AN METALLURGICAL VIEW AT IREL,OSCOM

A METALLURGYCAL REVIEW ON MINERAL
PROCESSING AT INDIAN RARE EARTHS
LIMITED(OSCOM),
ODISHA
A PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE
DEGREE
Of
BACHELOR OF TECHNOLOGY IN
METALLURGICAL ENGINEERING
BY
JEETENDRA MAHARANA
Roll No: 14MET039
Department of Metallurgical Engineering
Gandhi Institute of Engineering and Technology,Gunupur

A METALLURGYCAL REVIEW ON MINERAL
PROCESSING AT INDIAN RARE EARTHS
LIMITED,CHATRAPUR,ODISHA
A PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE
DEGREE
Of
BACHELOR OF TECHNOLOGY IN
METALLURGICAL ENGINEERING
BY
JEETENDRA MAHARANA
Roll No: 14MET039
Under guidance of
DR.B.R MISHRA
Department of Technical Service
Indian Rear Earth Limited, Chatrapur, Ganjam

iii
DEPARTMENT OF TECHNICAL SERVICE ,
INDIAN RARE EARTHS LIMITED,
MATIKHALO,CHATRAPUR,GANJAM,ODISHA
CERTIFICATE
This is to certify that the thesis entitled “A Metallurical Review at
Indian Rare Earths Limited” submitted by Mr. Jeetendra Maharana
in partial fulfillment of the requirements for the award of Bachelor of
Technology degree in Metallurgcal Engineering at Gandhi Institute of
Technology, Gunupur(B.P.U.T) is an authentic work carried out by him
under my supervision and guidance.
To the best of my knowledge, the matter embodied in the thesis has not
been submitted to any other University/Institute for the award of any
Degree or Diploma.
Submitted to
A.K. Tripathy
Date- Dept. of Technical Training Institute
Indian Rare Earths limited, (OSCOM)

iv
ABSTRACT
India, gifted with a coastline of over 6000 km, hosts some of the largest and richest shoreline
placers. The beach and dune sands in India contain heavy minerals like ilmenite, rutile, garnet,
zircon, monazite and sillimanite. A combination of favorable factors like network of drainage,
aided by wind and coastal processes like waves and currents, have influenced the formation of
the beach and adjoining dune sands.
Ilmenite-rich major beach and dune sand deposits occur in the coastal stretches of Kerala
(Chavara), Tamil Nadu (Manavala kurichi, Midalam, Vayakallur), Andhra Pradesh, Orissa
(Matikhala,Chatrapur) and Maharashtra. The Indian ilmenite commonly contains 50-60%
TiO2 and is suitable for various process technologies. Zircon, monazite and Sillimanite are
ubiquitous in both the beach and inland red Teri sands, and constitute potential co-products.
The Indian resources of placer minerals are: 348 Million tons (Mt) of Ilmenite, 107 Mt of
garnet, 21 Mt of zircon, 18 Mt of monazite and 130 Mt of Sillimanite. Indian resources
constitute about 35% of world resources of Ilmenite, 10% of Rutile, 14% of Zircon and 71.4%
of Monazite. India meets about 10% of the world requirement of garnet. This unique status is
largely due to the exploratory efforts of the Atomic Minerals Directorate for Exploration and
Research (AMD) of the Department of Atomic Energy, Government of India since1950s.

v
ACKNOWLEDGEMENT
I wish to express my unfathomed gratitude and indebtedness to Dr. B.R.
Mishara (Project Guide), Department of Technical Service, IRELChatrapur for
entrusting this review topic with me and for his ever-helpful guidance, assistive
critical appraisal and tutelage during the project work.
I am thankful to DGM (Safety & Training), IRE Limited (OSCOM) Chatrapur,
Orissa for allowing me to visit the mining and processing areas at a very short
notice and providing logistic support. I am thankful to Dr. B.R. Mishra (Senior
Manager), Mr.P.K.Mishra for assistance in the visit to IRELtd.
I would like to thank Gandhi Institute of Oceanography, Goa for their
assistance in providing study literature on request.
Date- JEETENDRA MAHARANA
14MET039, 7TH
Semester
Department of Metallurgical
Engineering,
GIETGunupur-765022

vi
CONTENTS
TITLES PAGES
1. Introduction
.
-Historical Background
2. Literature Review
-Distribution of heavy Minerals
in Indian Beach Sand Deposit.
- Factors Controlling Formation
of Beach Placers.
-Mines Act, Rules & Regulation Relating
to Beach Mining in India.
- Regulatory Framework for Exploitation
of Deposits
- Coastal Zone Regulation.
- Mine Planning Activities
- Sand Mining Policy
-Classification of Mineral Based on Their Physical Properties
3. Indian Rare Earth Limited:
- IREL Chavara, Kollam, Kerela.
-IREL Chatarpur, Ganjam, Orissa
-Heavy Mineral Reserve at OSCOM
-Information about OSCOM
-Properties and chemical composition of mineral
4.Mining and Processing Methodology
- Dredging and Wet Up-gradation Plant

vii
-Mining
-Trommel
- Spiral.
-Specification of spirals
-Heavy Up-Gradation Plant
-Mineral separation Plant
-Ilumenite
-Rutile
-Monazite
-Zircon
-Garnet
-sillimanite
5.Equmpent UESD At MSP
-Rotary Dryer/Kiln
-Electrical Separator
-High Tension Separator
-Electrostatic Plate Separator
-IRMS
-Magnetic Separator techniques

viii
-Wet Separator
-Dry Separator
-REDMS
-RERMS
-Cross Belt Magnetic Separator
-Wet Table
-Air Table
-Flotex Density separator
-Hydrosizer
-Hydrocyclones
-Forth Flotation
-Screw Conveyer
-Bucket Conveyer
-Bucket and Belt Separator
-Quality Control
-Used and Application Of Heavy Minerals
6.Sefefty Status in IREL,(oscom)
7.Conclusion
8.Refarences

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HISTORICAL BACKGROUND
India is bestowed with its mineral deposits especially with a coastline of 6000 km. Heavy
mineral deposits of Manavalakuruchi in the state of Travancore (now Tamilnadu ) was
discovered by Schomberg , a German chemist in 1909 which was proved richer and
economical compared to rest of the world .
Interestingly, Mineral sands then mined from rich seasonal Beach washings for only
one mineral i.e. Monazite, which produce incandescence by infusing the paraffin mantle in a
solution of thorium and cerium compounds, lost its worth due to arrival of filament lamp.
World War I gave the British an opportunity to sieze the German -sponsored company
and Schomberg was arrested and sent to Madras. The interest of monazite importers was
ceased after 1920. First shipment of illmenite from India was effected in 1922 and production
expanded in 1940 contributing nearly 80 % of the world production which is almost 300,000
tonnes.
The Atomic Energy Commission was commissioned in 1948 by Govt. of India. Indian
Rare Earths Limited was incorporated as a private company as a joint venture with the then
Government of Travancore, Cochin in 1950 under the Indian Companies Act, 1913. IREL
became a full-fledged Govt. undertaking under DAE in 1963. OSCOM was set up during 1972,
construction had been started in 1975 and mining had been started in 1984.Accordingly IREL
took over the asets of the closed mineral Operation Companies at Chavara and
Manavalakurichy.Manavalakurichy plant come into the operation in 1968 and the Chavara
plant in 1970.After agap of 20 years,Accordingly IREL commissioned its largest Division
called Odisha sand Complex (OSCOM) at Chatrapur,Odisha.Today IREL operates these four
units and products/sells six heavy minerals namely ilmenite, rutile, zircon, monazite,
sillimanite, and granite as well as various value added product.
Main objective of IREL is to emerge as a leading international player in the area of
mining and separation of beach sand deposits to produce minerals as well as process value
added products. It has mineral processing plants at Tamilnadu, Kerala, and Odisha, Rare Earths
division at Alwaye, Kerala and Research center at Kollam, Kerala. Its corporate offices are in
Mumbai, Maharashtra.

3
Objectives of this study
1. To review the problems and prospects of sand mining in India
2. Case study of Chhatrapur sand mining complex, Odisha
3. Developing a computer program to address some of the problems

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DISTRIBUTION OF HEAVY MINERALS IN INDIAN BEACH SAND DEPOSITS
India is gifted with valuable resources of beach sand minerals. Indian coast-line along
Kerala, Tamil Nadu, Odisha, and Andhra Pradesh where significant deposits of different
minerals are available is presented below. The important economic minerals are such as -
Ilmanite(Feo. TiO2)
Rutile (TiO2)
Monazite (Ce,La,Y,Th)PO4 Garnet
Sillimanite (Al2O3.SiO2) Zircon (ZrO2.SiO2)
Varying in size, concentration and grade ranging from 5% to 45%.
So far estimated Indian resources of placer minerals are (Mir Azam Ali et al., 2001).
348 million tons (mt) of ilmenite
107 mt of garnet
21 mt of zircon
18 mt of rutile
130 mt of sillimanite
According to Rajamanickam et al. (2004), of the total global inferred reserves of 1775 million
tones of placer minerals, India is bestowed with a reserve of :
1. 278 million tons of ilmenite
2. 13 million tons of rutile
3. 18 million tons of zircon
4. 07 million tons of monazite
5. 86 million tons of granite
6. 84 million tons of sillimanite

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FACTORS CONTROLLING FORMATION OF BEACH SAND DEPOSITS
Heavy mineral sands are a class of ore deposit which is an important source of rare earth elements
and the industrial minerals such as diamond, sapphire, garnet, and other precious metals or
gemstones. Placer deposits are formed usually in beach environments by concentration due to the
specific gravity of the mineral grains. Heavy minerals (aside from gold placers) exist within
streambeds, but most are relatively small and of a low grade .The grade of a heavy mineral sand ore
deposit is usually low. Within the 21st century, the cut-off grades of heavy minerals, as a total heavy
mineral (THM) concentrate from the raw sand, in most ore deposits of this type is around 1% heavy
minerals, although several are of higher grade. Total heavy mineral concentrate (THM), components
are typically for:
Zircon- 1% to 50% of THM,
Ilmenite- 10% to 60% of THM
Rutile- 5% to 25% of THM
Leucoxene- 1% to 10% of THM
Typically magnetite, Chromite, garnet which is trash minerals usually accounts the
remaining bulk of the THM content.
The Beach sand minerals are most recently originated minerals deposits. These are
originated in southern hemisphere due to continental drifts. Due to motion between different plates
and repeated weathering i.e. heating and cooling, cracks are developed in between the rocks and
water gets entered into these cracks. Parent rock is subjected to weathering and erosion and
transferred along with sea water and finally sediment in a suitable basin. Continued erosion due to
air and water takes place and concentration goes on increasing with time.
The source of heavy mineral sands is within the erosional areas of a river where the eroded
minerals are dumped into the ocean, thereafter the sediments are caught up in littoral or long shore
drift. Rocks are sometimes eroded directly by the wave action and washed up onto beaches and the
lighter minerals are winnowed.

7
The source rocks determine the composition of the economic minerals. Usually granite is
the source of zircon, Rutile, monazite, and some Ilmenite. The source of Ilmenite, garnet is
ultramafic and mafic rocks, such as kimberlite or basalt. Garnet is sourced commonly from
metamorphic rocks, such as amphibolite schists. Precious metals are generally sourced from
deposits hosted within metamorphic rocks.
MAJOR PRODUCERS OF BEACH SAND IN INDIA
1. Indian rear earth limited (IREL)
2. V.V.Minerals
3. Beach Mineral Company
4. Transworld Garnet Sand
5. India Ocean Garnet Sand
6. Tata Iron & Steel Company (TISCO)
FACTORS CONTROLLING FORMATION OF BEACH PLACERS
Some of the geological and geomorphological factors that control the concentration of heavy
minerals along the Indian coast are as follows:
❖ Geological control: The physico-chemical behaviour of provenance rocks, i.e.,
igneous,
metamorphic or sedimentary and the effect of various geological processes have
played a vital role in contributing sediments to form a placer deposit.
❖ ClimaticFactor:Theclimateoftheregionhasagreatroletoplayindecomposingand
disintegrating the rock and mineral fragments that get liberated and concentrated.
Tropical to sub-tropical climate promotes deep chemical weathering along coastal
region. These conditions also favoured the formation of laterites that, in effect, is a
process of preconcentration.
❖ Drainage Pattern: The availability of young and youthful rivers and their high
density,
coupled with climatic factors, played a prominent role in the supply of material for
concentration along favourable locales, especially along the Ghat section of Kerala

8
and Tamil Nadu coasts. The rivers joining the Bay of Bengal on the east coast,
however, have attained maturity and in many cases delta systems have developed; e.g.
Mahanadi, Godavari, Krishna, Cauvery etc.
❖ Coastal Processes: Wave velocity, long shore currents and wind speed also have
their
effects in littoral transport, sorting and deposition of placer minerals. Emergence and
submergence of the coast during geological past also affected the beach placer
formation.
Apart from these, numerous other factors that helped in the formation of these deposits are
coastal geomorphology, neo-tectonics and continental shelf morphology.
FACTORS AFFECTING PLACER DEPOSITS
TECHNO ACTIVITY
Uplift and tilting
Faulting Including Block faulting coastal faulting
Subsidence volcanicity
CLIMATE CHANGE
Arid and cold or warn
Humid and work or cold
Cyclic Climatic Change
SEA-LEVEL CHANGE COUSED BY ISOSTATIC AND EUSTATIC CHANGES AND
BY CONTINENTAL DIPERAL & ATTRACTION
Falling sea level
Rising sea level

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MINES ACT, RULES & REGULATIONS RELATING TO BEACH
SAND MINING IN INDIA
Acts, Rules & Regulation applicable for beach sand mining:-
Mines Act, 1952
MMDR Act, 1957
Atomic energy Act, 1962
Environment protection Act, 1986
Forest Act, 1988
Mines rules, 1955
Mines crèches rules 1966
Mines vocational training rules,1966
Mineral concession rules, 1960
Mineral conservation and Development rule, 1988
Indian Electricity Rule, 2007
Metalliferrous Mines Regulations, 1961
These mines are governed by the following Regulatory Bodies:
1. Director General of Mines Safety, Dhanbad
2. Indian Bureau of Mines, Nagpur
3. Director of Mines, Orissa
Royalty:
Section 9 of MMDR Act 1957 fixed for a period 3 years Ilmenite/Rutile/Zircon: 2%
of sale price on advolerem basis. Sillimanite: 2.5% of sale price on advolerem basis.
Garnet: 3% of sale price on advolerem basis.

1
0
Monazite: Rs125/tonne (Ad-valorem not applicable)
For non-atomic minerals (Garnet & Sillimanite), sale price = IBM published value +
20% For atomic minerals (Ilmenite, Rutile, Zircon), sale price = invoice price in case of
domestic sale
= FOB or CIF price less handling expenses in case of export
Dead rent:
In case of natural calamity, if there is stoppage of production and also there is no stock for
sales, dead rent will be paid.
Environmental Protection Act, 1986:
It is also known as Umbrella Act, 1986. Coastal Regulation Zone (CRZ), February, 1991: It is
measured 500 m from the appropriate base line towards the land site and 200 m measured
towards the sea from high tide line
The origin of the Chavara deposits belong to the parent rock types available in the Western Ghat
Mountain ranges which contain these minerals in very low concentration to call for profitable
extraction. The main source rocks are Khondalites, Chamockites, Gneiss, Granites, Laterites
and Sandstones etc.

1
2
REGULATORY FRAMEWORK FOR EXPLOITATION OF DEPOSITS
The exploitation of beach sand deposits and separation of heavy minerals are guided under
various regulatory framework and statutory provisions as follows:
❖ The minerals occur in the placer deposits and mined for further beneficiation and
separation of its constituent minerals. Hence Mines Act 1952, Metalliferous Minerals
Regulation 1961, Mines & Minerals (Development & Regulation) Act 1957,
Mineral
Concession Rules 1960, Mineral Conservation Development Rules 1988 etc. are
applicable.
❖ Ilmenite, rutile, zircon, monazite & leucoxene (brown ilmenite) are defined as
‘Prescribed
Substances’ under Atomic Energy Act, 1962. Necessary license and approvals are to
be obtained from DAE before proceeding with the installations and operation of
mining and mineral separation plant.
❖ Monazite is one of the constituent minerals in the beach sand placer deposit,
which
constitutes thorium and uranium and has a potential use for nuclear application. The
beach placer deposits are located within 500 m from the high tide line (HTL) of the
sea shore and covered under the Coastal Regulatory Zone (CRZ). Under the
notification, the entrepreneurs have to obtain No Objection Certificate (NOC) from
the State Pollution Control Board, Dept. of Environment of the State Govt. and also
from MoEF, Govt. of India prior to the installation of plants withinCRZ.

1
3
COASTAL ZONE REGULATION
It is permissible to mine inside the Coastal Regulation Zone for “those rare minerals not
available outside the Coastal Regulation areas”. The minerals to be mined in this leasehold fall
in Schedule I of MM (R&D) Act 1987 and fulfill the condition prescribed for mining inside
the Coastal Regulation Zone. Hence mining operations in this household will not be affected
by Coastal Zone Regulations of Govt. of India.
HM Reserve (in million tonnes)
Mineral World India Chavara
Ilmenite 1,722 348 12.7
Rutile 255 18 1.0
Zircon 80 21 0.9
Sillimanite 454 84 2.0
Production of IRE Ltd.
Plant Chavara OSCOM Manawalakur
chi
Ilmenite 1,54,000 2,20,000 90,000
Rutile 9,500 10,000 3,000
Zircon 14,000 8,000 6,500
Sillimanite 7,000 30,000 -
Zirflor 7,000 - -

1
4
MINE PLANNING ACTIVITIES
Preliminary Investigation
Prospecting and Exploration
Deposition evaluation
Selection of Equipment
Set Sequence of Operation
Phased acquisition of land
Current Mining Activity
Guide operating personnel
Dredge path planning
Giving drilling data at closed intervals
Map showing approach road, power lines, water lines etc.
Monitor advance rate of dredge and depth of cutting
Prepare production statistics
Ensuring rehabilitation of mined out area
Promotion of ecological aspects with the help of systematic plantation
SAND MINING POLICY
❖ Mining leases are to be granted solely for the purpose of miningonly.
❖ Mining leases will be granted only to those factories in the State in the joint sector
which produce value addedproducts.
❖ Proposals for establishing such factories as mentioned above shall be examined first
by the Kerala State Industrial Development Corporation before placing it before the
Council of Ministers forconsideration.
❖ AstudywillbeconductedbytheDepartmentofMiningandGeologyandtheCentrefor
Earth Science Studies jointly as to the quantum of mineral sand which could be
mined in the area, and a report given to the Government.
Anotificationundertherelevantstatutewillbeissuedprohibitingallfutureusesoflands
bearing the mineral sand, for other purposes.

10
❖ Action will be taken to request Govt. of India for increasing the present loyalty of mineral
sand.
❖ The eight blocks in the Chavara Barrier Beach area, at present earmarked for Kerala
Minerals and Metals Limited and the Indian Rare Earths will not be leased out to any other
applicants.
CLASSIFICATION OF MINERAL BASED ON THEIR PHYSICAL PROPERTIES
CONDUCTING MAGNETIC SP. GRAVITY
Ilmenite Ilmenite Monazite
Rutile Garnet Zircon
Monazite Ilmenite
Rutile
Garnet
Silimanite

11
INDIAN RARE EARTH
LIMITED
❖ CHAVARA
❖ CHATARPUR(OSCOM)

12
IREL Chavara, Kollam, Kerela
INTRODUCTION
LOCATION:
The Chavara plant is located at about 19 km from the proposed area and 1.5 km from the NH
47, Kanyakumari- Salem Highway, and this is at 13 km from the district headquarters at
Kollam and 80 km from the capital city, Trivandrum. It has all the infrastructural facilities for
operating the mines and processing plant. Export of the minerals is through Neendakara Port,
which is about 5 km from the plant & Cochin Port which is 130 km to the North of the
IREplant.
Production Capacity
The present production capacity of Chavara unit stands at 154000 tonnes of ilmenite, 9500
tonnes of rutile, 14000 tonnes of zircon and 7000 tonnes of sillimanite. In addition the plant
has facilities for annual production of ground zircon (-45 micron). With a sales turnover of
approx. Rs 105 crores and foreign exchange earning of over Rs 39 crores, this plant caters to
the requirement of a host of advanced markets viz. USA, Japan & many others in addition to
meeting the needs of domesticmarkets.
Certification
IRE Ltd., Chavara was certified to ISO 9002:1994 in September 2000. Subsequently the QMS
system is upgraded to ISO 9001:2000 in March 2004. The company is also certified to ISO
14001:1996 in March 2004 which was upgraded to ISO 14001:2004 in June 2006. Later all
systems were integrated and this integrated system was certified to OHSAS18001:1997.

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GEOLOGY OF DEPOSIT
Chavara deposit is rated as one of the best of its kind in the world owing to its unique
mineralogical assemblage, vast reserves and chemical characters of ilmenite with 60% TiO2.
The Chavara beach deposit covers a coastal length of 22.54 km and width of 225 m occurring
between the two tidal channels at Neendakara in the south and Kayamkulam in the north in
Kollam district. The coastal strip from Neendakara to Kayamkulam was divided into 8 blocks
for sanctioning mining lease. This leasehold falls to the east of Block II (IRE Block I) and
that block forms western boundary of this plot. The coastal deposits are placer deposits formed
between the two tidal channels. The barrier beach placer is under active exploitation by Indian
Rare Earths Ltd. The area had been under intensive mining for the past 6 decades. Private
parties carried out the mining operations in this area even before the formation of Indian Rare
Earths Ltd. The total area of the barrier beach is
4.2 sq. km with an average THM content of 49.08%. The deposit has a thickness of 7.62 m
and the grade gradually depletes with depth. The collection of seasonal washings of 35%
grade which accumulate during southwest monsoon is also being carried out wherever the
seawalls are non- existent. The Neendakara-Kayamkulam Eastern Extension between the T.S.
Canal and one kilometer to the east over an area of 19.22 sq. km records THM grade of the
order of 10.05%. The heavy mineral concentration depletes gradually due east. The
Neendakara – Kayamkulam Eastern Extension (Phase II) is the extension of phase I for 6 km
inland or up to end of sand stretch. The northern sector of phase II covers an area of 45.8 sq.
km with an average THM grade of 7.41%. The southern sector is spread over an area of 50.39
sq. km recording THM grade of 7.5%. Extensive exploration has been carried out to the east of
the Kayal (canal). The area, however, has dense population and has created some social
problems. Only the surface dunes have been exploited leaving most of the deposituntouched.

14
It is proposed to mine the mineral sand of Vellanthuruthu Mining area by opencast method
using a cutter suction dredge floating on a set of pontoons. The dredge has a capacity of 120
tph and the loosened material along with water is pumped to gravity concentrators to enrich
the heavy minerals up to 85%. The waste sand from the plant will be deposited on the rear end
of the dredge pond for back filling.

15
IREL Chatrapur, Ganjam, Orissa (OSCOM)
INTRODUCTION
On August 18th, 1950 Indian Rare Earths Limited (IREL) was incorporated as a private limited
company, jointly owned by the Government of India and Government of Travancore, Cochin
with the primary intention of taking up commercial scale processing of monazite sand at its first
unit namely Rare Earths Division (RED) Aluva, Kerala for the recovery of thorium.
After becoming a fully fledged Central Government Undertaking in 1963 under the
administrative control of Department of Atomic Energy (DAE), IREL took over a number of
private companies engaged in mining and separation of beach sand minerals in southern part of
the country and established two more Divisions one at Chavara, Kerala and the other at
Manavalakurichi (MK), Tamil Nadu.
After a gap of about 20 years, IREL commissioned its largest Division called Orissa
Sand Complex (OSCOM) at Chatrapur, Ganjam, Odisha. Today IREL operates these units with
Corporate Office in Mumbai and produces/sells six heavy minerals namely Ilmenite, Monazite,
Sillimanite, Rutile, Zircon, and Garnet as well as various value added products.
OSCOM was commissioned at a place called Chatrapur about 150 Kms from
Bhubaneswar and about 320 km from all weather seaports Visakhapatnam to exploit the huge
placer deposit across a mining area of 24.64 km2
to produce 2,20,000 ton Ilmenite having 50%
TiO2 content and associated minerals like Sillimanite, Rutile, Zircon, Garnet, etc. For the first
time IREL ventured into dredging and concentration operation at OSCOM. It is quite efficiently
engaged in dredging of the raw sand, its upgradation, drying and finally separation plant.
Customers imported illmenite primarily for the production of slag and sulphatable TiO2
pigment. From 1992, A Thorium plant is in operation at OSCOM to produce 240 tpa mantle
grade Thorium Nitrate.
GEOLOGY OF THE DEPOSIT
The OSCOM deposit formed along the coast is the largest of its kind in India with a
length of about 18km and a width of about 1.5 km. The height of the deposit varies from a few

16
meters to 15m from the surface to water table. It is usually in the form of sand dunes and the
concentration of heavy minerals is highest in the surface. The concentration gradually
decreases with the increase of depth. The land is barren and devoid of vegetation except
occasional growth of casuarinas trees which requires less water to grow in the saline
environment. The sand deposit is less compact, free from over burden, clay or rock inthe
frontal dune area closer to the sea. However, the deposit away from the sea towards the land
sometimes contains clay lenses and compact sand.
The origin of the deposit belongs to the parent rock types available in the eastern ghat
and the Western Ghats Mountain ranges which contain these minerals in very low concentration
to call for profitable extraction. The main source rocks are Khondalites, Charnokites, Gnesis,
Granites, Laterites and Sandstones etc. When the source rocks are liberated from it and
transported downward by running water and rivers. A tropical climate with heavy rainfall
assists in the withering process. The liberated minerals transported downward are deposited at
the seashore in an unsorted condition. The river Rushikulya acted as transportation agent for the
heavy minerals and deposition in Bay ofBengal.
The actual sorting and concentration takes place due to the actions of two principal
agents. A breaking wave takes all the foreshore minerals to the beach but the backwash carries
only the lighter minerals back to the sea. Repeated action of waves results in sorting and the
concentration of heavy minerals in beach placer deposit. After the concentration is over, action
of the wind further enriches the concentration by blowing away the finer and the lighter sand
particles. Statigraphically, the deposit is of recent age and its country rock belongs to
Pleistocene age. No fault planes joints or geological disturbances are exciting in the deposit.
For the purpose of evaluation and presentation of the deposit, the OSCOM deposit is divided
into two sectors viz. south andnorth.
Mining Lease Area:

17
o 2877.76 Hectares (from 21.03.1979 to 20.03.1999)
o 2464.054 Hectares (from 21.03.1999 to 20.03.2019)
HEAVY MINERAL RESERVE AT OSCOM
LOCATION:
DIRECTIO
N
LATITUDE LONGIT
UDENortheast 19º 21’ 30” 85º03’23”
Central position 19º 18’ 33” 84º 58’ 36”
Southwest 19º 15’ 38” 84º 55’ 00”
INFORMATION ABOUT OSCOM
LOCATION
Matikhal village, Chatrapur taluka , Ganjam dist., Odisha state.(Let. 19 Degree 16’
North, Long. 84 Degree 33’ Eat, Height about 17m)
WORKS TERRAIN
Plain, Seashore
CLIMATIC CONDITION
The Climatic Cond. Pertaining to site are generally as Indicated Below;
14 Degree celcius
32.2 Degree celcios
16.6 Degree celcios
87% (May-June)
65% (Nov-Dec)

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MEANWIND SPEED
7 to 12 kms (Dec-Jan).20 to 3 Kms (apr-may).A supper Cyclone with a wind speed of 200
km per hour hit the IREL ,OSCOM site on 17th
oct 1999
ANNUAL MAIN RAINFALL
About 2010 mm having more than 80% rain fall during the months of June to
October
UCEPTIBILITY TO EARTHQUAKE
Falling under zone-2 as defined IN I : 1983. However an increased Horizontal
seismic coefficient corresponding to zone-4 shall be used for deign purposes
RAILWAYS
The main board gaunge line o feast coast Railway line connecting kolkota and
Chennai passes at a distance of 7 km from the boundary of the plant ite
The major railway station are BBSR At distance of about 22 km and Chatrapur at a distance
of about 6 km.IREL has private broad gauge railway siding extending from Chatrapur railway
station to exiting IREL plant ite.
SEA PORT
Kolkata port I at a distance 550 km by road/rail vizag port I at adistance of 360 km by
road/rail.
AIRPORT
The nearet airport I at BBSR at a distance of 160 kms by Road. Flights are available to
BBSR from kolkata ,Mumbai, Chennai and new delhi.
The actual sorting and concentration takes place due to two principal agents. A breaking wave
takes the foreshore minerals to the beach and the backwash carries the lighter minerals back to
the sea. And this to and fro action of waves results in sorting and the concentration of
heavy.
minerals in beach placer deposit. Action of the wind enriches the concentration by blowing the
finer and the lighter sand particles. The OSCOM deposit can be classified into two sectors viz.
south and north for the purpose of evaluation and presentation of the deposit.
Mining Lease Area
2877.76 Hectares from 21/03/1979 to 20/03/1999 2464.054 Hectares from 21/03/1999 to
20/03/2019

19
Properties & Chemical Composition of Minerals
Proper
ties
Il
me
nit
e
Rut
ile
Zi
rc
on
Mona
zite
Gar
net*
Sillim
anite
Thoriu
m
Chem
ical
form
ula
Fe
Ti
O3
TiO
2
ZrO
2
SiO2
or
Zr
Si
O4
(La,Ce
,Y,Th
)PO4
ThOU
3O8
A3B2(
SiO4)
3
Al2O3
SiO2
or
Al2S
iO5
Th(NO3
).4.5H
2O
Colour Bl
ac
k
Bla
ck
Red
dish
Pale
yellow
Pi
nk
Colour
less
White
Magn
etic
Prope
rty
Ma
g
Non
-
mag
Non
-
mag
Fee
bly
mag
netic
Mode
ratel
y
mag
netic
Non-
mag
---
Electr
ical
prope
rty
Co
n
d
u
c
t
i
n
g
Con
d
u
c
t
i
n
g
Non
-con
Non-
con
Non
-con
Non-
con
---
Speci
fic
gravi
ty
4.5
4
4.25 4.6
t
o
4
.
7
4
.
6
8
5.25 3.9 -
4.1
4.11
3.20-
3.25
3.25Bulk
density
2.8 2.6 2
.
8
8
2.98 2.2
to
2.3
1.88
Chemical composition (typical)
TiO2 50.
25
94.5 0.7 0.2
5FeO 34.
1
24 to
27
0.005(F
e)Fe2O3 12.
76
1.1 0.3 0.4
Al2O3 0.4
5
20 to
21.5
56.
4SiO2 0.8 0.9 3
1
.
5
38 to
38.5
36.
9Cr2O3 0.0
5MnO 0.5
5P2O5 0.0
3
0.06 0.1 29.8
V2O5 0.2
2CaO 0.0
5MgO 0.7
8ZrO2 1.2 65 2.2
Th 42
pp
m
U <3
pp
m
0.35 0.0005(
U3O8)ThO2 8.2 45.3
Aci
d
insolu
bles
3.5
Total
oxides
66.7 0.1(RE
O)Impuriti
es in
product
(max
%)
G
ar-
1
M
on
-
0.1
Zir
-
1.5
Mo
n-
0.3
Si
ll-
2,
Rut
-
0.5
Mo
n-
0.3
Ilm-
4.0
Qtz-
4
Mon--
0.3

21
MINING AND PROCESSING
METHODOLOGY

22
Basic Unit Operations
The complete operation at Indian Rare Earths Ltd can be broadly classified as:
1. Mining/Dredging & Preconcentration [Dredging & Wet Upgradation Plant (DWUP)]
2. Heavy mineral Upgradation [Heavy Mineral Upgradation Plant (HUP)]
3. Mineral separation [Mineral Separation Plant (MSP)]
(PROCESSES OF OSCOM)
( HIERARCHY OF OSCOM OFFICIALS )

23
Dredging and Wet Upgradation Plant (DWUP)
The OSCOM have a huge placer deposit with a length of 18 Kms and width of 1.5 Kms running
parallel to the coast of Bay of Bengal. Northern boundary of the mining area is Rusikulya River and
southern boundary is Gopalpur town. The estimated reserves are 230 MT (1.5m below MSL) and
440 MT (6m below MSL). Mining is divided in two sections; North section and South section. The
whole mining area is classified in three zones; plenty zone, Intermediate zone and rare zone.
This plant is in complete floating condition. It floats in a pond having diameter 200m and
depth of 6m. The whole unit can be divided in two groups:
1) Mining/dredging
2) Pre-concentration
Mining
The mining procedure followed for the excavation of beach sand is completely different from the
surface or underground mining. The procedure followed is commonly known as DREDGING.
Dredging can be defined as an excavation activity or operation which is carried out at partly
underwater, in shallow depth of sea or fresh water areas with the purpose of gathering up bottom
sediments and disposing of them at a different location. A dredge is a device used for dredging for
scraping or sucking the seabed. A dredger is a boat or ship equipped with a dredge. The process of
dredging creates wastes (excess material), which are conveyed to another location different from the
dredged area. The dredge Capacity is about 500 TPH and dredge depth is nearly 6m. The RPM of the
motor used is 368 with a power of 525KW.In OSCOM, There are two different types of dredge used
for dredging purposes:
Cutter Suction Dredge: A cutter-suction dredger's (CSD) suction tube has a cutter head at the
suction inlet, used to loosen the earth and convey it to the suction mouth. The cutter can also be used
for hard surface materials like gravels or rocks. The dredged material is usually sucked up by a wear-
resistant centrifugal pump which is discharged through a pipe line or to a barge. In recent years, in
order to excavate harder rock without blasting, dredgers with more powerful cutters have been built.
Bucket wheel Dredge: The bucket-wheel dredge is identical to the cutter suction dredge apart from

24
the position of wheel excavator which is used in lieu of the rotary cutter. In both the cases, the cutter
attached to the ladder rotates and cuts the sand and thus make a suspension of sand in water which is
pumped out to the Trommel.
Pre-concentration:
In this stage, the amount of heavies is upgraded up to 90%. Then it is sent to HUP for further
treatment. The suspension formed by the dredger is pumped to the Trommel with aperture size is
4mm, which rotates at 6RPM with a motor power of 37KW. The undersize of the Trommel is sent to
bins from where it is sent to the spirals for concentration and the oversize usually containing pebbles,
grass and other waste materials. In spirals 4-stage of cleaning takes place i.e. Rougher, Cleaner,
Recleaner and Scavenger. Each spiral with 144 starts and each used at 2TPH and the total capacity is
576 TPH. Concentrate from the rougher spirals is sent to cleaner spirals, middlings to Scavenger
spirals and tailings to the Hydrocyclone from where the overflow (water) is sent to Trommel
discharge and the underflow is the rejects (sand) which is thrown for back
( DREDGER AT OSCOM )
filling of the pits. Cleaner concentrate is sent to Recleaner, middlings is recirculated and tailings to

25
the scavenger. Recleaner concentrate is final concentrate which is sent to HUP (Heavy upgradation
plant), middlings is recirculated and tailings are sent to cleaner. The scavenger concentrate is sent to
cleaner circuit, middlings is recirculated and tailings are sent to Hydrocyclone. By this process the
amount of heavies are improved to 90-92%
. Dredge Cutter
Type Rosette type with 5 cutting vanes
Material Ni-hard chrome
Speed 0-34 RPM
Motor Capacity 75 KW
Cutting Torque 690 to 1835 kg-m
Cutter Ladder Power Pack
Capacity 75 KW, 415 Volts, 128 Amps
Pressure 250 bars
Speed 1475 RPM
Ladder Lift 6 m
TROMMEL:-
The major inputs to a trommel screening model can be categorized according to screen
construction parameters, operating conditions, feed characteristics, and computer simulation
parameters. Screen construction parameters include diameter, total length, screening surface
length, inclination angle, aperture size, aperture shape, and open area fraction. In most cases,
the only operating conditions that can be altered are mass feed rate and rotational speed,
although on some screens inclination angle also can be adjusted. Feed characteristics include
the size and material distribution of the feed, as well as material properties of the feed such as
bulk density, moisture content, and coefficients of friction.

26
Computer simulation parameters. Refer to solution algorithm requirements such as
timestep increments, distance increments, and convergence criteria. The major outputs that
are desired from a trammel screening model vary with the application of the model. In
general, this information includes the location of the material in the screen, the residence
time of the material in the screen, the number of cycles the material goes through while in
the screen, the screening efficiency, the mass splits, and the size and material distributions
of the undersize and oversize fractions. Material action inside a rotating trommel screen may
take several:different forms depending upon the rotational spyed of the screen, the loading
of the screen, material properties of the feed, and the presence of lifters. The emphasis in
this report will be on "centrifugal action" in which a particle is 449 carried above the
horizontal plane that passes through the center of the screen until at some point it detaches
from the screen and falls until it contacts either the screen surface or material that is already
in contact with the screen surface. The particle rises to its point of detachment as the result
of centrifugal force. Modeling of another type of material action, referred to as kiln action, is
dealt with elsewhere. In kiln action, a particle remains stationary with respect to the screen
surface as the screen turns until the particle reachesa position at the surface of the bed. At
this point, the particle tumbles down along the surface of the bed until it comes to rest at
some lower position. The cycle is then repeated. Under certain conditions,both centrifugal
action and kiln action may occur simultaneously with respect to material at different radii in
the screen. In the case of centrifugal action, axial advance of a particle occurs during periods
of falling through the ai!. and during periods of slippage on the screen In both instances,
axial advance is due to the gravitational component in the axial direction. Slippage may
further affect particle dynamics by determiningthe height to which a particle can be carried

27
up the screen surface before it detaches. Unfortunately, accounting for slippage significantly
complicates the model. For this reason, two particle dynamics models are presented. In the
first model, slippage is neglected; whereas in the second model it is taken into account.
A particle remains in contact with the screen until the force component of gravity in
the radial direction exceeds the centrifugal force. A free body diagram illustrating this
condition is shown in figure A force balance leads to the relation for the departure
(FREE BODY DIAGRAM FOR FORCES )
ON PARTICLE AT DEPARTURE POIN
(Particle Motion Trommel)

28
( FLOW CIRCUIT OF HEAVY MINERAL )
Spirals
Spirals are gravity separators where slurry is fed to at a pulp density of about 20-25%, the size range
is commonly 3mm to 75 microns and as the slurry flows down the curved channel, lighter particles
due to action of centrifugal forces will report to the outer area of the spirals as tail while the heavier
particles are pulled inward due to drag force and report to the inner area of the spiral as concentrate,
thus effecting the separation. Modern spirals are constructed from fiberglass and plastic and can treat
1-3TPH of feed effectively. The operating parameters are feed rate, pulp density, feed grade, splitter
openings, position of distributors, diameter of spirals etc.
Principle of operation:
In spirals, the separation of HM has been done from the rest of the sand by the combined action

29
of centrifugal force, gravitational force and drag force. The trough of the spiral is inclined towards
the centre. So, the heavier particles slide towards the centre quickly, as they fall from the top. Due to
the centrifugal force, the lighter particles move outside and heavier towards the centre. The particles
having high specific gravities move towards the centre of the spiral column and subsequently tapped
by means of splitters. Due to all above reasons, heavier particles move towards centre and are
collected as concentrate, whereas lighter particles are collected from the outer portion of the spiral
as tails with the help of splitter openings.
Operating parameters in Spirals:
❖ FeedGrade
❖ FeedSizing
❖ FeedRate
❖ Feed Pulp Density
❖ SplitterPosition
❖ DiverterPosition
( PHOTOGRAPHS OF SPIRALS )

30
( Section view OF SPIRALS )
( deposition of heavy minerals in spiral )

31
SPECIFICATION OF SPIRALS
Heavy Upgradation Plant (HUP)
This is the stage where the concentration of heavy is further upgraded to 98%. The feed to
HUP plant is the Recleaner concentrate of the DWUP where heavy minerals concentration is
90-92%. The heavy minerals are received from Dredge and Wet upgradation plant (DWUP) at
the Re- pulping area of Mineral Separation Plant (MSP). These materials are pumped for up
gradation in heavy Upgradation Plant (HUP) at MSP. When HUP is not in operation the
material is stockpiled at RPA. These accumulated heavies are pushed for pumping to HUP be
the help of Earth Moving Equipments (EMEs) whenever required. In HUP, the feed is treated
in gravity separation equipment like spirals and Hydrocyclones and the unwanted lighter
material is pumped to reject dumping yard and the upgraded heavy mineral is pumped to the
dry feed yard through Hydrocyclones for natural dewatering and finally it is fed to main plant
by EMEs for drying and further separation.

32
MINERAL SPECIFICATION AT HUP
Mineral Separation Plant (MSP)
In the mineral separation plant (MSP), the heavy minerals like Ilmenite, Rutile,
monazite, zircon and Silliminite are separated from the upgraded feed minerals on the
basis of their physical properties like electrostatic & magnetic property, surface
characteristics and specific gravity. The plant comprised of different floor and equipped
with different material handling equipment like bucket elevators, belt conveyors, screw
conveyors, drag conveyors to facilitate smooth transport of materials to the desired
machines for example Rotary Dryer, High tension separators, Magnetic separators,
Shaft dryers, Electrostatic Separators etc. Beside this, there is a wet processing circuit
which comprises of Spirals, Floatex, Wet Tables, Flotation cells etc and Slurry Pumps
are used to transport materials from one point to another.
Annual Production Capacity of MSP:-
Ilmenite: 220000 TPA
Rutile: 7400 TPA
Zircon: 5000 TPA
Sillimanite: 8000 TPA

33
Monazite: 2350 TPA
Ilmenite Circuit
The first activity in the MSP includes the drying of the feed material by rotary dryer of
50TPH capacity using Furnace Oil. In the next operation, the bone dried feed (140-150oC)
material is fed for High Tension Separators (HTS) where conducting minerals like Ilmenite and
Rutile are separated from non-conducting minerals like Zircon, Monazite, Garnet and
Sillimanite. Then, the conducting part is fed to Induced Roll Magnetic Separators (IRMS) and
Ilmenite being magnetic, separated out from nonmagnetic Rutile and stored in Ilmenite ware
house. For further recovery of the products, the middling fraction of High Tension Separator
and IRMS are treated in Shaft Dryers followed by HTS, Electrostatic Separators (ESP), Rare
Earth Drum Magnetic Separators (RED) and IRMS etc.
Rutile Circuit
The Rutile has conducting and nonmagnetic property is being produced by treating the
nonmagnetic fraction of IRMS, REDs etc in Rutile circuit consists of a shaft dryer, HTS,
EPS,High Intensity Induced Magnetic Separators (HIRMS), Cross Belt magnetic Separator
(CBMS) and vibratory screen etc. Then the Rutile product from the circuit is collected in
hoppers followed by bagging in 50kg bags in ware house.
Monazite Circuit
The non conducting fraction is fed to HIRMS followed by REDs to separate the feebly
magnetic Monazite and magnetic Garnet from it. Then Garnet part is sent to the reject yard
along with the HUP rejects. For further recovery of Monazite from feebly magnetic fraction is
treated in Semi Lift Magnetic Separators (SLMS) and Air tables. The Monazite product is at
present pumped to trench located in specified area for future use. Monazite is being a
radioactive mineral in nature the processing area is protected by barricading for trespassers and
the radiation level in the Monazite circuit at different level is monitored by the Health Physics
Unit under BARC at OSCOM.
Zircon Circuit
The non conducting nonmagnetic fraction is then treated in Wet circuit consisting of
Floatex density Separator, Spirals, Wet tables etc to separate Zircon and Sillimanite rich fraction
from it. The heavier fraction of this circuit is mainly Zircon, which is dried in a Rotary Dryer

34
followed by operation in HTS and Air table for further purification. Then the Zircon product is
collected in hopper followed by bagging in 50kg bags in ware house.
Sillimanite Circuit
The lighter fraction in the wet circuit is mainly Sillimanite, which is separated from the
unwanted quartz in froth flotation operation by using different chemicals like sodium silicate
(depressant for quartz), soda ash (pH modifier), oleic acid (frother) etc. Finally the sillimanite is
dried in a dryer followed by magnetic operation and stored in ware house. Apart from the above
to support the dryers heating system, there is a furnace oil handling system consisting of a day
tank capacity of 20KL and three screw pumps for pumping furnace oil to different dryers.

35
( CIRCUITS FOR SEPARATION OF DIFFERENT MINERALS AT
MSP )
Equipments Used at MSP
Rotary Dryer /Killn:-
Rotary dryer or rotary killn is the most essential and important equipment of the mineral
separation plant. From the rotary dryer the dry cycle is starts means it converts the wet sand to
the dry sand by absorving the moisture content from the went sand at bone dry
temparature(150ºC-160ºC). So after every wet cycle there are one rotary dryer is present
(Rotary Dryer)
The rotary drier is basically a cylinder, inclined slightly to the horizontal, which may be
rotated, or the shell may be stationary, and an agitator inside may revolve slowly. In
either case, the wet material is fed in at the upper end, and the rotation, or agitation,
advances the material progressively to the lower end, where it is discharged. Figure
shows a direct heat rotary drier. Typical dimensions for a unit like this are 9 ft diameter
and 45 ft length. In direct-heat revolving rotary driers, hot air or a mixture of flue gases
and air travels through the cylinder. The feed rate, the speed of rotation or agitation, the

36
volume of heated air or gases, and their temperature are so regulated that the solid runs
on two circular tracks and is turned by a girth gear that meshes with a driven pinion.
The inclination is one in sixteen for high capacities and one in thirty for
low ones. As the shell revolves, the solid is carried upward one-fourth of the circumference;
it then rolls back to a lower level, exposing fresh surfaces to the action of the heat as it does
so. Simple rotary driers serve well enough when fuel is cheap. The efficiency is greatly
improved by placing longitudinal plates 3 or 4 in. wide on the inside of the cylinder. These
are called lifting flights. These carry part of the solid half-way around the circumference
and drop it through the whole of is dried just before discharge. The shell fits loosely into a
stationary housing at each end. The material is brought to a chute that runs through the
housing; the latter also carries the exhaust pipe. The revolving shell a diameter in the central
part of the cylinder where the air is hottest and least laden with moisture. By bending the
edge of the lifter slightly inward, some of the material is delivered only in the third quarter
of the circle, producing a nearly uniform fall of the material throughout the cross section of
the cylinder. The heated air streams through a rain of particles. This is the most common
form of revolving rotary cylinder. It has high capacity, is simple in operation, and is
continuous.
In the MSP of OSCOM three rotary dryers are used . they are
1) Main dryer
2) Zircon Dryer
3) Sillimanite Dryer
Main Dryer:-
Main dryer is the big sized rotary dryer which have 18 meter length and
3meter diameter. This rotary dryer is present before all the mineral circuits. Because
before all the circuit the sands from the hydrosizer have to moisture free, that can it will
be separate easilyin the high tension separators. This main dryer have capacity of 5TPH.
The shell of the dryer is made upof cast iron which is supported by the four support
roller. The support rollers are made upof mild steel. For easy dryfication the shell is
present at inclination angle of 1:40 slope ratio. There are two thrust rollers are present
which are helps to balance the shell at the inclination. One graphite plate is present on
the girth gear which is very helps in clean the sand and other dust particles by the chair
pad and helps to move the dryer shell in backward or frontward.

37
To rotate the dryer shell there are one 90kw motor is used which is rotates in 960rpm.
The motor is connected to the gear reduction box by the help of fluid coupling for the
safety precaution. The another end of the gear box connected with the pinion which is
connected with the girth gear of thr dryer shell. When the girth gear and pinion both are
madeup of EN8 steel. There are 154 no. of teeth are present on the girth gear and 21 no.
teeth is present on the pinion gear, the speed of the girth gear is 2rpm, and the speed of
the pinion is 12rpm for carry the heavy thrust. Inside the dryer shell there are no. of
lifter plate and semilifter plates are present, which are helps to contact the wet sand with
hot air. Inside the dryer shell high amount of temperature sre produced for safety

38
maintanance inside the wall of shell the dilute air are moves which are helps to reduce
the temperature of the wall of the shell. To produce the hot air furnace oil and oxygen
are burns together for atomize the fuel forced air is gives to the burnt fuel flow. To
extrct the moisture carried air there are induce draft fans (I.D Fan) are used. The
capacity of suction of air is 1Nm3(Normal m3). After suction of the air the I.D fan sent
the moisture carried air to the stack or chimminy. For the easy or smooth operation of
the rotary dryer there are three type of blowers are have used, the blowers are
1) Combustion Blower
2) Atomizing Blower
3) Dilute Blower
Electrical Separators
Electrical separators utilize the difference in electrical conductivity between the various
minerals in the ore feed. Since almost all minerals show some difference in conductivity
it would appear to represent the universal concentrating method. The fact that the feed
must be perfectly dry imposes limitations on the process, but it also suffers from the
some disadvantage as, the capacity is very small for finely divided material. For most
efficient operation, the feed should be in a layer, one particle deep, which severely
restricts the throughput if the particles are as small as, say, 75 microns. In MSP, there
are three different types of Electrical Separators which are being used depending upon
the requirement.
High Tension Separator
High-tension roll separator (HTS) utilizes the differences in surface
conductivities of conducting and non-conducting minerals thereby affecting their
separation. Feed heated to bone dry temperature (~120 °C) is fed to a rotating drum,
which is grounded. A high DC voltage is applied as a result of which air surrounding
the electrodes is ionized and mineral particles get charged. The conducting particles
(ilmenite & rutile) lose their surface charge quickly through the grounded rotor and fall
down due to centrifugal and gravity forces. Non-conducting particles cannot lose their
acquired charge easily and get pinned to the drum and are removed with the help of an
AC wire or scrapped off by a brush.

39
PRINCIPLE OF High Tension Separator
( Photograph of high tension separator )

40
MODELLING HIGH TENSION SEPARATOR:-
In principle, HTR modelling appears straightforward. Each particle on the roll is
subject to a number of forces, varying in magnitude with time and position on the roll. The
magnitude of these forces determines how the particle behaves, and hence its separation
response. The major radial forces are gravity FGR centrifugal FC, electrostatic pinning Fp and
electrostatic image attraction FI
(Radial forces acting on a particle on the HTR roll)
The force is the electrostatic force between the particle and the charge it induces on the
grounded roll. The pinning force is the electrostatic force acting on the charged particle in the
presence of the static electric field. The radial force balance is then:
FC= FGR + FI + Fp
Where,

41
Operating Parameters in HTS
❖ Feedrate
❖ Speed of theroll
❖ Voltage
❖ Electrodedistance
❖ Temperature
ELECTROSTAIC PLATE SEPARATOR
Final cleaning of the HTS products is often carried out in purely electrostatic separators, which
employ the "lifting effect" only. The feed particles gravitate down a sloping, grounded plate into an
electrostatic field induced by a large, oval, high-voltage electrode.
Operating Parameters in EPS
❖ Feedrate
❖ Feedtemperature
❖ DCvoltage
❖ Splitterposition
❖ Electrodeposition

42
Coronastat Separator
It separates minerals based on their differences in surface conductivities using a unique
combination of three electrodes. Each electrode has a unique function. The ionizing electrode ionizes
the feed particles; the induction electrode forces the decay of charged conducting particles while the
capacitance electrode applies a holding force to non-conducting particles as they travel through the
separation zone, thus effecting the proper separation. The operating parameters are once again same as
the HTS.
MAGNATIC SEPARATORS:-
There are five different types of magnetic separators used at MSP.
Induced Roll Magnetic Separators:-
Magnetic field is produced when an electric current (D.C.) is passed through a coil of
wire (the induction process). The magnetic field intensity generated in an electro-magnetic
separator is dependent upon:
:-Amplitude of current (amps) – Variable
:-Number of turns in coil (Windings) – Fixed
:-The length of the iron circuit – Fixed
:-Magnetic permeability of iron circuit (This includes the air gap in iron circuit necessary for
separation zone)

43
It is one of a series of high intensity electromagnetic machines designed for the
separation of granular materials having very weak magnetic susceptibility. The unit consists of
a number of specially designed laminated rollers rotating between the poles of powerful
electromagnets. Mineral Technologies specialise in custom designed IRM units to suit specific
client requirements.

44
It is one of a series of high intensity electromagnetic machines designed for the
separation of granular materials having very weak magnetic susceptibility. The unit consists of
a number of specially designed laminated rollers rotating between the poles of powerful
electromagnets. Mineral Technologies specialise in custom designed IRM units to suit specific
client requirements
Features:-
Designed for continuous, heavy duty applications
Optional low intensity drum for removal of particles with high
magnetic susceptibility
Laminated roller profiles selected to suit mineral feed particle
size
Magnet pole (nose iron) profiles selected to suit application
Adjustable magnet poles (air gap) for intensity optimisation
Coil rated for continuous use giving up to 2 Tesla adjustable to
suit application
Magnetic circuit design for minimal flux leakage
Single feed point for 2 start separator
Trash screen to protect against tramp oversize
Single fibre separation roller wiping brush on each separation
stage
Adjustable splitter position with provision for a middlings
fraction on the lower rollers
Control panel incorporating magnetic field control, motor starter and interlocks
IRMS is used for :
Removal of any magnetic contaminants from non-magnetic products to meet grade targets
Production of glass / silica sand and other industrial minerals
Cleaning of zircon or rutile products
Separation of high temperature feedstocks
Scalper drum magnets can be fitted to remove highly susceptible magnetic contaminants
when required

45
Option to retreat magnetics, middlings or non-magnetics on lower rollers
New feed presented to all rolls for 4 x single pass separation
Knifegates on feed and dust ports to allow isolation
Optional VSD on feed roll to give remote control of feed rate
Optional Drive Arrangements :
a) Belt and pulley driven - standard
b) Feed rollers only – direct drive with VSD control
c) Feed and separation rollers – direct drive with VSD control
Magnetic Separation Techniques:-
Normally silica sand producers prefer to process material in the wet state to obviate the
need for costly drying, although some producers process after any drying stage to achieve
maximum benefit.
Wet Separation:-
Until recently the only wet high intensity magnetic separation or WHIMS available was
based on the Jones carousel design as produced in the 1950’s. The design is based around a
rotating annulus or carousel containing a magnetic matrix. As the matrix passes through a high
intensity magnetic circuit, a high intensity magnetic field and gradient are induced in to the
matrix. The feed passes vertically through the induced matrix section capturing magnetic
particles.
Fundamentals:-
It is important to understand the basic principles of a induced matrix separator. Many
people incorrectly associate the separation power of a magnet with the gauss figure it is said to
generate. This is
only part of the ability of a magnet to separate. The magnetic intensity which is measured in
gauss or tesla (1 tesla = 10000 gauss) is the number of magnetic flux lines per unit area. If we
examine a particle inserted in a uniform magnetic field (fig 1), we see that the force exerted on
the particle is equal and no relative attraction will be seen. If however we insert the same
particle into a non-uniform field with a differing intensity across the gap we see that the
magnetic field intensity changes across the gap and a unequal force is exerted on the particle
resulting in movement to the area of highest intensity. This changing flux intensity is termed a

46
magnetic gradient and is the moving force behind separation. In short, intensity magnetises the
particle and magnetic gradient moves the particle. When a matrix wire is inserted into a uniform
magnetic field, the field is distorted passing through the matrix wire and polarising the wire to
creating points of high intensity and gradient. In a separator matrix there are thousands of such
points available ensuring a high contact ratio with magnetic particle.
Separation Parameters:-
As part of the process investigation separation parameters were explored identifying the
following as the most important.
magnetic susceptibility:-The ability of a particle to be magnetised
-The intensity of magnetic field required to magnetise and hold a particle of
specific susceptibility.
-The resistance of a medium to the movement of a particle
through it. With sand this is normally relation to the solids density.
-This controls the dwell time that the particle is exposed to the magnetic
field. A low velocity will enable the magnetic field to capture and hold a particle, whereas a
high velocity will result in only a deflection and no capture. This effect is more important as
magnetic susceptibility decreases
Dry Separation:-
The roll of dry magnetic separation for the treatment of silica sands has always
been confined to relatively specialist grades produced in small quantities. The part played by
dry magnetic separation for the treatment of silica sands and more commonly feldspathic sands,
has always been confined to relatively specialist grades produced in small quantities. Production
of such materials is normally for a bagged material, and a lower iron specification is often
associated with such a product. Therefore this premium type of material can command a higher
selling price and therefore stand additional process costs. Early magnetic separators used in the
sand industry were the Induced Roll Magnetic separator or IMR. The IMR system is an
electromagnetic system relying on the induction of a high intensity field into a laminated roll.

47
The separating roll is comprised of alternate discs of mild steel and a non-magnetic metal. The
roll is situated between the 2 poles of the electromagnetic circuit and high intensity and high
gradient fields are induced into the steel discs. The intensity of the induced field is controlled by
the force generated by the electromagnet and also the air gap between the pole and the roll.
Consequently the smaller the air gap between the roll and the pole, the smaller the space
available for the feed to pass, the smaller the acceptable granulometry and the lower the
capacity. Maximum fields of 18,000 gauss can be generated on the IMR roll but at a minimal
capacity. As a result IMR systems gave effective separation on a limited size range but at a high
capital and operating costs. Although the power consumption of the electromagnet on IMR
units is relatively low at typically 2.0 - 4.0kw, the motor drive power consumption is high at
typically 3.0 kw because of the magnetic drag produced on the induced rolls.

48
Rare earth Drum Magnetic Separators:-
Rare earth drum separator (REDS) is a kind of magnetic separator which separates the minerals
on the basis of their difference in magnetic properties. It works on similar principle as the
Induced roll magnetic separator but it differs in its basic construction and its operation. In this
the magnetic field is produced by permanent magnets. The magnetic element is constructed
with the help of blocks of Neodymium Iron Boron ceramic magnets, Iron or steel pole are not
used in this configuration i.e. an ironless design. The magnetic element consists of five main
magnetic poles; each pole consists of two magnetic blocks. There are also two trailing poles to
provide “Diminishing” magnetic field intensity. This configuration generates a peak magnetic
field intensity of 6-7 Kilogausses on the drum surface.
The magnetic circuit remains stationary within the drum shell and spans an arc of
approximately 1200. A single RED can treat up to 5 TPH effectively. A release mechanism is
provided to dislodge minor amounts of ferromagnetic material from the drum surface.
The operating parameters are:
 feed rate
 roll speeds
 feed temperature splitter positions
The Rare Earth Roll Separator:-
The rapid development of high energy rare earth permanent magnet material over the

49
last 15 years has enabled new high intensity permanent magnet designs. The rare earth roll was
developed as a low energy replacement for the IMR and utilizes alternate discs of magnet
material and steel. The magnetic field is then induced into the steel disc in a similar manner to
the IMR.
Material is fed onto the permanent roll using an extremely thin transport belt which in turn
removes the magnetic particles from the underside of the roll. The magnetic field generated on
the induced poles is between 18000 and 21000 gauss but this drops with the addition of the
transport belt to nominally 13000 gauss. Total energy consumption is very low, at nominally
0.75kw per roll with the only other consumable being the transport belt.
Principle of Mineral Separation In RERS

50
(Photograph Of RERS)
As the magnetic field produced by the permanent roll decreases rapidly with distance
from the roll surface, a very thin transport belt and feed depth are required for the best
separation.
Normally for sand separations a 0.15mm kevlar transport belt is used with a life of up to 2000
hrs.
The biggest problem associated with the 75mm diameter designs which are commonly
produced is the capacity limitations. For sand 2.0 - 3.0 t/h per meter width is usual. Obviously,
for higher capacities the number of units required will be large with the attendant problems of
feed splitting and a larger number of belts to maintain. Firstly Eriez Magnetics has approached
the problem of capacity by exploring by developing increased diameter roll which have
increased capacity. A comparison of capacities against grade is shown on the graph below for
75, 100 and 300 mm diameter units on a single pass.
The operating parameters are
Magnetic field current
 Air gap
 feed rate
 roll speed
 splitter position
 Generally feed rate is maintained at 4-5TPH per roll and the roll speed is around
150RPM.

51
Cross Belt magnetic Separators
It is a high intensity magnetic separator in which feed is allowed to pass through a main belt and a
number of cross belts. Magnetic particles get attracted to the bottom part of the cross belt due to the
influence of electromagnet placed over the cross belt which carries them out of magnetic field while
non-magnetic particles pass on unaffected. The magnetic field is in the range of about 19-20 Kilogauss
and the capacity is about 1.5-2.0TPH.
( Cross Belt magnetic Separators )
magnetic field current
:- Air gap
:- Belt speed
:- feed rate

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Gravity Concentrator :-
Gravity concentration methods separate minerals of different specific gravity by their
relative movement in response to gravity and one or more other forces, the latter offers
resistance to the motion by a viscous fluid, such as water or air. Different kinds of gravity
concentrators are being used in MSP.
Wet Tables :-
Wet table consists of an inclined deck fitted with riffles. With given reciprocating motion at
right angle to the flow of water, heavier minerals settle down in the riffles and concentrates are
carried along the diagonal line of the table. The lighter minerals cannot settle in the riffles and are
washed along with the water as tailings. The pulp density we generally maintain is 25-30% of solid.
:-quantity of wash water
:-deck slope
:-feed rate
:-stoke length
:-speed
:-pulp density
( Wet Tables)

53
There are various types of wet tables including the Deister, Holman, and Wilfley that
are built to handle either coarse or fine feeds.
Variables:-
– Angle of deck (steeper angle less weight to concentrate)
– Length of stroke(longer the stroke , the more the sideways motion and hence more weight to
concentrate up to a maximum)
– Frequency of stroke (similar to length i.e., the more frequent the more sideways motion up to
a maximum)
– Splitter positions (the position of the splitters on the concentrate launder will determine the
weight take to concentrate)
– Feed rate and density (above a maximum of typically 2 tph per full size table and density
typically 40% solids, depending on the type and particle size of the feed) separation will be
reduced.
– Wash water (wash water is added along the top of the table to assist solids flow maintain low
solids density, preventing ‘‘dry spots’’, and washing slimes to tails
– Riffle height (a low riffle height will be better for fine feeds and vice versa).

54
Advantages:-
Highly selective, with high upgrading ratio if used correctly
– Able to see separation and make adjustments
Disadvantages:-
Low capacity, large floor area requirements
– Require frequent operator attention, checking and adjustment
– Feed should be sized
(Photograph Of Wet Table Gravity Separator)
Air Tables
Air tables are gravity concentrators which use air as a separating medium. Compressed air is allowed
below the vibrating table whose surface is covered with a perforated cloth. The feed is supplied near the
top of the inclined table. Lighter particle are lifted by the air and flow downwards as tailings. The
oscillating motion of the table causes the heavy minerals in contact with the table surface to move
upward and is collected as concentrate.
Operating parameters are:
 quantity of air
 feed rate

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 deck inclination
 splitter opening
 stoke length
 speed
Variables:-
– As per wet tables (deck slope, stroke length, stroke frequency, splitters)
– Fluidising air flow (increased flow maintains bed mobility up to a maximum)
Advantages:-
– Where the process before or after is dry, air tables eliminate the need for additional thermal
drying
– Highly selective
Disadvantages:-
– Low capacity, large floor area required
– Even more frequent operator attention required than wet tables (regular brushing the decks to
prevent blinding, splitter adjustment)

56
Techniques Of Separation:-
The basic principle of operation of the gravity separator is that it takes advantage of the
difference in size , shape and specific gravity of particles. The actual separation takes place in
two steps . The first is in the vertical direction by stratification of the seeds and the second is in
the horizontal direction by the table motion and gravity. Both of these actions take place at the
same time all across the deck of the separator to give a continuous grading of material till it
leaves the table. The first step, the vertical separation of the material, is the key that allows the
separation to be made . If the material is not first stratified the second step cannot take place.
The stratification of material is accomplished by air being blown thru the porous deck and in
effect floating the light material away from the heavies . With the deck load stratified the
second step is
ready to take place .
The second step , the separation in the horizontal direction, is accomplished by gravity
and by the deck motion. The deck of the machine is slanted in two directions; from the feed
zone up to the heavy end discharge and from the feed zone down to the discharge edge. This
slanting of the deck allows the light material floating in air to flow down hill by gravity , while
the table motion conveys the heavy materials , in contact with the deck, uphill. It can be readily
seen that the stratification of the material by fluidization with air is the key to an effective
separation . Also, that to get the most efficient separation the material must be stratified as soon
as it is fed on the deck. The reason for this is to utilize the maximum amount of the deck surface
to make the separation after the material has been stratified.
There are four simple adjustments on the gravity separator that control the factors affecting the
separation; amount of air 1 table speed , end raise and side raise . No one of these adjustments can be
called more important than the other because they all effect the separation.
One thing that may confuse an operator is that the effect of the various adjustments is quite
similar. To illustrate this, listed below is the different adjustments that can be used to
accomplish the same thing:
Move deck load to heavy end.
1. Increase Speed
2. Decrease Air
3. Decrease End Raise

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4. Decrease Side Raise
(This picture how the deck load should appear when properly stratified)
Move deck load to heavy end.
1. Increase Speed
2. Decrease Air
3. Decrease End Raise
4. Decrease Side Raise
Move deck load to light end.
1. Decrease Speed
2. Increase Air

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3. Increase End Raise
4. Increase Side Raise
The air adjustment, amount of air, is the key to an effective separation. If there is too much
air it will cause bubbling of the deck load, which causes mixing and upsets the stratification.
Also, too much air will blow the heavy seeds out of contact with the deck and cause them to
report toward the light end of the deck. Too little air will cause only the lightest seeds to be
fluidized and most of the seed will be conveyed up the deck to the heavy end.
Floatex Density Separators
It is a hindered settling classifier and the material is classified on the basis of the settling
velocity. The principle employed by a floatex density separator is that when a rising current of
water is introduced into the classifier over the whole of its area, the mineral expanded into a
state teeter, in which the mineral particles classify themselves so that the coarser and heavier
particles report to the bottom of the column where they relatively stay close to each other with
high velocities of water flowing between them, while the finer and lighter particles will be
dispersed to the higher levels of the column where they will stay in a more open suspension.
Thus in a teetering column of sand the pulp gravity will be greater towards the bottom where
the particles are laying closer to each other.
The principle employed by a floatex density separator is that when a rising current of
water is introduced into the classifier over the whole of its area, the mineral expanded into a

59
state teeter, in which the mineral particles classify themselves so that the coarser and heavier
particles report to the bottom of the column where they relatively stay close to each other with
high velocities of water flowing between them, while the finer and lighter particles will be
dispersed to the higher levels of the column where they will stay in a more open suspension.
Thus in a teetering column of sand the pulp gravity will be greater towards the bottom where
the particles are laying closer to each other.
Hydrosizers are a development of the teeter column classifiers that use the principle of
particle settling to achieve a separation between fine/light particles and coarse/heavy particles in
an environment of a rising flow of water in a tank generated by injection water through a
manifold about two thirds of the way down the tank, which creates an overflow of the former,
and an underflow of the latter. A particle of sufficient weight due to its SG and size will settle
faster in a fluid than a particle of lower SG and size. If there is a rising up-current of fluid then
at a certain volumetric rate the up-current velocity will exceed the settling velocity of the
lighter/ smaller particles but not that of the heavier/coarser particles and a separation will
takeplace.
Variables:-
– Injection water flow rate (increasing water flow rate will increase the weight of particles (and
SG/size) of particles reporting to overflow.
– Column density (increasing the SG of the slurry contained in the column between the
injection water manifold and the overflow weir will increase the weight to overflow).
– Underflow discharge (increasing the underflow discharge volume rate will reduce the solids
density of the column and tend to reduce the upward flow, thus reducing theSG/sizeof theove
rflow solids)
– Mass flow rate of feed (increased feed rate above an optimum level will reduce the
sharpness of separation)
Advantages:-
– Precise automatic control of the separation based on SG measurement of the column head in a
control loop with the underflow valve
– Able to observe both products and make easy adjustments to control mechanism if required
– No moving parts

60
– Can be wet or dry fed
Disadvantages:-
– Require dedicated injection water pump that can deliver a clean, constant but adjustablesupply
– Large water requirement
– Large volume for given capacity required (relative to hydrocyclones)
– Require steady feed rate
Hydrocyclones
Hydrocyclone is a classifying device that utilizes the centrifugal force to accelerate the settling rate of
particles. A typical Hydrocyclone consists of a conically shaped container, open at its apex or
underflow, connected to a cylindrical section, with a tangential feed inlet. The top opening is closed
with the help of a plate through which passes an axially mounted overflow pipe. The feed is introduced
under pressure through the tangential entry which imparts a swirling motion to the pulp. This generates
a vortex in the cyclone, with a low-pressure zone along the vertical axis. An air core develops along the
axis, normally connected to the atmosphere through the apex opening, but in part created by dissolved
air coming out of solution in the zone of low pressure. Feed particles in the pulp are subjected to two
opposing forces viz. an outward centrifugal force and an inward drag force. The centrifugal force
causes coarse and heavy particles to report as underflow while the action of the drag force results in
fine and light particles reporting as underflow.
feed inlet diameter
 spigot diameter
 vortex finder diameter
 feed pressure
 pulp density
 cut size

61
Variables:-
– Feed pressure (this is the driving force behind the separation, such that the greater the
pressure, the finer the size separation achieved)
– Vortex finder diameter (the greater the diameter, the larger the overflow and the lower the
pressure, hence the separation will be coarser)
– Spigot diameter (likewise, the greater the diameter, the larger the flow so the underflow will
be finer or wetter); variable spigots can be used
– Siphoning (if the overflow discharges lower relative to the underflow a siphon effect will
occur causing increased solids and flow to overflow; this is overcome by introducing a vacuum
break)
– Feed density (if the density is too high: typically above 35% solids then separation will be
affected)
– Angle and length of the cone section (increased length and shallower angle will reduce the cut
size)
– Barrel diameter (the larger the diameter, the greater the capacity, the lower the pressure and
the coarser the cut size)
Advantages:-
– High capacity for the volume and floor area required

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– No moving parts
– Limited operator attention
Disadvantages:-
– Not easily adjustable for changing feed and product requirements
– Need to be fed under pressure and at a steady rate
Froth Flotation:_
Flotation is a process where the desired mineral particles in pulp are selectively floated by their
attachment to rising bubbles. In MSP, slurry containing sillimanite and quartz is conditioned in
the first stage with sodium silicate and soda ash.
(Froth Flotation Cell)
Flotation is a process of separation and concentration based on differences in the
physicochemical properties of interfaces. Flotation can take place either at a liquid–gas, a
liquid–liquid, a liquid–solid or a solid–gas interface.
For example, oil flotation takes place on the interface between oil and water. Film flotation
takes place on a free water surface. In this flotation process, hydrophobic particles float on the
free surface and are thereby separated from non floatable hydrophilic particles, which sink into
the liquid phase. In carrier flotation, colloidal particles attach themselves onto the surface of
larger particles (carrier minerals) and float together with the carrier minerals.
In froth flotation, the flotation takes place on a gas–liquid interface. Hydrophobic particles,
which may be molecular, colloidal, or macro-particulate in size, are selectively adsorbed or

63
attached to and remain on the surface of gas bubbles rising through suspension, and are thereby
concentrated or separated from the suspension in the form of froth.
Of the flotation techniques, froth flotation is the only technique that has significant industrial
application. Froth flotation has been used by mineral and chemical engineers for the separation
and concentration of aqueous suspensions or solutions of a variety of minerals, precipitates,
inorganic waste constituents,
and even microorganisms and proteins.
The carrier and agglomerate flotation processes have been developed to increase the kinetics
of bubble–particle interaction in the fine particle flotation. Sometimes, for simplicity, froth
flotation is simply termed as flotation. Froth flotation essentially is an application of foams. The
separation process is based on the surface properties such as wettability and surface charge of
the components to be separated.
It is estimated that over two billion tons of various ores and coal are treated annually by
flotation processes worldwide. The scope of flotation technology is being broadened to include
other areas, such as waste paper recycling, food processing and secondary resource recovery.
Today, deinking by flotation annually contributes 130 million tons of recovered paper to the
worldwide paper production.
Flotation cells
Flotation works efficiently only if the particulates to be flotated are fully liberated (i.e.,
individually free particles) from the other phases. The mixture of appropriately sized and
liberated particles (viz. the flotation feed) from which the selected particles are to be floated is
first conditioned with the appropriate reagents. This suspension (of about 1:3 solids to water by
weight) constitutes the flotation pulp.
It is then placed and agitated using impellers in a suitable container called flotation cell.
Air is drawn in or sometimes fed into the cell near the impeller to form fine bubbles. These
fine bubbles collide with the particles, attach to those particles which have the acquired
hydrophobicity, and rise to the surface where they form a froth, which is removed as a flotation
concentrate (a froth product) by skimming. The hydrophilic particles that are not floated with
the bubbles remain in the pulp, and are removed from the cell as tailings.
Flotation conditions
Energy is needed for the bubble–particle attachment. The bubble–particle aggregate can be

64
viewed of occurring in two steps. In the first step, energy is required to deform the bubble in
order to make attachment of the particle possible. The bubble has a spherical surface. When the
particle encounters the bubble, the bubble slightly deforms, which results in a larger surface
area and hence in an increase in surface energy. In the second step, part of the liquid–vapor and
liquid–solid interfaces is replaced by the solid–vapor interface.
Forthflotation to occur, the bubble–particle aggregate must be stable. Therefore, the energy
gain of the detachment process must be high enough and must not be overcome by external
forces. The work done by attachment is negative, and it should lead to a decrease in energy.
Both the detachment work and the work of deformation are positive.
The contact angle always decreases (i.e., cos increases) with decreasing liquid–vapor
surface tension. Surfactants can be used to manipulate the surface energies of the liquid–solid
and liquid–vapor interfaces in order to modify the contact angle. Thus, the surfactant
concentration can be varied to control floatability.
Indeed, the floatability varies with the surfactant concentration. A competition exists between
floatability and stability. At low surfactant concentration, both the particle and the bubble
surfaces are sparsely loaded with surfactant and the surfactant facilitates floatability.
On the other hand, at very high surfactant concentrations, both the particle and the bubble
surfaces are saturated and there is maximum stability against particle bubble aggregation so that
there is no floatability. In between these two extremes, there lies optimal floatability. This
occurs when the adsorbed surfactant molecules lower the surface tension thereby minimizing
the attachment energy, but the surface is not loaded too much with surfactant to prevent
aggregation.
Operating parameters are:
:-slurry pH
:-air pressure
:-froth depth
:-reagent dosage
:-air flow
:-feed rate
:-Quantity of wash water

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:-conditioning time
:-feed rate
Material transport Medium:-
There are three types of material transport medium are used. They are
1) Screw Conveyer
2) Belt Conveyer
3) Bucket Belt Conveyer
These conveyers are used for transport the extracted minerals or beach sand in the mineral
separation plant in OSCOM. Generally these are used in feed system or feed line. According to
their working they are used in different places as per requirement.
Screw Conveyer:-
Screw conveyer is a very use full type conveyer. These are used where single material input
and multipoint output is required. This type of conveyers also uses for carrying high heated
materials. Like in the MSP at OSCOM the bone dry sand comes to the HTS through the screw
conveyers The screw conveyor is one of the oldest methods of conveying materials known to
mankind with the original design dating back to more than two thousand years. The first type of
screw conveyor was the Archimedes' screw, used since ancient times to pump irrigation water.
A screw conveyor mechanism consists of a rotating helical screw blade, called a "flighting",
usually within a tube, to move liquid or granular materials. They are used in many bulk
handling industries. Since the screw conveyor came into general use a little over a century ago
for moving grains, fine coal and other bulk material of the times, it has come to occupy a unique
place in a growing area of material handling processing. Today, modern technology has made
the screw conveyor one of the most efficient and economical methods of moving bulk material.

66
(Screw Conveyor)
Need:-
As stated above Screw Conveyors are used in a variety of situations. Some of this situations
require material to be transported over a large distance or at considerable heights. The path from
receiving point to delivery point may not always be a straight one or even a constant one.
Depending upon the material to be transported, or the storage capacity of the bins, the screw
conveyor may need to be adjusted. For example when storing grains in a silo, considerable
energy can be saved if the grains are first conveyed up to a minimum height and then the
conveyor is adjusted to deliver up to a greater height. Similar, in construction sites, when
material is conveyed to fill structures for pillars etc., a huge amount of power consumption can
be avoid by conveying in segmented heights by using a flexible conveyor.

67
Concepts Available:-
(Screw Conveyor Dimensions) (Inside Spline and Inserted Body)
Till date various concepts have been developed to satisfy the need of a screw
conveyor. Like some of the few below. In April 1958, Inventors Marion H Fennimore and Ivan
J Stephenson invented a Screw Auger for Conveying grain. In handling bulk materials such as
grain and the like, screw or auger conveyors are frequently used. However, in certain
circumstances there is no open path between the point where the material is located, and the
point to which it is to be transported.
Belt Conveyer:-
Belt conveyer is a simple type of conveyer in which the materials are transported on a
leather or synthetic rubber belt. This type of conveyer is very simple in mechanisim. It have two
ends one is head stock(live poiint) and another is tail stock(dead point). At the head stock the
motor is fitted with the drum which is helps to rotate the belt by the help of couplings. In
between the drum and the motor there is speed reducer gear box is present , which is helps to
maintain the speed ration in between the motor and the drum roller. The another part of the belt
conveyer is the tail stock.At this point the dead drum roller is present. There are two tension
rods are present which are used to maintain the tension on the belt , this type of situation comes
when the belt gets elongetes due to its ductile property. Some times extra drum rollers are
hangged to maintain the tightness of the belt.

68
(Belt Conveyer)
Belt capacities:-
For maximum haulage efficiency , conveyers sgould be operated fully loade dat maximum
recommended speed.
Belt caapacity is depend upon these inter related factors:
(Drum Roller) (Motor With Gear Box)
Belt Width:-
Minimum belt width may be influenced by loading or transfer point requirements, or by
material lump size and fins mix. Through ability and load support restriction , will also
influence final belt width selection.
Belt Speed:-
Possible belt speed is influenced by many factors importantly the loading discharge and
transfer arrangements maintenance standards, lump sizes etc.

69
Material Bulk Density And Surcharge Angle:-
Due to undulation of the belt passing over the conveyer idlers , idlers the natural
angle of repose of the material is decreased. The decreased angle is known as ANGLE OF
SURCHARGE is one of the most important characteristics in determining carrying capacity as
directly governs the cross sectional areas of the material on the belt and hence the “volume ”
being conveyed.
Inclination Angle:-
The angle of inclination of a conveyer changes the carrying capacity. The load cross-
section areaof an inclined load is reduced when viewed in a vertical plane as the surcharge angle
is reduced perpendicular to the belt. An approximation of the reduced capacity can be
determined by multiplying the horizontal capacity by the cosine of the inclination angle.
Effectively the capacity reduction is usually less than 3%
(Inclined belt Conveyer) (Motion of weighted belt Conveyer)
Throwing Angle:-
For standard 3 roll idlers, the most common through angles from 20˚ to 45˚ are
not uncommon. Stepper through angles give increased but can have consequences for convex
and concave curves and transitions zones.
Bucket Belt Conveyer/Elevator:-
Bucket belt conveyer is also one type of belt conveyer but this conveyer is used to
elevate or carry the material from bottom to top. In this type of conveyer bucket like structures
are fixed with the help of screw and nut with the belt. These buckets are helps to carry the
materials from feed point or bottom point to the charging point or top point. The IREL,

70
Chatrapur, OSCOM is a mineral process industry so the feeding points are present column wise
so this bucket belt elevator is a very helpful or important equipment in the material transport
system. This conveyer also has two end points, one is head or top point and another is the tail or
bottom point. The motor is fixed with the head or top point with the help of couplings to the
drum roller. To maintain the speed of the drum roller there is gear box is present which is helps
to control the speed between motor spindle and drum.
(Bucket Belt Elevator) (Drum Roller)
Bucket conveyors are used quite frequently in many bulk material conveying applications. However,
many aspects of bucket conveyor design, features, and performance are not always well understood in the
marketplace. Bucket conveyors are used quite frequently in many bulk material conveying applications. However,

71
many aspects of bucket conveyor design, features, and performance are not always well understood in the
marketplace.
Size limitations of a bucket belt conveyer:-
Theoretically, a bucket conveyor of almost any size could be constructed. Practically,
however, there are limits on the heights and lengths that are achievable with current
technologies. In many applications, the objective is to achieve your vertical conveying
requirements while using the least amount of floor space. Equipment height, or discharge
elevation, can vary by manufacturer. For example, we have made bucket conveyors with
discharge elevations of 120 ft, and it is possible to go higher with tandem belting. However, for
many applications, discharge elevations in the range of 8 to 40 ft are more typical.
Z-type bucket conveyors are frequently used to transverse long horizontals when it is desirable
to
avoid a transfer to another piece of equipment, or where space is too limited to allow for
another horizontal conveyor.
Power requirements of bucket belt conveyer:-
One of the major advantages to bucket conveyors is the lower power requirements of the
equipment.
With the weight of a loaded bucket assembly on either side of the vertical elevation of the
conveyor being equal, the system is in balance. The only power required is that needed to
overcome the inertia of the system and the weight of the material being lifted. Consequently,
well-designed bucket conveyors can be operated with relative low energy requirements.
Feed system of bucket belt conveyer:-
As with any conveyor, accurate in feed control is critical to ensure successful
material handling when the conveyor is operating. Material should be delivered to the bucket
conveyor in a uniform or metered fashion – this prevents any sudden increase in the amount of
product being introduced into the conveyor. Any dramatic changes or surges in input material
can cause the buckets to overfill, causing material spillage. Often, vibratory feeders, screw
conveyors, belt conveyors, and rotary valves are used to deliver material to a bucket conveyor
in a uniform and consistent manner.

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. QUALITY CONTROL:-
Independent collection, suitable analysis, and reporting of final MSP product samples:
1)Analysis and reporting for quality control of final Thorium plant product samples.
2)Analysis of chemicals received at Central stores as per order for quality control.
3)Technical Service is continuously checking for specification and the impurities present in the
minerals before giving them confirmation for marketing.
(Specification and impurities content of the minerals before giving them
confirmation for marketing)

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Uses of the Minerals
Ilmen
ite
Mainly used in the manufacture of Titanium Dioxide (a white pigment). Also
used in the production of Synthetic Rutile (S.R. is used in the manufacture of
pigment, plastic industry and paper industry), Ferro-Titanium alloys, production
of titanium metal which is used in aircraft industries.
Rutile
Used for coating of welding electrodes and for the production of Titanium
Dioxide pigment and Titanium Tetrachloride used for the production of titanium
metal/sponge.
Zirco
n
Used in foundries, Ceramics and Refractories industries. Also used in the
manufacture of Zirconium metal alloys and chemicals. Computer monitors,
Television screens, Yttria Zirconia for oxygen sensors, cutting tools, scratch
resistant bracelets, American Diamond, nuclear reactors in alloy form.
Sillim
anite
Mainly used in the manufacture of refractory bricks for high temperature
application. Also used in high alumina refractory, steel and glass industries,
cement kilns and heat treatment furnaces.
Garn
et
Used in the manufacture of abrasives, Grinding wheels, for polishing glass/TV
tubes, as sand blasting media, water jet cutting and in water filtration, cleansing
of casing/pipes in petroleum industry. As powder for, ceramics, glass polishing
and antiskid surfaces, polishing of picture tubes.
Mona
zite
Extraction of Thorium concentrate and Rare earth Compounds. Used as fuel for
nuclear reactors, used in the manufacture of detergent chemicals, gas-mantles,
permanent magnets, colour TV tubes, fluorescent lights.

74
USES AND APLICATIONS OF HEAVY MINERALS
(Photo Graph Of Heavy Minerals)
6.1. Uses of different products:-
Ilmenite & Rutile:
(Ilmenite)
As Titanium (TiO2) white pigment: Used in Paints/ Varnishes, Plastic, Paper, Rubber, Printing
ink, coated fabric textiles, Cosmetics, sun protection creams and Pharmaceuticals.
As Titanium (Ti) sponge/metal: Used in Chemical industry, Aerospace & Aviation industry,
Surgical equipments, Electrical turbines tubing, Bullet proof vests, Different alloys in Iron &
steel industry, Immersion heater tubes, Consumer goods, Spectacle frames, Golf clubs.
Used for coating of welding electrodes.

75
Zircon:
(Zircon sand)
Used in Ceramics, Foundries, Refractories, Glazing tiles, Television and Computer monitors
and White wars.
It is also used in manufacture of Zirconium chemicals/metal, American diamond, Scratch free
bracelets, Cutting tools, Yttria Zirconia as oxygen sensors. Zircon free from Hafnium is used in
nuclear reactors as cladding tubes to hold nuclear fuel.
Sillimanite:
(Sillmanite sand)
Mainly used for the manufacture of High grade refractory bricks, high Alumina Refractories,
Cement kilns and Heat treatment furnaces.
Garnet:

76
Used for manufacture of Blasting media, Abrasives, Grinding wheels, Mosaic cutting stones,
Decorative wall plasters, Ceramics, Polishing of picture tubes, Glass polishing & Antiskid
surface for roads, air strips, runways, water filter, water jet cutting, Artificial Granite
tiles/Heavy duty floor tiles, cleaning of casings/pipes in petroleum industry and as a gemstone.
Monazite:
(Monazite)
Extraction of thorium concentrate and rare earth compounds.
Rare earth chlorides: Widely used in the manufacture of Misch metal used for lighter flints,
for the production of catalysts for cracking, for the manufacture of metallic soaps which is used
as Dryer in paints, starting material for the production of pure rare earths & rare earth
compounds, removal of organic impurities and decolourisation of paper mills effluents and for
the manufacture of special ferrous casting.
Rare earth Fluorides: Used in manufacture of arc carbon electrodes to increase the arc
intensity, rare earth alloys, for production of nodular cast iron, special steels.
Rare earth Oxides: In the arc carbon industries to increase the arc intensity by factor ten, the
emitted light is identical to natural sun light, for glass polishing in Optical.

77
Cerium oxide: Used in Polishing optical lenses, plate glasses, TV tube face plates; prism etc.
finds application in semiconductor devices, UV absorber in Glasses, radiation protective
glasses, yellow color and decolorizing etc.
Cerium hydrates: Used in manufacture of polishing composition, in the decolorizing of glass,
as an opacifier, as an ingredient in Ultraviolet.
Didymium compound: Use in manufacture of pure rare earth compound, in glass, ceramics,
and nuclear & electronic industries and for improving the workability of stainless steel alloys.
Samarium oxide: For the extraction of samarium metal this finds use in manufacture of
samarium cobalt; used as permanent magnet with high coercive force and high magnetic
energy.
Gadolinium oxide: In the manufacture of Gadolinium-Gallium-Garnet (GGG) substrates of
magnetic bubbles and Microwave garnets.
Yttrium oxide: In the manufacture of phosphor for color tubes and Fluorescents tubes, super
conductors and artificial gems.
Europium: Three bond lamps, cathode ray tubes (CRT), flat plasma TV screen and phosphors.
Terbium: Luminescence, phosphors.
Dysprosium: Luminescence, phosphors, application for nuclear industry, ceramics.
Holmium: Application for nuclear industry, ceramics, laser.
Erbium: Nuclear reactors, ceramics, glass coloring, optic fibers, medical applications, laser.
Thorium Nitrate: Gas handling Industry
Thorium Oxide: Fluorescence tubes & starters; Catalyst for Petroleum industry
Uranium Oxide: Nuclear Industry
Tri sodium phosphate: Descaling, Degreasing, Detergents.

AN METALLURGICAL VIEW AT IREL,OSCOM

AN METALLURGICAL VIEW AT IREL,OSCOM

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