids

used in this investigation. By this the phosphoric acid

consumption can also be reduced.

1.12 Sea NodulesRecovering metallic values from sea nodules(NML):

A direct smelting process was developed on 20 kgscale for recovering Cu, Ni & Co (as an alloy) frompolymetallic sea nodules containing 1 - 1.2% Cu & Niand 0.01% Co. About 90% Cu & Ni and 88% Corecovery was achieved. The slag generated throughthis process was further treated to recover Mn asstandard grade Fe-Si-Mn with overall 80% Mnrecovery. A modified reduction roast-ammonia leachprocess was also developed for processing ofpolymetallic sea nodules, with 94% Cu & Ni and 70%Co recoveries. The process was tested undercontinuous mode (10 kg/batch scale recycle leaching)& the residues generated were smelted to recover Mn.

1.13 Silica Sand

Beneficiation of silica sand for Reduction ofFe

2O

3 content (IBM):

M/s. Asahi Glass India Ltd approached IndianBureau of Mines with a request to explore the possibilityof utilising the silica sand available as overburden ofGMDC, Rajpardi Lignite Mine for manufacturing glass.The original sample assayed 96.5% SiO

2, 0.64% Fe

2O

3,

0.42% TiO2, 1.13% Al

2O

3 and 1.03% LOI. Ore Dressing

Division of IBM has developed a beneficiation processfor the said sand which comprises scrubbing, tabling,magnetic separation and attrition scrubbing. Theprocess yielded a silica sand concentrate assaying99.3% SiO

2, 0.079% Fe

2O

3, 0.15% Al

2O

3, 0.04% TiO

2 with

wt.% yield of 60. The industrial application of the abovecan convert the overburden, dumped as waste, into auseful industrial product for glass making.

2. MININGNational Institute of Rock Mechanics (NIRM)

NIRM is a premier centre of research in appliedand basic Rock Mechanics. During 2010-11, NIRMwas involved in projects from construction projects inpower sector (hydel, nuclear), communication sector(metros, rails) and mining sector. This instituteundertakes investigations at various stages of theprojects, i.e., feasibility report (FR), detailed projectreport (DPR), construction and post-constructionstages. The following studies have been undertaken.

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• Geological and geotechnical investigations forpreparation of DPR for 2 x 350 MW Malshej GhatStorage Scheme. Maharashtra, Project No. EG0901.

• Geological investigations for undergroundstorage caverns at Vishakapatnam, Project No. EC0902.

• Seismotectonic evaluation of Kudankulam-Atomic Power Plant within 30 km area, NPCL, EG0903.

• Cross-hole seismic tomography at Sainj HEP,Himachal Pradesh, Project No. GP1001.

• Laboratory Rock Mechanics investigations -underground rock cavern for storage of crude oil atPadur (part B SKE&C-KCT), Project No. RF1001.

• Deformation monitoring of UndergroundPowerhouse Cavern of Sardar Sarovar Project, ProjectNo. NM0803C.

• 3D Numerical Modelling of PowerhouseComplex of TapovanVishnugad HE Project and DesiltingChamber and Power house Complex of Lohari-Nag palaHydroelectric Project, Project No. NM0704.

• Analysis of instrumentation data of machinehall and desilting complex of Nathpa Jhakri hydropower station, Project No. NM0904C.

• Controlled blast design for rock excavationclose structures and green concrete and groundvibration measurement near Unit 7 & 8, Nuclear plant,RAPP, Kota Hindustan Construction Company Limited,Mumbai - Project No. RB 1004C.

• Slope stability studies at Iron Ore Mines ofM/s Mysore Minerals Ltd, Hospet, Project No.SS 1001.

• Slope stability studies at Iron ore Mines ofM/s SMIL, Goa Project No. SS0701.

• Strata Monitoring during Development inNo. 3 Seam at KTK-2 Incline, Bhupalpalli Area, SCCLProject No. GC 0903.

• Project entitled "Study on blasting dustmanagement system in an opencast coal mine", CoalS &T Project (Code: EE/35), Ministry of Mines, Govt. ofIndia.• Preliminary Report on "Possible causes of rock fallfrom sides at Hamsa Minerals & Exports Granite Mineand Suggestions for remedial measures".

Indian Bureau of Mines (IBM):

Mining Research Cell of TMP Division, IBMconducted a techno-economic evaluation and prepareda status report on availability of manganese ore.

Techno-economic Evaluat ion of BalaghatHolem’s Shaft Deepening Project at Balaghatdistrict of Madhya Pradesh for MOIL Ltd.

On the request of MOIL, Nagpur, study ofTechno-economic Evaluation of their Balaghat Holem’sShaft Deepening Project at Balaghat Mine, BalaghatDistrict, Madhya Pradesh, was carried out forexamination of techno-economic evaluation andfinancial justification of proposed vertical deepeningof that shaft on the basis of financial models. In orderto maintain the leading status, development of mine toexploit the ore reserves below the 12th level to 16.5thlevel which is essential for them. The MOIL hasprepared the proposal to estimate the anticipated in &out cash-flow of the project. The same has beenexamined by IBM.

The IBM team re-estimated the recoverablereserves of 3.14 million tonnes for which operatingcost was considered as ̀ 1953/- per tonne with annualincrement factor of 5%. After examining the cash-flowstatement, IBM has stated in the report that all thecapital investment incurring in the project will berecovered within 6-month period as cash flow in anyyear before depreciation and income tax is more than` 42 crore. Considering the calculated IRR 94% andNPV ` 576 crore, IBM concluded that the project ofdeepening of shaft between 12.5th level to 16.5th levelis viable and beneficial to MOIL.

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3. ENVIRONMENT

Indian Bureau of Mines (IBM):

During 2010-11, Mining Research Cell of T.M.P.Division, IBM has carried out four studies, one forEnvironmental Quality Monitoring, and three forGround Vibration due to Blasting in Mines. The salientfeatures of the studies and activities are as follows:

Study of Ground Vibrations due to Blasting in

Amil and Thandiber i Limestone Mines of

M/s Binani Cements Ltd , d is tr ic t : S irohi ,

Rajasthan (IBM):

On the request of M/s Binani Cements Ltd, district

Sirohi, Rajasthan, study of ground vibrations due to

blasting at their Thandiberi Limestone Mines (Lease

Area 254.125 Hect.) and Amli Limestone Mines (Lease

Area 468.68 Hect.) was carried out to study the impact

of blast induced ground vibrations on the nearby

structures, human settlements and to suggest control

measures to minimise the adverse impact of the same.

Under this study, eight blasts at the Amli Limestone

Mine area and one blast at Thandiberi Limestone Mine

were carried out and monitored at various points in the

area.

In the Amli Limestone Mine, the charge weightper delay of 600 kg, which is presently under practice,was kept and monitored. It was found that the groundvibration intensity and air over pressure (sound level)due to blasting is well within the safe limit and therefore,no danger to any structures in the nearby area.

In the Thandiberi Limestone Mine, normally thecharge weight per delay is kept below 500 kg. The peakparticle velocity for the charge weight for 500 kg for adistance of 700 m is found to be 10.18 mm/sec whichwas above the safe limit. Therefore, for ThandiberiMine, it was suggested that the charge weight shouldbe restricted to 450 kg for which calculated peak particlevelocity is 9.50 mm/sec which is well within the safelimit as per DGMS Circular. The air over pressure (soundlevel) due to blasting is also well within the limit. Thefrequencies below 8 Hz are ‘Nil’ and so there will not beany danger to nearby structures of the mine.

Study of Ground Vibration Monitoring due toblasting in Chargao – Gotadi Stone Quarry inBhivapur Tehsil, Near Umred, district Nagpur,for M/s Modern Mineral Industries, Nagpur (IBM):

On the request of M/s Modern Mineral Industries,

Nagpur (Maharashtra), a study of Ground Vibrations

due to blasting at their Chargao Gotadi Stone Quarry,

Taluka, Bhivapur, near Umred, district Nagpur

(Maharashtra) over a lease area of 2.45 ha was carried

out to study the impact of blast induced ground

vibrations on the nearby structures, human settlement

and to suggest control measures to minimise the

adverse impact of the same. Under this study, six blasts

were carried out at Chargao Gotadi Stone Quarry site

and monitored at three different points in the area.

Normally, in Chargao Gotadi Stone Quarry, the

charge weight per delay is 55.60 kg (i.e. less than 60

kg). The observed peak particle velocity for this charge

weight of 55.60 kg for a distance of 100 m is

3.11 mm/sec which is well within the safe limit. The

Status Report onAvailability of Manganese Oreover an area of 26 .97 ha In Vi l lage:Shannkerp ipar iya , Taluka: Kher langi ,district:Balaghat, Madhya Pradesh, for M/sM.V.P. Minerals (P) Ltd, Hyderabad (IBM):

On the request of M/s M.V.P. Minerals (P) Ltd,Hyderabad (Andhra Pradesh), an assignment ofpreparation of Status Report on Availability ofManganese Ore over an area of 26.97 ha. In Village:Shannkerpipariya, Taluka: Kherlangi, District: Balaghat,Madhya Pradesh has been carried out. The area showsmineralisation of manganese at two places only, i.e. inold pits/trenches. The ore available in the area ismedium grade in manganese content with lowphosphorous. The reconnaissance survey shows thatthe area appears to be manganese ore prospect withproper prospecting/exploration.

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ground vibration intensity estimated for even maximum

charge weight per delay of 200 kg, presently not

practised, is also well within the safe limit. The Mine

Office and labour hutments which are at a distance of

100 m, the calculated PPV is 46.5 mm/sec for a maximum

charge per delay of 25.0 kg which is outside the safe

limit. The frequencies below 8 Hz are considered

serious for potential structural damage. During the

study, it has been found that the frequencies below

8 Hz are ‘Nil’ and hence there will not be any danger to

nearby structures. The air over pressure (sound level)

due to blasting is also well within the limit. Some safety

measures have also been suggested for minimising

further blast vibrations effects in the report submitted

to the party.

National Institute of Rock Mechanics (NIRM):

The following projects were undertaken byNIRM:

• Study on ground vibration and airoverpressure due to blasting at HRT of Parbatihydroelectric project (Stage-III) Behali, Kullu, HimachalPradesh, NHPC Ltd, Project No. RB 1005, August2010.

• Ground vibration and air overpressure studyat Mangampet Barytes Project using differentexplosives, APMDC Ltd, Mangampet Cuddapah,Andhra Pradesh, Project No. RB 1003C.

• Technical guidance for rock blasting andmonitoring of ground vibration, air over pressure andfly rock during excavation at underground stations ofBangalore Metro (BMRCL).

imyb2011_r&d

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