Post on 14-Jul-2020
Theme: 4M – Mining, Minerals, Metals and Materials
K Muraleedharan
Theme Director, 4M CSIR-Central Glass and Ceramics Research Institute
Kolkata 700032
First Interaction Meeting led by Theme Directorate 4 M on 13th March, 2018
India
China
World
Rest (other than Asia Pacific)
Asia Pacific
Domestic Material Consumption / Capita
Courtesy: UNEP China’s performance has been very impressive
Domestic Material Consumption: Asia Pacific
Courtesy: UNEP
In India, there has been increase Far less as compared to China
The Materials Development Cycle
DISCOVERY DEVELOPMENT
ENGINEERING MANUFACTURING
SUSTAINING We have excelled in discovery and development in the past.
However, engineering and manufacturing aspects and efforts to develop sustainable materials solutions with faster induction and reduced life-cycle cost as well as green and environment friendly solutions is the challenge today
The Challenge: Capability to develop, manufacture, and deploy advanced materials
• at least two times faster than is possible today • at a fraction of current cost
Sub Themes
• Raw Materials
• Minerals & Beneficiation
• Extraction & Refining Technologies
• Materials Processing & Equipment
• Advanced Materials
• Advanced Manufacturing
• Modeling & Simulation
• Surface Engineering
• Waste to Wealth
Area: Mining With 87 minerals (10 metallic, 47 non-metllic, 3 atomic, 4 fuel and 23
minor minerals) and nearly 2700 reported mines in India, this sector in India has a huge potential.
Some of the challenges for Indian Mining industry are: • Rising input costs • Land & its allocation • Logistics • Degrading quality of ores • Lack of proper database & of qualified manpower and • Unknown number of illegal & small mines.
The need of the hour in this sector are • A comprehensive roadmap • New geography • Life extension of exiting machinery, control of corrosion • New equipment & technology for exploration (e.g., robotics &
simulation) • Proper utilization of available resources
Area: Minerals
Mineral resources are key material basis for socio-economic development. Mineral resources are also of extreme strategic importance for the country Unlike China, India has not taken a lead in developing a comprehesive roadmap for exploitation of mineral resources The first task is to create a national roadmap where CSIR can take a lead.
Area: Metals
The Indian metal business is focused on • Steel • Aluminium • Copper • Zinc • Lead • Rare earths and • Titanium
For all metals, per capita consumption in the Indian context is substantially lower than the global average. Same is the case for R&D expenditure
Opportunities are huge due to rising demands
Lack of strategic positioning is the main challenge along with dumping by China
Iron & Steel : Current Status
India is the world’s largest producer of sponge iron with a host of coal based units, located in the mineral-rich states of the country. Indian sponge iron production contributes more than one-third of the global production.
India is world’s third larges steel producer. (~ 125 Mtpa as per data of 2017).
India is expected to reach 2nd position globally very soon (140Mtpa)
India’s per capita consumption of Steel is 57 kg/a while it is 460 kg/a in China, 507kg/a in Japan and 1157 kg/a in Korea. • The world average is 215 kg/a. Indian market is expected to
grow to 200 kg/a by 2030.
TV 2035 has defined goals for the materials for the year 2035. Metals Glass and Ceramics
Education Medical Sciences&Healthcare Food and Agriculture Water Energy Environment Habitat Transportation Infrastructure Manufacturing
Materials Information and
Communication Technology
Need of materials technologies for the strategic sector • SA to RM has compiled the requirements of materials
technologies and a approval has been sought from Government for special funds (Rs 10,000Cr)
• Similarly, an effort is ongoing for the establishment of manufacturing technologies for Defence
• ISRO have also identified the requirements and a letter from Chairman ISRO is received by DG, CSIR
• Talks are on with various units of DAE for identification of materials needs.
• Some agencies such as NTPC, BEL, BHEL etc. are also approaching CSIR for technology developments
FTT Projects Institute/Laboratory Project
CSIR-AMPRI Aluminium Composite Foams (ACFs) for Crashworthiness Applications
Fibre and particulate reinforced hybrid polymeric composite as architectural interior for building
construction material
CSIR-CGCRI
Paper-based Ceramic Separator for Li-ion Battery Application
Packaged Fiber Laser Modules for Industrial and Medical Applications
Development of Reaction Bonded Silicon Nitride Ceramic Radome
Superior Refractory for Induction Furnace to enable Refining of Steel
SiAION Insert for High Speed cutting of hard materials
Fast Recovery Trace moisture sensor and Meter for detection of trace moisture present in
transformer oil
Development of novel Ion doped Hydrxyapatite (HAp) by spray drying method and its utilization for
plasma spray coating on medical implants with/without ion doping
CSIR-IMMT
Electrophoretic Deposition (EPD) for Industrial Application
Maximize the recovery of iron values from lean grade iron ore by reduction roasting and pelletisation
of high LOI and high Blaine number iron ore fines
Process Development for production of flaky graphite, high purity graphite and graphite from natural
graphite
Recovery of Alumina from fly ash
CSIR-NML
Technology for extraction of tungsten (yellow tungsten oxide or ammonium paratungstate or
metallic W-powder) from a variety of scraps
Development of Hydrogen standard in Steel
Low Phosphorus steel through furnace route using DRI as major ferruginous raw material-an
industrial assessment
16 FTT Projects
Leads from XII Plan projects
• Needs compilation and brain storming
• Propose a group of scientists to do this
• The group may also identify New FTT projects; FTC projects from the various leads
Director of one lab/Institute – Chairman
3-4 members
Technology Compendium
• Present compilation lacks information
• Propose a group of scientists to do this afresh
• All lab Dir/s or reps to forward information to Dr Mohanty by 31 March 2018.
• The group will compile the Technology Compendum for the 4M cluster
Theme Director – Chairman
3-4 members
Sample projects • Increasing per capita consumption of all materials
• Use of Iron and steel in making • Farming equipments
• Engineering and plant machinery
• Heavy engineering
• Convert non-cocking coal to coking coal
• Recovery of Metal Values from lean and fine ores
• Technologies for use of magnetite ore in various iron making processes
• Processing of Ores, Minerals, and Mining and Industrial Waste (Plasma, pyro- and hydro- techniques)
• Indegeous refractories for metal, cement and other industries
• Reduction of impurities in ores (e.g. P in iron and silica in bauxite)
• Metal extraction technologies
Sample projects
• Metal and ceramic powder making technology for Additive manufacturing
• Waste to wealth, substitutes for wood, building materials, radiation shielding materials
• Surface Engineering; Thermal Barrier Coatings
• Bio-materials: Materials development and Product engg.
• Corrosion/erosion studies and life extension of pipe lines, mining equipments
• Modelling and simulation in mineral and metallurgical processes, materials technologies
• Increased use of steel and glass in infrastructural applications: buildings, bridges, roads
• Metal-cermet braking pads to replace current braking systems
• Advanced glass, ceramics and composites
High Purity Precursors and Raw Materials for Ceramics
99.9% purity quartz, alumina, boron nitride, silicon nitride, silicon carbide, stabilized zirconia, zirconium diboride, hafnium diboride, titania, titanium carbide, lanthanum hexaboride
Spherodized powders for net shape manufacturing
Ultra High Temperature Ceramics & Composites
Components : nose cone, leading edge of wings & tales, , parts of scramjet engine etc., combustor, shrouds, nozzles and blades
Material : UHTC (ZrB2/HfB2/TiC/SiC), C/SiC or SiC/SiC CMCs
Netshape & Additive Manufacturing / Refurbishment
Components : RBSN radomes, Ceramic Armour, Precision Optics etc.
Technology : Fused Deposition Moulding, Injection Moulding, Stereolithography, Maskless photolithography, LENS, Laser assisted refurbishment, Replicative & Incremental forming etc
Hard Ceramic Wear Parts & Cermet Break Dics
Component : Cutting tool inserts, liners, bearings, dies, break discs etc.
Material : M-AlON (e.g., SiAlON), Cermets
Ceramic Machining & Joining Technologies
Ultrasonic assisted machining, laser assisted machining, magnetorheological polishing, ductile mode machining, active brazing, high temperature adhesive bonding etc.
Advanced Ceramics & Composites : Themes
Specialty Refractory Materials
Refractory solutions for steel, cement, nonferrous and power generation sectors
Functional Materials
Smart Sensors for Manufacturing : High Curie temperature piezoceramics
Nanostructured ceramics for electronic & sensing devices
Advanced Ceramics for Energy & Environment
Energy Materials : Low temperature SOFC materials & sealing materials
Efficient & high performance ceramic membranes
NDT & SHM Technologies
• Robust techniques for NDT/SHM of ceramics and ceramic composite components
Advanced Ceramics & Composites : Themes
Activity title Participating
Labs
Additive manufacturing/ 3D printing of tailored
custom metallic and bioactive ceramic/ glass
implants for tissue engineering.
CSIR-CGCRI,
CSIR-IICB
Osteocondctive and biodegradable composites
(ceramic/polymer) for fracture and bone tissue
healing.
CSIR-CGCRI,
CSIR-IICB
Synthesis of biomaterials from biogenic sources
for bone replacement and wound healing.
CSIR-CGCRI,
CSIR-IICB
Biomimetic nanocomposite scaffolds. CSIR-NML
Biomaterials Activities under 4M Theme
Activity title Participating Labs
Materials and manufacturing technologies for hip, knee
and dental implants (including immune response of
debris).
CSIR-CGCRI, CSIR-
IICB, CSIR-NAL
The prospective treatment of type 2 diabetes by shRNA-
layered double hydroxide nanoceramic conjugate
CSIR-CGCRI
Biodegradable high-strength alloys of Mg and Fe. CSIR-NML, CSIR-
CGCRI, CSIR-NIIST
Hydrogels and their composites for tissue engineering. CSIR-IICB, CSIR-
CGCRI
Functionalized nanoparticles for diagnostics and imaging. CSIR-NML, CSIR-
CGCRI
Non-invasive cancer treatment using magnetic and
ultrasound fields.
CSIR-CGCRI, CSIR-
IICB
Biomaterials Activities under 4M Theme
Thank you