ACKNOWLEDGEMENT First and the foremost, I shall thank God Almighty who gave me the inner strength, resource and ability to complete the work successfully, without which all my efforts would have been in vain. I express my sincere gratitude to our principal, Dr. C. J. Joseph for providing me good guidance to do it in the required way. I am thankful to Prof.Binoy Baby of Department of Mechanical Engineering, for his valuable advice and motivation. I wholeheartedly thank my group tutors Mr.Peter Jose (Asst. Professor, Dept. of Mechanical Engineering) and Mr. Bonny John(Asst. Professor, Dept. of Mechanical Engineering) for their valuable advice and support. I also extend my sincere thanks to Kerala Minerals And Metals Ltd. For the permission granted for conducting industrial visit in the companies. Finally I take this opportunity to acknowledge the coordinators of our industrial visit program, who arranged it successfullyCONTENTS Chapter TitlePage No:? Introduction 3? History of The Company 5 ? Raw Materials 9 ? Manufacturing Facility 11? Products 15? Process 18? Sales & Marketing 20? Conclusion 21? Reference 22 1. INTRODUCTIONBringing more to your everyday life, KMML touches you in numerous ways. Be it the dress you wear, the cosmetics you use, the medicines you take, the paints you decorate your home with or the utility plastic products, our products are there. Eco-friendly & socially committed, it is the only integrated Titanium Dioxide facility having mining, mineral separation, synthetic rutile and pigment-production plants. Apart from producing rutile grade Titanium Dioxide pigment for various types of industries, it also produces other products like Illmenite, Rutile, Zircon, Sillimenite, Synthetic rutile etc. Manufacturing Titanium Dioxide through the chloride route, KMML produces very pure rutile grade Titanium dioxide pigment. The different grades churned out by KMML under brand name KEMOX has a ready market which asks for more. The commendable work in research by the R&D department has also helped KMML to add more colours to its portfolio. Fig 1.1:KMML Industry Pvt Ltd.With continued growth and demand in the economy and industry, the products of KMML are being lapped up by the eager market. This has in turn set the wheels turning for KMMLs expansion. KMML has always been responsive to social and environmental causes. Some of the initiatives taken by KMML have made a significant change to the area and its people. KMML is now in the aerospace industry & Defence applications with the commissioning of the Titanium Sponge Plant. The TSP is a joint venture of KMML, Vikram Sarabhai Space Centre (VSSC) and the Defence Metallurgical Research Laboratory (DMRL). The VSSC has fully funded the Rs.143-crore TSP project. With the inauguration of TSP, India becomes the 7th country in the world having the technology for producing titanium sponge, which is the raw material for titanium metal.Titanium sponge is known for its high strength but low weight, making it an ideal material for aircraft manufacture, including fighter aircraft. The material is also used in nuclear plants, Engine parts, Ocean platforms, Reactors, Heat Exchangers and to make dental implants and artificial bones.2. HISTORY The history of thebeaches of Sankarmangalam and nearby areas is inextricably intertwined with the history of the precious beaches and KMML. Precious, as was discovered in 1909 by the German scientist Dr. Schomberg who found traces of monazite in the sand flakes on the imported coir from Sankaramangalam. The beaches with a wealth of rare earth minerals became the center of scientific attraction. By 1932, a visionary private entrepreneur established the F. X. Perira and Sons (Travancore) Pvt. Ltd, the forerunner to KMML. During the course of time, KMML changed hands three times over. In 1956 it was taken over by the state government and was placed under the control of the industries department. The unit was subsequently converted as a limited company in 1972 by the name of The Kerala Minerals and Metals Ltd.with the following broad objectives.1. Optimum utilization of mineral wealth found along the sea coast of Kollam-Alappuzha Districts.2. Large scale generation of employment in the state in general.3. Overall growth and development of the local area in particular and the state in general. The construction of Titanium Dioxide Pigment using chloride technology started in 1979. The same was commissioned in 1984 as the first and only integrated Titanium Dioxide Plant in the world. Today, with over 2000 employees and a range of products, KMML has become part and parcel of local and international life. On 27th December 2006 Hon. Ex-Chief Minister of Kerala Shri V.S. Achuthanandan laid the foundation stone of the Titanium Sponge Plant in the presence of the Hon. Minister for Industries, Shri. Elamarom Kareem and other eminent dignitaries. On 27th February 2011 Honorable Minister of Defense Shri. A K Antony Inaugurated country's first Titanium Sponge Plant (TSP) at KMML. Fig 2.1: Inauguration Of Titanium Sponge PlantWith the inauguration of TSP, India became the 7th country in the world having the technology for producing titanium sponge, which is the raw material for titanium metal. Thus KMML has become a strategic Supplier of countrys present requirements of Titanium for its prestigious space missions. On 6th September 2011 KMML TSP manufactured the 1st Batch of Titanium sponge & now the production is in full swing.2.1 Milestones of KMML1974 Letter of Indent for the production of 48,000 tonnes of Titanium Dioxide Pigment through Chloride process technology. Collaboration agreement with: Benelite Corporation of America, USA Synthetic Rutile Plant. Woodall Duckham, U.K Acid Regeneration Plant Kerr McGee Chemical Corporation, USA Titanium Dioxide Pigment (Chloride process) 1979 Construction of plants started at Sankaramangalam, Chavara, Kollam 1983 R&D recognition for KMML laboratory by DSIR.1984 Commissioned the first fully integrated Titanium Dioxide Pigment Plant in the world. Launched for the first time in India, Rutile grade Titanium Dioxide Pigment under Trade Name: KEMOX RC-822. 1992 Launched another grade of Titanium Dioxide Pigment KEMOX RC-800. 1992 Launched Plastic Grade Pigment KEMOX RC-800 PG. 19921992 Won the First National Award for in-house R&D efforts in Industry for Technology Absorption under TAAS programmed by DSIR1997 A new grade of pigment for the new water based paint application was introduced KEMOX RC-813.1998 Launched another improved grade pigment KEMOX RC-822SG (Renamed as KEMOX RC-802)1998 Commercial production of Iron Oxide Bricks from the waste Iron Oxide an innovative development by in-house R&D.1998 Supported Combustion Process was successfully commissioned in one of thestreams in the Oxidation Plant. This In-house developed process is a significant break through which enables KMML to improve productivity of the plant and for further capacity enhancement.1999 Bypass system in both streams and support combustion in other streams was also commissioned. 1999 Erected and commissioned one more Chlorinator in Chlorination section. 2003 New modern Lime Preparation Plant (LPP) for effluent neutralization was commissioned. 2004 Commissioned new DM Plant and added two more digesters in IBP.2004 Commissioned a new product packaging machine, modern energy efficient filter and drier system, DCS system in Unit-400. 2005 World class quality management systems like ISO 14001 and OSHAS-1800 implemented2006 Capacity enhancement to 40,000MT2006 Foundation stone laid for Titanium sponge plant2007 Commissioned Recovery cyclone2008 Commissioned new ETP sludge and Oxide pond2009 Development of Nano Titanium Dioxide particles in laboratory scale.2010 Commissioned the Enhahced Zircon Recovery plant at MS Unit.2011 Indias first commercial titanium oxy chloride pilot plant commissioned on 16/6/20112011 Indias first commercial plant for synthesis of nano titanium dioxide commissioned on 19/7/20112011 Commissioned the Siliminite Recovery Sysytem at MS Unit2011 Started the sale of Siliminite. --on 18th August 20112011 Birth of First Batch of Titanium Sponge on 06.09.20113. RAW MATERIALS Material Approximate Annual Req.Silica Sand 1,200 MTSodium Silicate 3,280 MTBeneficiated Ilmenite 4,644 MTHydrated Lime 12,800 MTAluminium Chloride 950 MTSulphuric Acid 1,800 MTPotassium Chloride 114 MTPetroleum Coke Npf Grade 6228 MTHydrochloric Acid 24,537 MTLiquid Chlorine In Containers 8,043 MTCaustic Soda Lye 3,400 MTRaw Ilmenite 12,000 MTFloculant 11,330 MTCabosil 1.900 MTTrimethylol Ethane (trimet) 240 MTZirconium Orthosulphate 300MTTri Iso Proponol Amine 27 MTSuccinic Acid 6 MTFurnace Oil 28,029 KLLiquified Petrolium Gas 4,000 MTAluminium Hydrate 1,280 MTCalcined Petroleum Coke 18,500 MT 4. MANUFACTURING FACILITYThe sands are washed onto the beach by the waves every day. They are called beach washing. These sands are the raw materials naturally harvested by KMML for the manufacture of the finest grades of Titanium Dioxide pigment and other products.KMML is India's only RUTILE GRADE TITANIUM DIOXIDE MANUFACTURING FACILITY (through Chloride Route). The Manufacturing Plant at KMML comprises the Mineral Separation Unit and the TP Unit (Ilmenite Beneficiation Plant, Acid Regeneration Plant, Pigment Production Plant, Oxygen Plant & Utility Section). Fig 4.1: U200 ScrubberThe raw Ilmenite obtained from the Mineral Separation Unit is taken to the manufacturing facility for further processing. Titanium Dioxide is manufactured here using the chloride route. The chloride route is better than the sulphate route as highest levels of purity can be achieved with this.The process mainly consists of four steps:? Reduction and Leaching of raw ilmenite to 90-92% TiO2? Ilmenite Beneficiation? Regeneration of spent HCl? Conversion of Beneficiated Ilmenite to TiO2The resultant TiO2is used to produce TiO2pigments of different grades. The by product Iron Oxide of the process is used to make the popular Iron Bricks. Special care is taken to regenerate the acid and keep the pollution to near zero levels.The facility follows stringent Safety, Health and Environmental Policies and Practices at every step of the manufacturing process.4.1 Titanium Sponge Plant (TSP): Fig 4.2: Titanium Sponge PlantTitanium Sponge Plant is first plant in India to produce Titanium Sponge, which is the intermediate product to Titanium Metal. Titanium Sponge Plant has its three sections as below.4.2 Tickle Purification Plant (TPP): Fig 4.3: Tickle Purification PlantTitanium Tetra Chloride (TiCl4) is the main raw material for the production of Titanium Sponge, which is available as pigment grade TiCl4in the Titanium Pigment Unit of KMML. This pigment garde TiCl4is further purified in to metal grade TiCl4though double stage fractional distillation in Tickle Purification Plant.4.3 Metal Production Plant (MPP):Formation of Titanium Sponge took place at the Metal Production Plant of TSP through Kroll Process.The raw materials used are metal grade TiCl4and the high purity Magnesium (Mg) metal. The processes involves reduction of TiCl4with Mg and pyro-vacuum distillation to tap out the MgCl2produced as by product during the process. Fig 4.4: Metal Production Plant4.4 Sponge Handling Plant (SHP): Fig 4.5: Sponge Storage Final product formation of the Titanium Sponge Produced is taking place in SHP, where cutting of the sponge using hydraulic presses, shredding, and pelletizing to required size are done.All the sponge formation processes are taking place under high purity argon atmosphere for which separate argon storage with evaporators along with utilities like compressed air, water treatment system etc are installed in the titanium sponge plant. Fig 4.6: Sponge Handling PlantThe Manufacturing Facility at KMML is equipped with the following Units / Plants / Sections.Click on each to know more about each plant or the processes involved in the production of the Titanium Dioxide pigments of various grades and other products manufactured by KMML. 5. PRODUCTS KMML always maintains high standards of perfection, achieving technical excellence in every phase of production. Catering to strict guidelines, KMML offers a wide range of products for quality conscious customers. Our products go into the manufacture of a variety of products used in everyday life. Dress materials, facial creams, tablets, newsprints, wood paints, emulsions, enamels, plastics, tooth paste, rubber products, cosmetics, and printing ink All contain titanium dioxide. Believe it, you need our products to brighten your life. Titanium Dioxide Pigment(Rutile) KEMOX RC 800 KEMOX RC 802 KEMOX RC 808 KEMOX RC 822 KEMOX RC 800 PG KEMOX RC 813 Magnesium Chloride Nano Titanium Dioxide Pigment (Rutile) NanoKemox NanoKemox 100 HB NanoKemox 102 HB NanoKemox 102 HL NanoKemox 108 HL Titanium oxy chloride KMML grade Titanium Tetra Chloride Ilmenite Monazite Sillimenite Zircon Leucoxene Rutile Titanium Sponge Grade 1: 99.70% Ti & BHN 85- 110, Size 2 to 25 mm Grade 2: 99.60% Ti & BHN 110-150, Size 2 to 25 mm Grade 3: 99.00% Ti & BHN >150, Size 2 to 25 mm Ti Fines: 99.00% Ti & BHN >150, Size < 2 mm Off Grade: BHN >150, Size 2 to 25 mm 6. PROCESSThe Kerala Minerals and Metals Ltd (KMML) is the worlds first fully integrated Titanium Dioxide Plant. KMML is also Indias first and only manufacturer of Rutile Grade Titanium dioxide by chloride process. 6.1 The Process in Brief: Titanium dioxide (TiO2), also referred to as Titania, is a substance as old as the earth itself.Titanium dioxide is readily mined in its purest form from beach sand. The beaches of Sankarmangalam and nearby areas in Kollam are inextricably intertwined with the history of this substance and KMML. Dr. Schomberg, a German Scientist, discovered in 1909 traces of monazite in the sand flakes on the imported coir from Sankaramangalam. The beaches with a wealth of rare earth minerals became the Centre of scientific attraction. ? Titanium Dioxide is essentially harvested from sea. The Mineral Separation Unit (MS Unit) of KMML is engaged in the separation of Ilmenite, Rutile, Leucoxene, Monazite, Silliminite etc from the beach sand. The MS Unit employs Gravitational, Magnetic & High Tension Electrostatic Techniques for separation of minerals from the sand.? Raw Ilmenite is chemically processed to remove impurities such as iron, leaving the pure, white pigment available for use.? KMML is Indias first and only manufacturer of Rutile Grade Titanium dioxide by chloride process.? The chloride process produces TiO2 products by reacting titanium ores with chlorine gas.? The chlorides of impurity metals are removed from Titanium Tetra Chloride (TiCl4) through various processes to complete the recovery of TiCl4. It is further purified by distillation to obtain pure Titanium Tetra Chloride in the liquid form which is stored in storage vessels. Titanium Tetra Chloride is vaporized, pre heated and oxidized with oxygen in the Oxidation Plant to produce raw Titanium Dioxide at a high temperature.? Beneficiated Ilmenite (BI) is the raw material for the Pigment Production Plant. BI from Ilmenite Beneficiation Plant is chlorinated in the Chlorination Plant to produce Titanium Tetra Chloride (Tickle). Chlorine reacts with Titanium Dioxide and other metallic oxide impurities in BI in the presence of petroleum coke at a temperature of 9000C in a fluidised bed chlorinator to produce chlorides of Titanium and other impurity metals. ? The raw Titanium Dioxide is then classified and surface treated with various chemicals, filtered and washed to remove the salts, sent to the dryer and then to the microniser, in the Pigment Surface Treatment & Finishing Plant. The Titanium Dioxide pigment (in powder form) is subsequently packed.? The plant uses recycling and regeneration methods at various levels of processing, including acid regeneration, which ensures negligent pollution. Responsible harvesting from the seas reaffirms our commitment to the environment.The Technology being adopted for production of titanium sponge is a batch process based on the Kroll process. The titanium sponge plant is designed to produce 500 TPY of commercially pure Titanium sponge by the reduction and pyro-vacuum distillation of anhydrous titanium tetrachloride (TiCl4 ) with MagnesiumMagnesio- Thermic Reduction of Titanium Tetrachloride(TiCl4) into Titanium Sponge (Ti) and Magnesium Chloride i.e. MgCl2TiCl4 (g) +2Mg (l) =2MgCl2 (l) +Ti(s)Purification of the sponge cake by Pyro-Vacuum distillation to remove locked up magnesium and MgCl2.The main steps involved in the process are: ? Purification of pigment grade tickle to metal grade ? Magnesio-thermic reduction of tickle? High temperature vacuum distillation of Magnesium and Magnesium Chloride? Handling, grading and evaluation of titanium sponge7. SALES & MARKETTINGThe marketing network of KMML is spread worldwide. KMML exports to the developed and developing nations and has earned a two star rating as an exporting house. The web of over 30 offices servicing 50 odd nations is the backbone of the marketing network.KMMLs products are supplied to industries all over the globe, including countries like China, Korea UK, Philippines, South Africa, Turkey, Mauritius, Dubai and Sri Lanka. At KMML, customer is the king. A team of motivated marketing experts, who make it their business to find out your views, highlights our customer consciousness. Maintaining close contacts, they are perfectly aware of the customers needs and are instrumental in offering world-class services and prompt attention to your every requirement.Major customers in the domestic market are served directly by the company. KMML has an all India network of 12 stockists to meet requirements of our customers. 8. CONCLUSIONTitanium Dioxide is used in paints and all paints are formed by adding colours to this component. As in the report the process of titanium dioxide is discussed by making an efficiency of almost 85% by reusing the components and producing the several components in easy ways.Such a firm could be more profitable if careful handling of machines is done. Since Schomberg has discovered the minerals in Sankaramangalam we are able get a firm like this going and who knows there arent more such treasures in our earth even the sand we stand upon.9. REFERRENCEwww.kmml.com? Wikipedia? Information collected from the personals of the firm