development of column flotation technology at national metallurgical ...
development of column flotation technology at national metallurgical ...
development of column flotation technology at national metallurgical ...
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N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 1 <strong>of</strong> 10DEVELOPMENT OF COLUMN FLOTATION TECHNOLOGY ATNATIONAL METALLURGICAL LABORATORY (CSIR)N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory (NML) Madras Centre by its extensive R&D efforts haddeveloped indigenous autom<strong>at</strong>ed labor<strong>at</strong>ory, pilot and commercial <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> units. The Centremade a pioneering effort in demonstr<strong>at</strong>ing the <strong>technology</strong> by installing and conducting feasibilitystudies <strong>at</strong> the plant premises <strong>of</strong> various mineral benefici<strong>at</strong>ion industries in our country.Design, Development & Field Tests <strong>of</strong> Lab ColumnFully autom<strong>at</strong>ed labor<strong>at</strong>ory model <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> was designed, fabric<strong>at</strong>ed and extensivelyfield tested for various ores and minerals <strong>at</strong> different mineral processing plants. Internal spargers <strong>of</strong>several types were developed to suit different applic<strong>at</strong>ions. Special <strong>at</strong>tention was paid in spargerdesign to gener<strong>at</strong>e required bubble size and bubble flux to suit a wide range <strong>of</strong> applic<strong>at</strong>ions. Theoverall <strong>column</strong> design facilit<strong>at</strong>es the vari<strong>at</strong>ion <strong>of</strong> <strong>column</strong> height, feed injection point, froth depth etc.Specific<strong>at</strong>ion <strong>of</strong> Lab Column:Diameter - 74mmHeight - 10m, variable – several flanged sections.Sparger - Internal – different porositiesThe sparger is <strong>of</strong> internal type fitted with sintered bronze disc <strong>of</strong> desired porosity. DifferentialPressure Transmitter (DPT) coupled with a micro processor based dual-loop controller was adoptedto maintain the interface between slurry and froth. The interface can be visualised from display onthe LCD screen <strong>of</strong> the controller. At the steady st<strong>at</strong>e, the interface level could be maintained within+/- 2 cm. Various electronic gadgets were incorpor<strong>at</strong>ed to monitor and record the variables likeairflow, slurry flow, wash w<strong>at</strong>er flow etc. The NML lab <strong>column</strong> and the centralized control panel isshown below.ColumnColumn Control Str<strong>at</strong>egy
N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 2 <strong>of</strong> 10Field Tests: Hindustan Copper Ltd., Malanjkhand (Copper) Kudremukh Iron Ore Co. Ltd., Kudremukh (Iron) Gujar<strong>at</strong> Mineral Development Corpor<strong>at</strong>ion, Ahmedabad (Fluorspar) Gujar<strong>at</strong> Mineral Development Corpor<strong>at</strong>ion, Ahmedabad (Cu-Pb-Zn)) Hindustan Zinc Ltd., Udaipur (Agucha, Lead-Zinc) Hindustan Zinc Ltd., Udaipur (Dariba, Lead-Zinc) Bhar<strong>at</strong> Gold Mines Ltd., KGF, Karn<strong>at</strong>aka (Gold)Chronological Activities <strong>of</strong> the field tests with Labor<strong>at</strong>ory Flot<strong>at</strong>ion ColumnYear Project Title Sponsor Test Site198719881989-911992-93Explor<strong>at</strong>ory project on fine particleprocessing by new techniquesDevelopment <strong>of</strong> 3 types <strong>of</strong> cells –conventional <strong>column</strong>, electro-<strong>column</strong>& combin<strong>at</strong>ion.Design & <strong>development</strong> <strong>of</strong> fullyautom<strong>at</strong>ed <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> with st<strong>at</strong>e<strong>of</strong>-theinstrumentsAmenability studies <strong>at</strong> Malanjkhandcopper project – copper oreMinistry <strong>of</strong> MinesMinistry <strong>of</strong> MinesNML Internal resourcesHindustan Copper LtdNMLMCNMLMCNMLMCMalanjkahand,M.P1993-94Feasibility studies <strong>at</strong> Kudremukh IronOre Company Ltd.Kudremukh Iron Ore Co.Ltd.Kudremukh,Karn<strong>at</strong>aka1994-95Fluorspar benefici<strong>at</strong>ion <strong>at</strong> Gujar<strong>at</strong>Mineral Development Corpn.Gujar<strong>at</strong> MineralDevelopment CorpnKadipani,Gujar<strong>at</strong>1995-96Column <strong>flot<strong>at</strong>ion</strong> <strong>of</strong> Pb-Zn ore <strong>at</strong>Agucha, HZLHindustan Zinc Ltd.Agucha,Rajasthan1996-97Column <strong>flot<strong>at</strong>ion</strong> <strong>of</strong> Pb-Zn ore <strong>at</strong>Dariba, HZLHindustan Zinc Ltd.Dariba,Rajasthan1997-981998-992007-08Benefici<strong>at</strong>ion <strong>of</strong> multi metal ore <strong>at</strong>Ambaji, GMDC – Cu-Pb-Zn oreAmenability studies <strong>at</strong> Bhar<strong>at</strong> GoldMines Ltd. – Gold oreBenefici<strong>at</strong>ion <strong>of</strong> siliceous limestonefrom Jayanthipuram depositGujar<strong>at</strong> MineralDevelopment CorpnBhar<strong>at</strong> Gold Mines Ltd.Madras Cements Ltd.,ChennaiAmbam<strong>at</strong>ha,Gujar<strong>at</strong>Kolar GoldFields,Karn<strong>at</strong>akaNMLMC
Commercializ<strong>at</strong>ion <strong>of</strong> Labor<strong>at</strong>ory Flot<strong>at</strong>ion ColumnN<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 3 <strong>of</strong> 10After field tests the labor<strong>at</strong>ory <strong>column</strong> was standardized and erected an autom<strong>at</strong>ic systems toNMDC R&D Centre Hyderabad by particip<strong>at</strong>ing in a global tender. The system was installed and isbeing utilized for the benefici<strong>at</strong>ion R&D studies <strong>of</strong> iron ore fines. One more system was installed <strong>at</strong>the Department <strong>of</strong> Mining Engineering, Golden Valley Institute <strong>of</strong> Technology, KGF, Karn<strong>at</strong>aka fortheir curriculum introduced in B.Tec. Course.1999Transfer <strong>of</strong> Fully Autom<strong>at</strong>edLabor<strong>at</strong>ory Column to N M D C R&DCentre, Hyderabad2001Transfer <strong>of</strong> Fully Autom<strong>at</strong>edLabor<strong>at</strong>ory Column to G V I T, KGF,Karn<strong>at</strong>aka
Bhar<strong>at</strong> Gold Mines Ltd., KGF (Gold ore) Gujar<strong>at</strong> Mineral Development Corpor<strong>at</strong>ion Ltd., Kadipani (Fluorspar) Indian Rare Earths Ltd., OSCOM, Ch<strong>at</strong>rapur (Sillimanite) Sociedade de Fomento Industrial Pvt. Ltd, Goa. (Iron ore) Calpro Mineral Technologies Ltd., Salem (Limestone) JSW Ltd., Tornagallu (Iron ore) T<strong>at</strong>a Steel, Joda (Iron ore)N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 5 <strong>of</strong> 10Chronological Activities <strong>of</strong> the field tests and Demonstr<strong>at</strong>ions with Pilot Flot<strong>at</strong>ion ColumnYear Project Title Sponsor Test Site19961996-971999-002001-022002-032003-042004-052006-072008-09Design & <strong>development</strong> <strong>of</strong> semicommercial,0.5m dia <strong>column</strong> withautom<strong>at</strong>ic controls.Demo <strong>of</strong> 0.5M dia <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> forgold ore benefici<strong>at</strong>ion <strong>at</strong> BGMLField testing <strong>of</strong> 0.5M dia <strong>column</strong> <strong>at</strong>Kadipani, GMDC, for fluorsparbenefici<strong>at</strong>ionDemo <strong>of</strong> <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> forsillimanite benefici<strong>at</strong>ion <strong>at</strong> OSCOM,OrissaColumn <strong>flot<strong>at</strong>ion</strong> <strong>of</strong> iron ore fines <strong>at</strong>Fomento, GoaDemo <strong>of</strong> 0.5M dia <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> forthe benefici<strong>at</strong>ion <strong>of</strong> Limestone <strong>at</strong>SalemStudies on the Benefici<strong>at</strong>ion <strong>of</strong>GarnetAmenability studies <strong>at</strong> JSW Steel Ltd.0.5M dia semi-commercial <strong>column</strong>Pilot Scale Column Flot<strong>at</strong>ion Studieson the Iron Ore Fines <strong>at</strong> JEIMNML Internal resourcesBhar<strong>at</strong> Gold Mines Ltd.Gujar<strong>at</strong> MineralDevelopment CorpnIndian Rare EarthsLimitedSociedade De FomentoIndustrial Ltd.Calpro MineralTechnologies India Pvt.Ltd.Indian Ocean GarnetSands Co. Pvt. Ltd.Jindal South West SteelsLtd.TATA Steel Ltd.NMLMCKolar GoldFields,Karn<strong>at</strong>akaKadipani,Gujar<strong>at</strong>OSCOM,Ch<strong>at</strong>rapur,OrissaMadgau, GoaSalem,TamilnaduTuticorin,TamilnaduVijayanagar,Ballery,Karn<strong>at</strong>akaJoda, Barbil,OrissaThis exercise cre<strong>at</strong>ed lot <strong>of</strong> interest and confidence in the industrial circles on <strong>column</strong> <strong>flot<strong>at</strong>ion</strong><strong>technology</strong> which lead the industry to adopt this <strong>technology</strong> in their oper<strong>at</strong>ions.
N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 6 <strong>of</strong> 10Design, Install<strong>at</strong>ion & Commissioning <strong>of</strong> Commercial Scale Flot<strong>at</strong>ion ColumnsBased on the successful demonstr<strong>at</strong>ion <strong>of</strong> semi-commercial <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> (0.5 m diameter) for thebenefici<strong>at</strong>ion <strong>of</strong> sillimanite and limestone , commercial size <strong>column</strong>s were designed andcommissioned for the following industries.(a). Indian Rare Earths Limited, OSCOM,Ch<strong>at</strong>rapur, Orissa: A commercial size <strong>flot<strong>at</strong>ion</strong><strong>column</strong> <strong>of</strong> 1.3 m dia and 10 m height was designedto tre<strong>at</strong> 7 t/h <strong>of</strong> sillimanite for IREL and installed <strong>at</strong>OSCOM, Ch<strong>at</strong>rapur. The <strong>column</strong> is equipped withst<strong>at</strong>e-<strong>of</strong>-the-art electronic gadgets for the effectivecontrol <strong>of</strong> the slurry/froth interface, slurry feed, airand wash w<strong>at</strong>er flow r<strong>at</strong>es. An indigenouslydeveloped ceramic spargers were incorpor<strong>at</strong>ed towith stand the highly abrasive sillimanite particles.The <strong>column</strong> was successfully commissioned duringNovember 2005. The performance <strong>of</strong> the <strong>flot<strong>at</strong>ion</strong><strong>column</strong> was evalu<strong>at</strong>ed and it was observed th<strong>at</strong> the<strong>column</strong> produced excellent <strong>metallurgical</strong>results for the designed capacity.The sillimamnite concentr<strong>at</strong>e assaying 98% (after magnetic separ<strong>at</strong>ion) with the recovery <strong>of</strong> 90% wasobtained from <strong>flot<strong>at</strong>ion</strong> <strong>column</strong>. With the introduction <strong>of</strong> the <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> in the sillimanite circuit,the production <strong>of</strong> sillimanite has been increased by about 40%.
N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 7 <strong>of</strong> 10(b). Calpro Mineral Technologies India Pvt. Ltd.: The Salem district <strong>of</strong> Tamilnadu is bestowed withmany limestone deposits owned by small mine owners. Namakkal <strong>of</strong> Salem district is famous forpoultry industry. Calcium in the form <strong>of</strong> CaCO 3 , is an essential ingredient in the poultry feed and thedemand is about 100 t/d. Since limestone is used to supplement Calcium content, it should be freefrom contamin<strong>at</strong>ion <strong>of</strong> chemicals. Also the silicacontent in limestone should be less than 2%.Hence, reverse <strong>flot<strong>at</strong>ion</strong> where in gangue/silicam<strong>at</strong>erials are flo<strong>at</strong>ed was adopted. Acommercial size <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> <strong>of</strong> 1.2 mdiameter was designed to tre<strong>at</strong> 6 t/h <strong>of</strong> limestoneand installed <strong>at</strong> the mines site <strong>of</strong> M/s CalproMineral Technologies India Pvt. Ltd., Salem.The <strong>column</strong> is completely autom<strong>at</strong>ic andindigenous in all respects.
N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 8 <strong>of</strong> 10(c). Indian Rare Earths Limited, Chavara, Kerala:S<strong>at</strong>isfied with the performance and oper<strong>at</strong>ion <strong>of</strong>NML <strong>column</strong> <strong>at</strong> OSCOM, Ch<strong>at</strong>rapur for thebenefici<strong>at</strong>ion <strong>of</strong> sillimanite, M/s IREL decided toinstall another <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> in their mineralsepar<strong>at</strong>ion plant <strong>at</strong> Chavara, Kerala. The <strong>column</strong> issimilar to the <strong>column</strong> <strong>at</strong> OSCOM in design andcapacity which has to tre<strong>at</strong> 6TPH <strong>of</strong> sillimanite. .The plant is commissioned in 2009 and is inoper<strong>at</strong>ion to the designed capacity.
Public<strong>at</strong>ions on Column Flot<strong>at</strong>ion:Peer Reviewed Intern<strong>at</strong>ional Journals : 08Peer Reviewed N<strong>at</strong>ional Journals : 02Intern<strong>at</strong>ional & N<strong>at</strong>ional Conference Proceedings : 19Internal Project Reports : 18N<strong>at</strong>ional Metallurgical Labor<strong>at</strong>ory Madras Centre Page 10 <strong>of</strong> 10Recognitions / Awards:Binani Gold Medal for Best Paper (IIM) - - - - - -- 1994Khare Award for Best Paper (IIME) - - - - - - - - 1998Altekar Award for Best Technology (NML) - - - - - - - - 2002Altekar Award for Best Technology (NML) - - - - - - - -- 2005Mineral Benefici<strong>at</strong>ion Award (IIME) - - - - - - - - - - -- 2006N<strong>at</strong>ional Mineral Award (Min. <strong>of</strong> Mines) - - -- - - - - -2006MOU with McNally Bhar<strong>at</strong> Engineering Co. Ltd., BangaloreLooking <strong>at</strong> the success <strong>of</strong> NML Flot<strong>at</strong>ion <strong>column</strong> in the benefici<strong>at</strong>ion <strong>of</strong> sillimanite andlimestone M/s McNally Bhar<strong>at</strong> Engineering Company Limited, a leading mineral processingequipment manufacturer and marketing organiz<strong>at</strong>ion showed interest in marketing the NML <strong>flot<strong>at</strong>ion</strong><strong>column</strong> <strong>technology</strong>. Both the organiz<strong>at</strong>ions come to an agreement and signed an Memorandum <strong>of</strong>Understanding in 2008. The salient fe<strong>at</strong>ure <strong>of</strong> the agreement is14.5% on the invoice value willbe remitted to NML by McNally Bhar<strong>at</strong> Engineering Co. Ltd. towards premium and royalty oneach supply <strong>of</strong> <strong>flot<strong>at</strong>ion</strong> <strong>column</strong>.Since then the following organiz<strong>at</strong>ions were placed the orders to procure the various <strong>column</strong>s.1. Pilot <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> <strong>of</strong> 0.5m diameter and 14m height with the st<strong>at</strong>e <strong>of</strong> the equipments andfully autom<strong>at</strong>ic controls - M/s RBSSN, Hospet, Karn<strong>at</strong>aka. Cost: Rs.28.00 lakhsSupplied, erected and commissioned.2. Fully autom<strong>at</strong>ic standard 74mm diameter labor<strong>at</strong>ory <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> with advanced controls –NEIST (CSIR), Jorh<strong>at</strong>, Assam. Cost: 18.00 lakhsSuccessfully commissioned and working s<strong>at</strong>isfactorily <strong>at</strong> NEIST Labor<strong>at</strong>ory.3. 70 tph capacity <strong>flot<strong>at</strong>ion</strong> <strong>column</strong> for the benefici<strong>at</strong>ion <strong>of</strong> barites <strong>at</strong> Mangampet, AP – M/sAndhra Barites Corpor<strong>at</strong>ion Ltd., Kadapa, Andhra Pradesh. Cost: 100.00 lakhsWork is in progress.
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