A REPORT ON INDUSTRIAL TRAINING

AT

Indian Rare Earths Ltd.

Submitted by,
Amal Jose

Krishnachandran U

Dan Lopez

Nandu Mohan

Ganesh

Varghis K Thomas

Joseph James Abraham

Vishak V

Department of Mechanical Engineering

TRAINING PERIOD: 09-09-2014 to 12-09-2014

ACKNOWLEDGEMENT

We have great pleasure to express our gratitude to all controlling officers of various
departments for providing us the opportunity to carry out the industrial training successfully.
We are extremely grateful to Mr. A. J. JANARDHANAN, Head, IREL, Chavara, Kollam,
for providing as with best facilities and atmosphere for the creative work, guidance and
encouragement.
We particularly wish to thank Mr. K. R. SREELAL, Senior Manager (Maintenance), IREL,
Chavara, Kollam, our guide for his valuable suggestions, advice and help at various stages of
the training. We owe a sense of gratitude for his co-operation without which the training
would have been very difficult.
We also thank the controlling officers of various departments within the factory for
their guidance, supervision, assistance and helpful suggestions given throughout the course
of this training without which this work would not have been successfully completed.
We thank all the faculties of the Department of Mechanical Engineering, Mar Baselios
College of Engineering and Technology, Thiruvananthapuram for their inspiring guidance and
support.
Above all, we thank God Almighty without whose blessings this effort would not have
been a reality.

CONTENTS
Introduction ............................................................................................................................... 1
Industry Profile........................................................................................................................... 3
Company Profile......................................................................................................................... 6
IREL Chavara............................................................................................................................... 8
Properties & Chemical Composition of Minerals .................................................................... 10
Uses of the Minerals ................................................................................................................ 11
Heavies Upgradation Plant (HUP) ............................................................................................ 12
Spiral ........................................................................................................................................ 13
Hydrocyclone Sand Separator.................................................................................................. 16
High Tension Roll Separator (HTRS) ......................................................................................... 17
Induced Roll Magnetic Separator (IRMS)................................................................................. 18
Electrostatic Plate Separator (ESPS) ........................................................................................ 20
Cross Belt magnetic Separators (CBMS) .................................................................................. 21
Wet High Intensity Magnetic Separator (WHIMS)................................................................... 22
Fluidised Bed Dryer (FBD) ........................................................................................................ 23
Wet Table ................................................................................................................................. 24
Floater ...................................................................................................................................... 25
Conclusion ................................................................................................................................ 26

Industrial Training IREL, Chavara

INTRODUCTION

The initial discovery of the rare mineral deposit in India was on the western coast. In
the year 1909, the presence of the mineral monazite was observed in coir, a coconut fibre,
shipped to Germany from India. He traced back to the place from where the coir was exported
and this lead to the discovery of the placer deposits of these minerals on the western coast
of India, in the erstwhile princely state of Travancore. As thorium nitrate, a chemical produced
from the mineral monazite was in good demand at that time for the production of mantles
for gas lights, efforts started immediately for recovery of monazite from this deposit. Even
though with the advent of electricity, the demand for gas lights and ion turn that for thorium
nitrate diminished, interest in these deposits continued since by that time technology
developed for the production of titanium dioxide from the mineral Ilmenite. During the period
1930 to 1955 a number of foreign and Indian owned companies operated in the then princely
state of Travancore for the production of the mineral Ilmenite from these deposits. However,
during the period 1955-1960 all these companies were closed down due to market and
management problems.
The Atomic Energy Commission was set up by the Government of India in the year
1948. Indian Rare Earths Limited (IREL) was incorporated in 1951 as a fully owned central
Government undertaking under the Department of Atomic Energy. IREL initially was
entrusted with acquiring the technology for the production of rare earths compounds from
the mineral monazite. As the beach sand mineral operation came to stoppage from the 1960s,
IREL at the instance of the central government decided to take over the beach sand mineral
beneficiation also. Accordingly IREL took over the assets of the closed mineral operation
companies at Chavara and Manavalakurichy. Manavalakurichy plant came into operation in
1968 and the Chavara plant in 1970. After a gap of 20 years, IREL commissioned its largest
Division called Orissa Sand Complex (OSCOM) at Chatrapur, Orissa. Today IREL operates these
four units and produces/sells six heavy minerals namely Ilmenite, rutile, zircon, monazite,
sillimanite and garnet as well as various value added products.

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Under the Indian Companies Act, 1913, Indian Rare Earths Limited was incorporated
in 1950 as a private company as a joint venture with the then Government of Travancore,
Cochin. In 1963, IREL became a full-fledged Govt. undertaking under DAE. In 1952, production
commenced at RED, which was dedicated to the nation by Sri Jawaharlal Nehru. OSCOM was
set up during 1972, construction had been started in 1975 and mining had been started in
1984.
Main objective of IREL is to emerge as a leading 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 Orissa, Tamil Nadu & Kerala, Rare Earths division
at Alwaye, Kerala and Research centre at Kollam, Kerala. Its registered and corporate offices
are in Mumbai, Maharashtra.
Corporate Research Centre is located at Kollam, Kerala and carries out research in the
field of value added products from beach sand minerals, undertakes consultancy projects on
mineral separation and flow sheet development, carrying out mineral analysis and caters to
the needs of internal and external customers.

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INDUSTRY PROFILE

Rare earths elements are series of chemical elements of the periodic table. The rare
elements with atomic numbers 57 through 71. In the early years these elements were
considered as rare elements and so they are called as rare earth metals. Later many elements
in this group were found splendid but their name remained unchanged. The primary source
of rare earth elements is greenish yellow coloured mineral sand, which is Monazite. Its
availability in nature is confined to certain beaches and rock found in certain countries. The
beaches containing the Monazite are found mixed with other minerals too. Most of these are
ores for valuable metals. An ore is a mineral form which metal can be separated economically.
These ores are Ilmenite, Rutile and Zircon. Ilmenite and Rutile forms the ore for Titanium,
Zircon for Zirconium. Even though Aluminium bearing metal Garnet and Sillimanite are also
found along with these beach sand minerals. But they are not commercially exploited for
Aluminium production due to economic reasons. However Garnet and Sillimanite in their
natural form are commercially significant. Ilmenite which is black in colour constitutes a major
chuck of these minerals (60%) presence of these minerals makes the beaches appear black.
These minerals are commercially known as beach sand minerals or heavy minerals.
The origin of beach sand is from rocks, which are rich with heavy minerals. This sand
particle reaches sea through rivers. The sea level is not remaining constant. It is regarded that
the sea level. It is now really 100 meters above what we had seen 20,000 years ago. This white
sand seen at the beach area contains the main constitute as Quartz. This is lighter than black
sand. As a result of movement of the sea this sand will erode away and black sand get
deposited. The black sand thus deposited 100 years ago is mined and processed.
In the year 1789 Fr. William George (1761- 1817) discovered Ilmenite in England and
stated that this black sand contains some important metal. But he failed to discover which
metal it was. After several time, in the year 1875 the Hungarian scientist Martin Heen Witch
Klapporth found the same metal contains in the Rutile minerals about which Fr. William
George mentioned. After a series of investigations are found those metals content as
Titanium after Titan of Greek mythology.

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Technology developed over the year has made the beach sand minerals to be utilized
in a variety of industrial and domestic applications. Monazite was mainly used in the gas
mantle industry. After the advent of electricity its demand decreased in the gas mantle
industry. Ilmenite and Rutile are used in high temperature refractory industry, ceramics
industry etc. Zircon is used in foundries, ceramics, refractories and in the manufacturing of
Zirconium chemicals, metals and alloys. Zirflour is used in foundries for high temperature
castings. Garnet is used in the manufacturing of abrasive polishing glass, TV tubes, for sand
blasting and for water filtration. The beach sand mining and processing industry has vast
future because of their demand in nuclear industry too. In the present scenario of booming
economics like India and china there is a huge demand for the beach sand minerals, Ilmenite
in particular.
The current world production capacity of Ilmenite and other Titanium feed stocks for
production of Titanium Dioxide Pigment, Titanium metal, Welding electrodes etc. is used
around 70 lakhs million tonnes per annum (TPA). Approximately half of this from beach sands
and the balance from Ilmenite rocks mostly found in Canada and Norway. In view of the
limited supply of natural Rutile its share of consumption in pigment production is rather small
and 55% of its total availability of about 5 lakhs TPA is used in the non-pigment applications
predominantly in the production of welding rods and Titanium metal. The present production
capacity of pigment in the world is just above 4 lakhs TPA. North America is the largest
producer with 37% of the global capacity. Europe with 32% capacity is the second largest
producer and Asia-Pacific region with 21% capacity is the third. The balance 10% distributed
among the rest of the world.
India has the largest resources base of 278 million tonnes for Ilmenite. This is the single
largest and Ilmenite and least exploited mineral deposit in the world. However 10% of this is
only minerable resources base in India for other minerals are:-

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Minerals

In Million Tones

Contribution to the world in %

Rutile

18

10

Zircon

21

14

Monazite

Sillimanite

130

25

Ilmenite

107

35

In India the installed production capacity for Ilmenite is around 5-2 lakh TPA (5-6% of global
Ilmenite production) and the production of Ilmenite and Rutile during 2004-05 was over 3-5
lakh tones and 1300 tonnes respectively.

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COMPANY PROFILE

On August 18, 1950 Indian Rare Earths Limited (IREL) was incorporated as a private
limited company jointly owned by the govt. of India and Govt. 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) Alwaye and Kerala for the recovery of thorium.
After becoming a full-fledged central govt. 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 other at
Manavalakurichy(MK), Tamil Nadu.
After a gap of 20 years IREL commissioned its largest division called Orissa Sand
Complex (OSCOM) at Chatrapur, Orissa. Today IREL operates these four units with corporate
office in Mumbai and produces/ sells six heavy minerals namely Ilmenite, Rutile, Zircon,
Monazite, Sillimanite and Garnet as well as various value added products IREL is making profit
for the last 6 years with its sales turnover reaching a peak exceeding Rs: 2600 million in 200001, with export component of above Rs: 1000 million.
Milestones of Indian Rare Earths Ltd.:
1950: IREL is incorporated as a private company jointly owned by the GOI & Govt. of
Travancore, Cochin.
1952: Production commences at RED, Alwaye. Late Prime Minister Shri Jawaharlal Nehru
dedicates RED to the Nation.
1953-55: Thorium Plant, Trombay owned by DAE is commissioned by IREL.
1963: IREL becomes a full-fledged Govt. undertaking under DAE.
1965: MK and Chavara Plants are taken over from Travancore Minerals Ltd. Production at MK
and refurbishing of Chavara Plant commence.
1966: IREL completes Uranium Mill Project at Jaduguda, hands over to UCIL.
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1967: IREL takes over H&W (Travancore) plant at MK. Mineral Division is formed comprising
Chavara & MK.
1970: Refurbished Chavara Plant goes into production. Capacity of MK Plant is expanded.
1973: Pilot Plant is setup for separation of individual Rare Earths.
1977: Commencement of OSCOM Project.
1979: Preconcentrator Plant is commissioned at MK.
1985: Modernization and Helium & Uranium Recovery Project (MOHUR) commences at RED.
1986: New DWC Plant commences at MK. HERO Project at Alwaye is commissioned.
Production is started at OSCOM.
1987: MOHUR is commissioned. New DWC Project commences at Chavara. New Thorium
Plant commences at OSCOM.
1988: Commencement of CUP at OSCOM and MK.
1990: MRDC is launched at Quilon. HERO Plant is commissioned at Alwaye. DWCP at Chavara,
CUP at OSCOM and MK are commissioned.
1990-91: IREL signs MOU with Government of India. Diversify Plant Project (DPP) starts trial
production for augmenting Cerium Hydrate, Didymium Carbonate at Alwaye.
1993-94: Co-generation Plant is commissioned at RED. NTP starts commercial production.
1994-95: Ilmenite quality is enhanced in Chavara and OSCOM. MRDC, Quilon is fully functional.
1995 96: RED gets ISO 9002 certificate.
1996-97: Microzir Plant is commissioned in Chavara.
1997-98: OSCOM gets ISO 9002 certificate. PRYNCE 95% Nd2O3 is commissioned at RED.
Thorium Plant at Trombay is closed.
1999-2000: MK and Chavara get ISO 9002 certificate. Corporate Plan is approved. IREL starts
paying the Government loan. Additional Recovery of Rutile and Zircon project is implemented
at MK. Joint venture proposals with SAL, AUSTPAC Resources are processed.

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IREL CHAVARA

Chavara plant is engaged in the processing of beach deposits available on the coastal
belt of Neendakara- Kayamkulam. 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 domestic markets.
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 OHSAS 18001:1997.
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 kilometre 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
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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 deposit untouched.
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.

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PROPERTIES & CHEMICAL COMPOSITION OF MINERALS

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USES OF THE MINERALS

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HEAVIES UPGRADATION PLANT (HUP)

In this stage the concentration of heavy is further upgraded to about 98%. The feed to
HUP is the Re-cleaner concentrate of the DWUP with a heavy mineral concentrate of 90-92%.
The heavy minerals are received from dredge and wet up gradation plant (DWUP) at the repulping area of mineral separation plant (MSP). This material is pumped to HUP from MSP. If
HUP is not operational the material is stocked at RPA. These accumulated heavies are pushed
for pumping to HUP with the earth moving equipments (EMEs). In HUP, the feed is treated in
gravity separation equipment like spirals and Hydrocyclones using slurry pumps. The lighter
unwanted material is pumped to be rejected into the dumping yard. The 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.

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SPIRAL

Spirals are gravity separators where slurry is fed to at a pulp density of about 20-25%,
the size range is commonly 3 mm to 75 microns and as the slurry flows down curved channel,
lighter particles due to action of centrifugal force will report to the outer area of the spirals
as tails 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 1-3 tph of feed effectively.
As larger and heavier particles sink to the bottom of the sluice faster and experience
more drag from the bottom, they travel slower, and so move towards the centre of the spiral.
Conversely, light particles stay towards the outside of the spiral, with the water, and quickly
reach the bottom. At the bottom, a "cut" is made with a set of adjustable bars, channels, or
slots, separating the low and high density parts.
The operating parameters are feed rate, pulp density, feed grade, splitter openings,
positon of distributors, diameter of spiral etc.
Many things can be done to improve the separation efficiency, including:

Changing the rate of material feed

Changing the grain size of the material

Changing the slurry mass percentage

Adjusting the cutter bar positions

Running the output of one spiral separator (often, a third, intermediate, cut) through
a second.

Adding wash-water inlets along the length of the spiral, to aid in separating light
minerals

Adding multiple outlets along the length, to improve the ability of the spiral to remove
heavy contaminants

Adding ridges on the sluice at an angle to the direction of flow.

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Typical spiral concentrators will use a slurry from about 20%-40% solids by weight,
with a particle size somewhere between 1.5-.075 mm (17-340 mesh), though somewhat
larger particle sizes are sometimes used. For good separation, the density difference between
the heavy minerals and the light minerals in the feedstock should be at least 1 g/cm3; and
because the separation is dependent upon size and density, spiral separators are most
effective at purifying ore if its particles are of uniform size and shape. A spiral separator may
process a couple tons per hour of ore, per flight, and multiple flights may be stacked in the
same space as one, to improve capacity

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HYDROCYCLONE SAND SEPARATOR

A Hydrocyclone separates sand and other solid matter from water with very little head
loss and 90% or better efficiency. There is no head loss build up and no clogging when the
solids are separated. Hydrocyclones are easy to operate and maintain, and have no moving
parts or screens. Versatility in system configurations and ease of installation are some of its
great advantages. A Hydrocyclone uses a tangential injection flow process, enhancing the
centrifugal forces and moving solid particles outwards. The dispersed particles move
downward in a spiral path into an underflow chamber (sedimentation tank) while clean liquid
moves upwards to the centre of the spiral, towards the top outlet. A specially designed rubber
insert protects the neck of the Hydrocyclone from erosion and increases separation efficiency.
The Sedimentation Tank can be drained automatically with an automatic flushing kit (an
electric valve, controller and small command filter). Automatic flushing will not interfere with
the proper functioning of the Hydrocyclone. The Hydrocyclone has a 100 micron protective
coating of extra durable polyester applied electrostatically and oven cured on a zincphosphate layer for maximal anti-corrosion protection.

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HIGH TENSION ROLL SEPARATOR (HTRS)

The heavy mineral concentrate when subjected to this process is separated into two
fractions - conducting and non-conducting, which are further processed to obtain the
individual mineral product. In high-tension roll separator (HTRS), when high D.C. voltage is
applied, the air surrounding the electrode gets ionized and mineral particles are charged- The
conducting minerals after acquiring the charge immediately dissipate the charge to the
grounded revolving roll and follow the trajectory due to the centrifugal force. The nonconducting minerals, slow in discharging the charge, is pinned to the roll and are wiped out
by the help of A.C. electrode and a mechanical wiper brush. In mineral sand industries, hightension roll separator and electrostatic plate separators are widely used to separate the
conducting and non-conducting fraction. Particle size influences separation behaviour in an
HTR separator as the surface charge on a coarse grain is lower in relation to its mass than on
a fine grain. Thus, a coarse grain is more readily thrown from the roll surface, and the
conducting fraction often contain coarse non-conductors. In the same way the nonconducting fraction often contains fine conducting particles because they are most influenced
by surface charge. A plate/ screen plate separator, where the "lifting effect" by a static
electrode is utilized for separation can help in such cases to remove small amount of nonconductors from a predominantly conducting feed (plate separator) and small amount of
conductors from a predominantly non-conducting feed (screen plate separator). In an
electrostatic separator fine grains are most affected by the lifting force and so fine conductors
are preferentially lifted to the electrode whereas in a high tension separator effective
separation of fine non-conductors from coarse conductors takes place. Thus, a combination
of these separators are used.

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INDUCED ROLL MAGNETIC SEPARATOR (IRMS)

Induced Roll Magnetic Separator: Magnetic field is produced when an electric current
(DC) 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)- variable

The roll, on to which the ore is fed, is composed of phosphate steel laminates compressed
together on a non-magnetic stainless-steel shaft. By using two sizes of lamination, differing
slightly in outer diameter, the roll is given a serrated profile which promotes the high field
intensity and gradient required. The magnetic field generated is around 12-16 Kilogauss. Nonmagnetic particles are thrown off the roll into the tailings compartment, whereas magnetic
are gripped, carried out of the influence of the field and deposited into the magnetic
compartment. The gap between the feed pole and rotor is adjustable and is usually decreased
from pole to pole to take off successively more weakly magnetic products. The setting of the
splitter plates cutting into the trajectory of the discharged material is obviously of great
importance. The capacity of this type separator is 3-4TPH. Mainly used in the separation of
Ilmenite from Rutile.
The operation parameters are magnetic field current, Air gap, Feed rate, roll speed, splitter
position etc. Generally feed rate is maintained at 4-5 TPH per roll and the roll speed is around
150RPM.

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ELECTROSTATIC PLATE SEPARATOR (ESPS)

Final cleaning of the HTRS 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.
It is a vertical type of equipment with a dome shaped electrode and grounded plates. On
applying DC voltage of about 20-25 KV and passing feed through the plate conducting
minerals are lifted towards the dome electrode while the non-conducting gravitates
downwards and thus the separation takes place. An ESPS is mainly used to separate fine
conducting particles from coarse non-conducting particles. The operating parameters are
same as the HTRS.

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CROSS BELT MAGNETIC SEPARATORS (CBMS)

It is a high intensity magnetic separator in which feed is allowed to pass through a min
belt and a number of cross belts. Due to the influence of electromagnet placed over the cross
belt magnetic particles get attracted to the bottom part of 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 19-20 Kilogauss and the capacity is 1.5-2.0 tph.

The operating parameters are magnetic field current, Air gap, Belt speed, feed rate etc.

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WET HIGH INTENSITY MAGNETIC SEPARATOR (WHIMS)

Feed material is introduced into the distributor above the machine at a predetermined
pulp density. This feed material is equally distributed to each of the stainless steel boil boxes
positioned above the rotor and then passed into the rotor assembly at the ascending point of
magnetic intensity. The magnetic particles contained in the feed are attracted to the
serrations on the salient pole plates while the non-magnetic particles fall freely through into
the catch box below. A regulated volume of water is provided to ensure the continuity of flow
of the non-magnetics and free any particles, which may be trapped by the collection of the
magnetics at the points of the serrated salient plates.
The magnetic fractions are transported to the midpoint of the 'null' zone located
between two poles of identical polarity. Here they are scoured free from the salient poles by
a pressurised volume of water and collected in their respective catch boxes located beneath
the rotor. Three catch-box segments, with adjustable splitters, are provided for each
separating zone to allow for maximum flexibility of operation and permit the selection of a
middling fraction if required. The product from each catch-box is taken through rubber hoses
to a collection box assembly secured beneath the machine.
In India WHIMS is used for mineral separation for the first time in Chavara plant. Being
equipment with high end automation there was apprehension and inertial perplexity initially
in operating and maintaining it, which naturally happens with any new technology. Hence we
adopted a comprehensive approach in our inhouse training for imparting how to use this new
technology by carefully taking into consideration behavioural, social, and contextual factors
and this bore fruit.

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FLUIDISED BED DRYER (FBD)

A fluidized bed consists of fluid-solid mixture that exhibits fluid-like properties. As such,
the upper surface of the bed is relatively horizontal, which is analogous to hydrostatic
behaviour. The bed can be considered to be a heterogeneous mixture of fluid and solid that
can be represented by a single bulk density.
Furthermore, an object with a higher density than the bed will sink, whereas an object
with a lower density than the bed will float, thus the bed can be considered to exhibit the
fluid behaviour expected of Archimedes' principle. As the "density", (actually the solid volume
fraction of the suspension), of the bed can be altered by changing the fluid fraction, objects
with different densities comparative to the bed can, by altering either the fluid or solid
fraction, be caused to sink or float.
In fluidized beds, the contact of the solid particles with the fluidization medium (a gas
or a liquid) is greatly enhanced when compared to packed beds. This behaviour in fluidized
combustion beds enables good thermal transport inside the system and good heat transfer
between the bed and its container. Similarly to the good heat transfer, which enables thermal
uniformity analogous to that of a well-mixed gas, the bed can have a significant heat-capacity
whilst maintaining a homogeneous temperature field.
Fluidized bed technology in dryers increases efficiency by allowing for the entire surface of
the subject of the drying to be suspended and therefore exposed to the air. This process can
also be combined with heating or cooling, as the application, if necessary.

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WET TABLE

A table consists of an inclined deck fitted with riffles. When the table is given a
reciprocating motion at right angle to the flow of the water, the heavier minerals settle down
in the riffles and carried along the diagonal line of the table as concentrate. The lighter
minerals do not settle in the riffles and are washed along with the water as tailings the pulp
density we generally maintain is 25-30% of solid.

The operating parameters are quantity of wash water, deck slope, feed rate, stoke length,
speed, pulp density etc.

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FLOATER

Flotation is a process where the desired mineral particles in pulp are selectively floated
by their attachment to rising bubbles. In MSP, a slurry containing sillimanite and quartz is
conditioned in the first stage with sodium silicate and soda ash. Soda ash is used to maintain
an alkaline pH of 8-9 while sodium silicate depresses quartz. In the second stage, slurry is
conditioned with oleic acid to collect Sillimanite as froth. The conditioned slurry is introduced
into a column floatation cell where air is introduced through spargers at the bottom. The
hydroscopic particles of Sillimanite attaches to the air bubbles in the collection zone and rise
up to the froth zone. Wash water system is attached to clean the froth for removal of
unwanted minerals from the froth. Quartz goes down as sink. The column cell is attached with
many auto controlled system. The cell is having auto controlled tails discharge valve to
discharge the quartz periodically.

Operating parameters are slurry pH, air pressure, froth depth, reagent dosage, air flow, feed
rate, Quantity of wash water, conditioning time, feed rate etc.

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Department of Mechanical Engineering

Industrial Training IREL, Chavara

CONCLUSION

Indian Rare Earths Ltd. is one among the public sector, which has an outstanding
performance in the processing of beach sand minerals available along the coastal belt. The
organization study in this unit is an unforgettable experience. The work culture is gratifying
and also the concern for safety, environment issues and the social responsibility prevailed in
this organization is worth studying.
This study helped me in having a pragmatic exposure to mining as well as processing
activities of the sand mining organizations. With the advent of technology and monotonically
increasing metal prices across the world, it is expected that study of placer and seabed mining
would be the need of the future as these resources are largely remained untapped.
It is desirable that the government should take adequate steps for proper exploitation
and utilization of these resources. With the amount of talent bank available in India, new
advances can be made in the mining as well as processing technology of placer minerals it can
be assured that the costs of these minerals would come down.

26
Department of Mechanical Engineering