TECHNOLOGY AND INDIAN MARKET SCENARIO -

MINING CHEMICAL

BHARAT CHEMTECH, CHENNAI

EXECUTIVE SUMMARY ........................................................................................6

SECTION I INDIAN MINING INDUSTRY STATUS ..................................................101.1. Dominant minerals in India and its rank in world mining industry.............................................10

1.2. Indian production of selected minerals ......................................................................................11

1.3. Indian production of minerals of all type....................................................................................11

1.4. Pattern of production of Indian mineral.....................................................................................12

1.5. Indian production, import and export ........................................................................................13

1.6. Number of Reporting mines in India...........................................................................................13

1.7. Number of minerals produced in India.......................................................................................14

1.8. Statewise production pattern of minerals ..................................................................................14

1.9. Major mining units in India .........................................................................................................14

SECTION II OVERVIEW ON MINING PROCESS ....................................................152.1. Metals and its ore .......................................................................................................................15

2.2. Type of ores and the metal extracted from the ores.................................................................15

2.3. Flow diagram for ores and the group metals..............................................................................16

2.4. Need for mining chemicals .........................................................................................................17

2.5. Main functions of mineral processing ........................................................................................17

2.6. Sequences of mining process - Outline.......................................................................................17

2.7. Detailed description of concentration process in mining...........................................................18

2.7.1. Hydraulic washing process (Gravity separation).......................................................................18

2.7.2.. Magnetic separation process...................................................................................................18

2.7.3. Chemical separation .................................................................................................................18

2.7.4. Froth floatation process............................................................................................................19

SECTION III INDUSTRY STATUS ON MAJOR MINES IN INDIA ..............................22

I COPPER...........................................................................................................221.1. Processing of copper ore ............................................................................................................22

1.2. Status of Indian copper mining industry.....................................................................................23

1.2.1. Import dependent on copper ore .......................................................................................23

1.2.2. Indian major players ...........................................................................................................23

1.2.3. Indian production................................................................................................................23

1.2.4. Indian demand copper metal..............................................................................................24

1.2.5. Profile of major players.......................................................................................................25

II ALUMINIUM ..................................................................................................282.1. Processing of aluminium ore ......................................................................................................28

2.2. Status of Indian aluminium mining industry...............................................................................31

III RON ..............................................................................................................382.1. Processing of iron ore .................................................................................................................38

2.2. Status of Indian iron mining industry..........................................................................................40

IV LEAD AND ZINC.............................................................................................47

V COAL..............................................................................................................50Need for washing non-coking coal..........................................................................................................50

Advantages of washing non-coking coal.................................................................................................50

Major players in coal mining...................................................................................................................51

Current status of coal washeries ............................................................................................................52

VI MICA ............................................................................................................53

SECTION IV INDIAN SUPPLY DEMAND SCENARIO ON MINING CHEMICAL.........54

I. FLOCCULANT / COAGULANT...........................................................................551.1. General details ............................................................................................................................55

1.2. Role of flocculant in Mineral processing.....................................................................................55

1.3. Selective flocculation .................................................................................................................56

1.4. Difference between coagulant and flocculant............................................................................56

1.5. Classification of flocculant ..........................................................................................................58

1.6. Advantages of polymeric floccs over inorganic flocs ..................................................................60

1.7. Usage of flocculants in metallic minerals ...................................................................................61

1.8. Coagulant Aids ............................................................................................................................64

1.9. Polyacrylamide............................................................................................................................68

1.10. Polyaluminium chloride ..........................................................................................................76

1.11. Other flocculants including specialty flocculant .....................................................................77

1.12. All India market for flocculants in water treatment sector ....................................................78

1.13. All India market for flocculants in mining sector ....................................................................78

II COLLECTORS ..................................................................................................792.1. General details ............................................................................................................................79

2.2. Major Collectors used in Indian mining industry ........................................................................84

2.3. Indian manufacturers..................................................................................................................85

2.4. Indian import / export level ........................................................................................................85

2.5. Indian demand for xanthates......................................................................................................86

2.6. All Indian demand for collectors.................................................................................................86

III FROTHERS.....................................................................................................873.1. General details ............................................................................................................................87

3.2. MIBK (Methyl isobutyl ketone) ...................................................................................................95

3.3. Glycol ethers ...............................................................................................................................97

3.4. Others including MIBC (Methyl isobutyl carbinol), 2-EH, diacetone alcohol..............................98

3.5. All Indian demand for frothers in mining industry .....................................................................99

IV OTHER MINING CHEMICALS........................................................................1004.1. Depressants...............................................................................................................................100

4.2. Activators ..................................................................................................................................101

4.3. Dispersant / Grinding Aid..........................................................................................................102

4.4. Others including Modifying agent ............................................................................................103

4.5. All India demand for other miscellaneous mining chemicals ...................................................104

V CONSOLIDATED ALL INDIA DEMAND FOR MINING CHEMICALS ....................105Productwise demand ............................................................................................................................105

Sectorwise demand pattern..................................................................................................................105

EXECUTIVE SUMMARYDominant minerals in India and its rank in world mining industry

Dominant minerals

Bauxite, Chromite,Copper, Iron,Lead manganeseLimestone zinc

India’s rank

1st Mica (alumino silicate);3rd Barite, chromite, coal & lignite;4th Iron ore;5th Bauxite6th Manganese.

Statewise production pattern of minerals

Need for mining chemicals

Minimizing water consumption

Maximizing recovery

Reducing land areas consumed by tailings disposal

Minimizing the costs and time required to rehabilitate such land.

Reduce the complexity of processing low quality ores

Aim to ease the accessibility from remote source

Type of chemical used in mineral processing

Flocculant / coagulant Collectors Frothers Depressants Activators Scale inhibitor Dispersant / Grinding aid Modifying agent (pH modifier, cationic modifier, ionic modifier, organic modifier) Agglomeration aid Rheology modifier Dust suppressor

Flocculants / coagulants

Conversion of stable state dispersion to the unstable state is termed destabilisation and the processes ofdestabilisation is termed as coagulation / flocculation.

Coagulation: If destabilisation is induced through charge neutralisation the process is called coagulation.

Flocculation: The process of forming larger agglomerates of particles through high molecular weightpolymeric materials is called flocculation.

Mostly used coagulants / flocculants compounds include

Polyacrylamide polyaluminium chloride.

All India market for flocculants in mining sector Rs. 108 crores

Collectors

Basis of froth flotation is the difference in wettabilities of minerals. Most minerals in nature arehydrophilic. They do not readily float in froth flotation.

Even some of the minerals which are hydrophobic in nature require supporting reagents to increase thehydrophobicity and some chemical reagents are added to float to the surface. The recovery is oftenimproved when a collector is used.

Chemicals that promote hydrophobicity of a mineral are called that mineral's “promoter” or “collector.”

Collectors get adsorbed on the mineral surfaces rendering the particles hydrophobic and “floatable”.

Major collectors used in Indian mining industry is sodium isopropyl xanthate.

All India market for collectors in water treatment sector Rs. 25 crores

Frothers

Frothers are liquids that produce the froth on which the flotation process depends. The froth resemblessoap suds and provides the physical separation between the mineral(s) floated and the pulp containingthe waste.

The froth must be strong enough to support the weight of the mineral floated and yet not be tenacious.It should have the tendency to break down when removed from the flotation cell. The frother shouldnot enhance the flotation of unwanted material.

When the mineral surface has been rendered hydrophobic by the use of a collector, stability of bubbleattachment especially at the pulp surface depends to a considerable extent on the efficiency of thefrother

Mostly used frothers in Indian mining industry are pine oil, MIBK and glycol based formulatorycompounds.

All India market for frothers in water treatment sector Rs. 60 crores

All India demand for other miscellaneous mining chemicals

Indian demand for other miscellaneous chemicals including scale inhibitor, dust depressant, pHmodifier, activators etc Rs. 157 crores

All India Productwise demand for mining chemicals

Mining chemicals Market value in Rs. Crores

Flocculant 108Collectors 25Frothers 60

Others including scale inhibitor, dust depressant,pH modifier, activators etc

157

Total 350

Sectorwise demand pattern for mining chemicals

SECTION IINDIAN MINING INDUSTRY STATUS1.1. Dominant minerals in India and its rank in world mining industry

Dominant minerals

Bauxite, Chromite,Copper, Iron,Lead manganeseLimestone zinc

India’s rank

1st Mica (alumino silicate);3rd Barite, chromite, coal & lignite;4th Iron ore;5th Bauxite6th Manganese.

1.2. Indian production of selected minerals

Coal ore 950 million tonnesBauxite ore 14 million tonnesIron ore 245 million tonnes (Fe content: 157 mil ton)Lead ore 92 million tonnes (Pb content)Copper ore 31 million tonnes (Cu content)Mica 5000 tonnes

1.3. Indian production of minerals of all type

1.4. Pattern of production of Indian mineral

s

Metallicminerals 18%

Non metallicminerals 12%

Fuel minerals70%

1.5. Indian production, import and export

1.6. Number of Reporting mines in India

1.7. Number of minerals produced in India

Type Number of mineralsFuel Minerals 4Metallic Minerals 11Non-metallic Minerals 52Minor minerals 22Total 89

1.8. Statewise production pattern of minerals

1.9. Major mining units in India

Bharat Aluminium Company Bharat Gold Mines Limited Bunder Project Coal India Ltd Dempo Gujarat Mineral Development

Corporation Limited Hindalco Industries Hindustan Copper Limited Hindustan Zinc Limited Hutti Gold Mines Limited Indian Rare Earths Limited Kudremukh Iron Ore Company Ltd. MOIL Limited

MSPL Limited National Aluminium Company National Mineral Development

Corporation Neyveli Lignite Corporation Obulapuram Mining Company Rajasthan State Mines and Minerals

Limited Sesa Goa Singareni Collieries Company Sterlite Industries Uranium Corporation of India Vedanta Resources

SECTION IIOVERVIEW ON MINING PROCESS2.1. Metals and its ore

Metal Ore Mineral Chemical FormulaAluminum Bauxite Al2O3·3H20Chromium Chromite FeCr2O4

Cobalt Skutterudite (Co,Ni,Fe)As3

CopperChalcopyriteChalcocite

Bornite

CuFeS2Cu2S

Cu5FeS4Iron Hematite Magnetite Fe2O3 Fe3O4Lead Galena Cerusite PbS PbCO3

Magnesium Dolomite Magnesite (Ca,Mg)CO3 MgCO3Manganese Pyrolusite MnO2

Mercury Cinnabar HgSNickel Pentlandite (Fe,Ni)9S8

Tin Cassiterite SnO2Titanium Ilmenite Rutile FeTiO3 TiO2Tungsten Scheelite Wolframite CaWO4 (Fe,Mn)WO4Uranium Uraninite UO2

Zinc Sphalerite ZnS2.2. Type of ores and the metal extracted from the ores

Type of ore Metals Compound (in the ore)

Oxide Ores

Aluminium Bauxite - Al2O

3, 2H

2O

Copper Cuprite - Cu2O

Iron Haematite - Fe2O

3Magnetite - Fe

3O

4

Sulphide Ores

Iron Iron Pyrite - FeS

CopperCopper Glance - Cu

2S,

Copper Pyrites - CuFeS2

Zinc Zinc Blende - ZnS

Carbonate OresCalcium Limestone - CaCO

3

Zinc Calamine - ZnCO3

Halide Ores

Sodium Rock Salt - NaClCalcium Fluorspar - CaF

2

Silver Horn Silver - AgClAluminium Cryolite - Na

3AlF

6

2.3. Flow diagram for ores and the group metals

2.4. Need for mining chemicals

Minimizing water consumption

Maximizing recovery

Reducing land areas consumed by tailings disposal

Minimizing the costs and time required to rehabilitate such land.

Reduce the complexity of processing low quality ores

Aim to ease the accessibility from remote source

2.5. Main functions of mineral processing

* Preparation of the valuable minerals from waste minerals .

* Separation of valuable minerals into two or more products

2.6. Sequences of mining process - Outline

Main process Sub process

Concentration of the ore (removal ofunwanted purify the ore).

1.Hydraulic washing.2. Gravity separation.3. Magnetic separation.4. Chemical separation.5. Froth floatation.

Conversion into metal oxide 1. Calcination for carbonate ore.2. Roasting for sulphide ore.

Reduction of metal oxide to metal

1. Roasting - mercury (Hg) is produced by roasting Cinnabar(HgS) in air.

2. Reduction - using highly reactive elements. Example:aluminium reduces manganese dioxide to manganese.

3. Electrolytic reduction - highly reactive elements, suchas sodium and mercury, are obtained by electrolyticreduction when the metal is deposited at cathode.

Refining of impure metal into pure metal

1. Electrolytic refining - of copper, gold, tin, lead, chromium,nickel, etc.2. Liquation process - for tin, lead and bismuth.3. Distillation process - for zinc, mercury.4. Oxidation process - for iron.

2.7. Detailed description of concentration process in mining

2.7.1. Hydraulic washing process (Gravity separation)

This process separates the heavier ore particles from the lighter gangue particles. This is done bywashing them in a stream (jet) of water over a vibrating, sloped table with grooves. Denser ore particlessettle in grooves. Lighter gangue particles are washed away.

2.7.2.. Magnetic separation process

This process is used in the extraction of metals which exhibit magnetic properties. For example, in theextraction of iron, crushed magnetite ore (iron) particles are separated using their magnetic property.The pulverized ore is moved on a conveyor belt. Electro-magnetic wheel of the conveyor attracts onlythe magnetic particles into a separate heap. Only the magnetic particles are attracted by the mag.Wheel.

2.7.3. Chemical separation

This process utilises the difference in some chemical properties of the metal and gangue particles fortheir separation.

For example, in the Bayer's process of aluminium extraction, the bauxite ore is treated with hot sodiumhydroxide solution.

Water soluble sodium aluminate formed is filtered to separate the undissolved gangue particles. Sodiumaluminate (NaAlO2) is further processed to get aluminium oxide (Al2O3).

2.7.4. Froth floatation process

Flotation is a process in which valuable minerals are separated from worthless material or othervaluable minerals by inducing them to gather in and on the surface of a froth layer.

This process is based on the ability of certain chemicals to modify the surface properties of themineral(s).

Some chemicals are used to generate the froth and still others are used to adjust the pH. Certainchemicals are even capable of depressing the flotation of minerals that are either to be recovered at alater time or are not to be recovered.

Sulfide and non-sulfide minerals as well as native metals are recovered by froth flotation.

Normal flotation- The economic minerals are floated with respect to the gangue minerals present.

Ex. For normal flotation Coal

Reverse flotation- Gangue mineral matter is floated with respect to the economic mineral.

Reverse flotation is generally applied when the impurity content of the feed material is high.

Ex. For reverse flotation Iron ore

2.7.4.1. General details

Basis of froth flotation is the difference in wettabilities of minerals. Most minerals in nature are hydrophilic. They do not readily float in froth flotation. Without reagents there would be no flotation and without flotation, the mining industry would

not exist. Even some of the minerals which are hydrophobic in nature require supporting reagents to

increase the hydrophobicity and some chemical reagents are added to float to the surface. The finely powdered ore is mixed with water and suitable collecting and frothing chemical in a

large tank. A current of compressed air agitates the mixture. The ore particles are wetted by oiland forms a froth at the top, which is removed. The gangue particles wetted by water settledown. Ore preferentially wetted by oil is removed as froth. Gangue wetted by water is removedafter it settles down

2.7.4.2. Mechanism of froth flotation

If a mixture of hydrophobic and hydrophilic particles are suspended in water, and air is bubbledthrough the suspension, then the hydrophobic particles will tend to attach to the air bubblesand float to the surface.

The froth layer that forms on the surface will then be heavily loaded with the hydrophobicmineral, and can be removed as a separated product.

The hydrophilic particles will have much less tendency to attach to air bubbles, and so it willremain in suspension and be flushed away.

SECTION IIIINDUSTRY STATUS ON MAJOR MINES IN INDIAI COPPER

1.1. Processing of copper ore

Types of copper ore

Oxide ores (simple leaching process)

Sulfide ores (Beneficiation in flotation cells)

Processing method

First the copper ore from open pit mine is blasted, loaded and transported to the primarycrushers.

The ore is crushed and ground to liberate the copper-bearing mineral from the waste materialor gangue.

The reduced product is then subjected to secondary crushing which typically involves a series ofrod or ball mills.

The final material particle size will normally be less than 100 microns.

During the final milling stage collectors are added to the slurry which render the sulphideparticles hydrophobic.

These copper minerals are then concentrated by flotation when air bubbles are introduced intothe slurry.

Frothers are normally added to the slurry to stabilise the copper particle.

Flocculant is added to the tailings from the flotation cells to promote rapid sedimentation,which returns to the process water circuit.

The thickened tailings are normally further dewatered by using flocculant.

The copper concentrate is removed and is then thickened and dewatered where flocculants areused to improve the sedimentation and filtration rates.

1.2. Status of Indian copper mining industry

1.2.1. Import dependent on copper ore

India is not a major producer of copper ore but it produces the refined form of copper.

It contributes to about 3.5 to 4% of the world’s total production of copper that sums up to afigure of 6 lakh tons.

India has always been an importer of copper ore to satisfy the domestic consumption demand.The countries from the ore is imported into India are

*Chile *Indonesia *Australia *Canada

India is indulged in importing copper ores from the ore exporting countries of the world andextract copper out of them as there is a shortage of copper mines in the country. Theproduction of copper in India is dependent on these imports only.

1.2.2. Indian major players

The following companies in India largely handle production of copper from its ore.

* Birla Copper (Hindalco)* Sterlite Industries* Hindustan Copper* M/s Jagadia Copper Ltd. (formerly SWIL Ltd.)

Has started operating its 50,000 tonnes plant based on secondary route.

1.2.3. Indian production

Production during the period 1997 47,500 tonnes

Present production capacity Around 10 lakh tonnes

Present production level Around 5 lakh tonnes

Plantwise installed capacity of copper

1.2.4. Indian demand copper metal

Domestic demand for copper Around 5 lakh tonnes.

Major consumers of copper

A major percentage i.e. 10% of the total consumption in India is contributed by the following two majortele-communication providers

BSNL MTNL

The rest of the demand is contributed by the construction and automobile sector.

1.2.5. Profile of major players

i. Hindustan Copper Ltd

Activity details

Hindustan Copper Limited (HCL), a Govt. of India Enterprise under the administrative control of theMinistry of Mines, is the only vertically integrated multi unit copper producer in India engaged in widespectrum of the following activities

Mining Beneficiation Smelting Refining Manufacturing of copper cathodes & continuous cast copper wire rods

Ore Reserves including resources:

Additional mining reserves (old mines):

Rakha mine 47.19 million tonnes @ 0.97% copperKendadih Mine 12.85 million tonnes @1.73% copperChapri Block 63.50 million tonnes @1.14% Cu

Khetri Copper Complex (KCC), Khetri Nagar, Rajasthan,Khetri Nagar- 333504 Jhunjhunu (Rajasthan)Tel No.: 91(0) 1593 220065/22030501593-22305 (Chemical Purchase department)Fax No.: 91(0) 1593 220038/220002E-Mail – kcc@hindustancopper.com

Activity Ore processing

Production capacity of metal 31000 tonnes per annum

Malanjkhand Copper Project (MCP)

Malanjkhand Copper ProjectP.O.- MalanjkhandDist. – BalaghatMadhya PradeshPh.- (07637) 257-072/042/040/032/016 /Fax – (07637) 257038 / 032E-Mail – hcl_mcp@hindustancopper.com, hclmcp@sancharnet.in, hclmcp1@sancharnet.in

Activity Open pit mine with a capacity of 2 million TPA of ore with a matching concentratorplant, Tailing Disposal System and other auxiliary facilities.

Taloja Copper Project (TCP), Taloja, Maharashtra.PLOT NO:E-33 TO E-36 M.I.D.C. AREAP.O. TALOJA-410 208, RAIGAD, MAHARASHTRAPhone – (022) 2740-2679Fax – (022) 2741-2468

Activity Continuous Cast Copper Rods (CCR) with a capacity of producing 60,000 TPA , Usingcopper metal produced by other units of its parent company and converts it into copper rods.

Indian Copper ComplexP.O. GhatsilaDist. – Singhbhum(E)JharkhandPhone – (06585) 225-768/492/873/869 400Fax – (06585) 225-806

Activity

» Established in 1930» Operating Mine: Surda~26 MT @ 1.20% Cu» Process plants to produce 19,000 TPA of refined copper

Production capacity of metal 20500 tonnes per annum

ii Sterlite Industries (I) Ltd

Contact details

SIPCOT Industrial Complex,Madurai Bypass Road,TV Puram P.OTuticorin- 628 002,Tamil NaduPhone No.: +91 461 4242591(10 lines)Fax: +91 461 2340203

Production details on metal – Period 2010

Copper 3.34 lakh tonnesZinc and lead 7.68 lakh tonnesAluminium 2.68 lakh tonnes

II ALUMINIUM2.1. Processing of aluminium ore

After crushing and grinding the ore to less than 1mm, it is then subjected to high temperature andpressure after the addition of concentrated sodium hydroxide. The alumina dissolves in the highlycaustic liquor and of the many impurities only silica is soluble.

After digestion the sand particles are removed with the slurry being settled in primary thickeners wherethe flocculant is added.

The aluminum industry relies on the Bayer process to produce alumina from bauxite. It remains themost economic means of extracting alumina, which in turn is vital for the production of aluminum metal- two to three tonnes of alumina are required to produce one tonne of aluminum, depending upon thecontent of alumina in the bauxite.

2.1.1. Production of alumina from bauxite

Bauxite is crushed, ground and digested in caustic soda (sodium hydroxide) at high pressure andtemperature. The resulting liquor contains a solution of sodium aluminate and undissolved bauxiteresidues containing iron, silicon, and titanium. These residues, known as “red mud”, settle gradually tothe bottom of the settling tank and are filtered and removed.

The clear sodium aluminate solution, which is called aluminate liquor, is pumped into a huge tank calleda precipitator. Fine particles of alumina are added to seed the precipitation of pure alumina particles asthe liquor cools.

The precipitation process is a batch as well as continuous. The solid particles concentration increases,which are removed, filtered and washed, and are then passed through a rotary or fluidized calciner at1100°C to drive off the chemically combined water. The result is a white powder, pure alumina. Thecaustic soda, which is called, spent liquor is recycled and returned to the start of the process and usedagain.

The Bayer Process :

Today all the alumina produced from bauxite uses the Bayer Process -an economical method ofproducing aluminium oxide which was discovered by an Austrian chemist Karl Bayer and patented in1887.

The process dissolves the aluminium component of bauxite ore in sodium hydroxide (caustic soda),removes impurities from the solution; and precipitates alumina trihydrate, which is then calcined toaluminium oxide

High-pressure digestion technology is adopted for the production of Alumina.

The Bauxite received from mines is stored in the open bauxite yard. It is blended and crushed. Thecrushed bauxite is then conveyed to Ball Mill section where the bauxite along with the recycled causticsoda solution called digestion liquor is ground. The slurry after grinding is stored in tanks and pumped toDesilication units after preheating.

The desilicated slurry is digested in the series of digesters by steam at high pressure. The digested slurryis flashed and diluted before going to settling tanks.

Flocculants are added for faster sedimentation of the mud. The settled mud (called Red Mud) issubsequently washed before going to red mud disposal area.

Hydrocyclone :

Under modernization programme with installation of Hydro cyclone which has pivot role for hydratefiltration.

Raw and fine crystals of alumina hydrate are separated through hydrostatic process from hydrate liquor.Fine crystals are resent to precipitation for seeding whereas raw crystals are sent as product tocalcinations through filtration process where finally it is turned into alumina powder. By way of usingthe hydro cyclone in alumina plant, the production and productivity is supposed to be improved 30 to40%.

The clear supernatant liquor (called aluminate liquor) is filtered and cooled in heat exchangers. Thecooled aluminate liquor is then pumped to precipitation unit. The precipitated hydrate is filtered,washed and stored in hydrate godown.

The product hydrate is fed to kiln where it is calcined at a temperature of 1200°C.

The Calcined alumina is stored in silos.

Smelting Process :

Bharat Aluminium Co. Ltd. (BALCO) uses VSS (Vertical Stud Soderberg) technology to produce Aluminiumfrom Alumina. Alumina is dissolved in an electrolytic bath of molten cryolite (Sodium AluminiumFluoride) within a large carbon or graphite lined steel container known as a "pot".

An electric current is passed through the electrolyte at low voltage, but very high current. The electriccurrent flows between a carbon anode (positive), made of petroleum coke and pitch, and a cathode(negative), formed by the thick carbon or graphite lining of the pot. Molten Aluminium is deposited atthe bottom of the pot and is siphoned off periodically. It is then taken to a holding furnace, cleaned andthen cast.

2.2. Status of Indian aluminium mining industry

2.2.1. Indian major players

Major players

Though there are more than 200 mines operating in the country, most of these are small open cast andmanually operated.

Industry is dominated by following five integrated players which are in the manufacture of alumina/aluminium,

Bharat Aluminium Company Limited (BALCO) National Aluminium Company Limited (NALCO), Hindustan Aluminium Corporation Limited (HINDALCO) Indian Aluminium Comp-any Limited (INDAL) Madras Aluminium Company Limited (MALCO)

Among these, the Panchpatmali bauxite mine of NALCO in Orissa accounts for about 40% of thecountry’s production.

Production capacity of Indian players

2.2.2. Indian availability of bauxite

India is self-sufficient in bauxite, the chief raw material for the manufacture of aluminium.

Indian available resources of bauxite Around 3 billion tonnes

Indian production of bauxite Around 14 million tonnes

Indian place in the world in bauxite availability 5th

Major state which have bauxite deposit Orissa and Andhra Pradesh (Around 90%)

Other major bauxite reserves containing states Jharkand, Andhra Pradesh, Maharashtra.

2.2.3. Profile of major players

BALCO

The public sector company BALCO was the first company in which the Government of India hasdisinvested its stakes to M/s Sterlite after liberalization.

The third largest Aluminium Company in India is held by Sterlite Industries which has 51% share holdingand by GOI, which holds the remaining 49%.

Activity and product range

Calcined alumina 200,000 tonnes per annumAluminium metal 100,000 tonnes per annumPower plant 270 MW

Capacity status on individual mining units

Aluminium Mines Inferred reservesmillion MT Aluminium Oxide %

Proved andProbablereserves

million MT

Aluminium Oxide %

Mainpat 5.0 48.0 6.6 48.0Bodai – Daldali 2.0 48.0 7.1 48.0

Pandrapat 8.0 48.0 - -Jamirapat 15.7 51.0 - -

Total BALCO 30.7 49.0 13.7 48.0

NALCO

Activity

Bauxite mining Alumina refining, Aluminium smelting and casting

Location Panchpatmali hills of Koraput district in Orissa

Availability

Resource 310 million tonesCapacity 4.8 million tonnes per annum

Quality The quality of ore is Alumina 45% and Silica 2%.

HINDALCO and INDAL

Both is flagship of Aditya Birla Group, are vertically integrated through all stages of the aluminiumbusiness.

Hindalco

Hindalco is the market leader in aluminium production followed by Nalco.

Business Primary aluminium, extrusions, rolled products, foils, and alloy wheels

Market share In the value-added segment, Hindalco, along with its subsidiary Indal, hasaround 50 per cent market share.

Smelting capacity 345,000 tonnesAlumina refining capacity 660,000 tonnesCaptive power plant 779 MW

Indal, Hirakud (Orissa)

Capacity 65,000 tonnes per annumCaptive Power Plant 67.5 MW

Mining division

Muri AluminaPost Chotamuri-835 101Dist: Ranchi, JharkhandPhone:(06522) 244253/334Fax: (06522) 244342

MALCO

Contact details

Post Box. 4, Mettur DamSalem District. - 636 402Tamilnadu, South IndiaPhone : 4298 - 222061 - 64Fax : 4298 - 222069, 222215E-mail : masec@vedanta.co.in

Activity

MALCO is the only integrated primary Aluminium Metal complex in the entire South India. MALCO wastaken over by the Sterlite group, a subsidiary of Vedanta resources in 1995.

Captive mining, refining, smelting Coal based Captive power generation

Method of mining

Method of mining used is open cast semi-mechanized. Overburden, which is in the form of soil &moorum, is first excavated by a combination of shovel/excavator and dumper in order to expose ore-zone.

Then the ore zone is drilled and blasted. The blasted ore is subject to sorting in order to upgrade the“ROM Grade” to “Plant Feed Grade” i.e. 34% Al2O3. Sorting is carried out at the mine-face and therejects associated in the ore zone are back-filled concurrently. The area is then levelled and afforested.

The sorted ore is then trucked to the Mettur Dam Complex for further processing.

Location of Bauxite Mines Reserves capacity

Yercaud , Salem district 0.8 million tonnesKolli hills, Namakkal district 0.9 million tonnes

Smelting and refining unit - Mettur

Smelting capacity 40,000 tonnes per annumRefinery capacity 80,000 tonnes per annum

III IRON2.1. Processing of iron ore

2.1.1. Type or iron ore

Haematite Magnetite

India is currently producing all the possible marketable products of iron ore, namely iron ore lumps, oreconcentrates, pellets, iron oxide powder and iron ore sinter. One of the most immediate technologicalchallenges facing the industry is to deal with the problem of processing alumina rich iron ore fines andslimes.

During the wet processing of iron ores, substantial amount of fine particles/slimes is generated indownstream which need to be recovered effectively for their usage and beneficiation.

The slime sample from Karnataka had a feed grade of 63.84% total Fe, 2.64% Silica and 3.98% alumina.

The dispersion of the fine iron ore particles were carried out with sodium hexa meta phosphate (SHMP),tetra sodium pyrophosphate (STPP) and Dispersant N6, a low molecular weight anionic poly-acrylamidepolymer. The effect of process parameters pulp density, types of reagents and their dosage on theseparation index following dispersion was studied

The selective flocculation studies were carried out on fully dispersed slime sample using modified starchand polyethylene oxide as selective flocculant. The results show that about 95% recovery could beachieved through the separation following dispersion with the enhancement of Fe grade from 1.5 wt. %to 2 wt. %.

2.2. Status of Indian iron mining industry

2.2.1. Indian Availability

2.2.4. Production of iron ore (lumps and fines) by principal states

In million tonnes

2.2.5. Major regions with haematite resources

Jharkhand-4036 million tonnes (28%), Orissa-4761 million tonnes (33%), Chattisgarh-2731 million tonnes (19%) Karnataka-1676 million tonnes (11%) Goa-713 million tonnes (5%).

The balance resources are spread over in the state of Maharashtra, Madhya Pradesh, Andhra Pradesh,Rajasthan, Uttar Pradesh and Assam together contain around 4% of haematite.

2.2.6. Major regions with magnetite resources

Karnataka-7812 million tonnes (74%), Andhra Pradesh-1464 million tonnes (14%)

Rajasthan-527 million tonnes (5% each), Tamil Nadu-482 million tonnes (5% each), Goa-214 million tonnes (2%).

Assam, Jharkhand, Nagaland, Bihar, Madhya Pradesh and Maharashtra together account for a meagershare of magnetite resources.

The most important magnetite deposits are located in Babubadan, Kudremukh, Bellary, Anadurga andBangarkal areas of Karnataka, Goa region, Ongole and Guntur districts of Andhra Pradesh etc. Otherdeposits are also located in Jharkhand, Bihar, Tamilnadu, Kerala and Assam etc.

2.2.7. Major iron ore mines in India

SAIL

SAIL has the second largest mining outfit in the country.

SL. NO MINES STATE YEAR OFCOMMISSIONING

RATEDCAPACITY (

IN MT)

Iron ore

1. KIRIBURU JHARKHAND 1964 4.25

2. MEGHAHATUBURU JHARKHAND 1985 4.30

3. BOLANI ORISSA 1960 4.20

4. BARSUA ORISSA 1960 2.01

5. KALTA ORISSA 1966 1.10

6. GUA JHARKHAND 1919 2.4

7. MANOHARPUR (Chiria) JHARKHAND 1907 0.7

Flux

6. Kuteshwar (Limestone) MADHYA PRADESH 1974 1.10

7. Bhawanathpur (Limestone) JHARKHAND 1979 0.80

8. Tulsidamar (Dolomite) JHARKHAND 1970 0.34

IV LEAD AND ZINC

V COAL1.Gravity separation: After the coal is mined, it is ground down by ball mills and is subjected gravityseparation to remove the waste.

2.Flotation process: Further purification is done by adding flotation agent

3. Sedimentation process: Fine coal is recovered by sedimentation process by adding flocculant.

4. Filtration / centrifugation: Fine grade coal end product is obtained by filtration / centrifugationprocess by adding flocculant to enhance the separation. In the case of brown coal or coal with high claycontent, prior to flocculant addition, there is the requirement to add coagulant to achieve efficientsolids capture.

Need for washing non-coking coal

• Freight saving owing to reduced ash• Consistency in the feed coal for better performance of end user• Problems in disposable of bottom ash and slag• Environmental pollution due to fly ash and trace elements• Power Plant equipments would be protected from high wear &

tear on coal and ash flow paths, combustion chambers, mills, crushers etc.

Advantages of washing non-coking coal

• High output for the thermal power plant• Plant utilisation factor increased from 73 to 96%• Specific consumption reduced from 770 gm to 530 gm per kwh• Auxiliary fuel consumption was reduced practically to nil• Auxiliary power consumption reduced by 1.5%• Minimization of deposits, clinker formation and leakage development in the boiler

Major players in coal mining

Current status of coal washeries

20 coal washeries ( 32.37 MTPA) for coking coal 28 coal washeries (70.35 MTPA) for Thermal coal Three more (Approx 21 MTPA) under various stages of

construction/approvals.

VI MICAIndia produces about 62% of world’s mica. Bihar (60%), Andhra Pradesh (20%) and Rajasthan (10%) arethe major mica mining states in India.

Mica is a natural valuable mineral product applied to a group of a complex aluminosilicate mineralshaving a sheet or plate like structure with different chemical compositions and physical properties.

The ordinary mica crystals as they come out of a mine is in form of rough books or lumps of irregularshape, size and thickness, associated with impurities and structural imperfections. They have to undergoa long operation of cutting, sorting and processing from crude to commercial quality.

The operations performed consists of cobbing or cleaning the crude crystals as extracted from the minewith its associated impurities; rifting or splitting the cobbed mica into usable sheets by sickle and thenby sharp knife removing major flaws and structural imperfections, such as cracks, holes, reeves,crossgrains and other physical defects to obtain the maximum usable area with minimum wastage.

SECTION IVINDIAN SUPPLY DEMAND SCENARIOON MINING CHEMICALMining chemicals form a crucial part of the chain, and are absolutely fundamental to maximisingrecovery. The industry has both commodity and specialised chemicals.

The type of chemical used in mineral processing include the following.

Flocculant / coagulant Collectors Frothers Depressants Activators Scale inhibitor Dispersant / Grinding aid Modifying agent (pH modifier, cationic modifier, ionic modifier, organic modifier) Agglomeration aid Rheology modifier Dust suppressor

I. FLOCCULANT / COAGULANT1.1. General details

Mineral slurries which contains colloidal particles in nature normally carry charges on their surface, andhence they are stable and not separable. The surface property of such colloidal particles can be changedby addition of some chemicals (coagulants / flocculants) so as to facilitate the separation of solids.

Conversion of stable state dispersion to the unstable state is termed destabilisation and the processes ofdestabilisation is termed as coagulation / flocculation.

A wide variety of chemicals exist for use in clearing raw water of suspended solids in coagulation/flocculation processes. It is typically found that combinations of coagulants can be used to achieve muchhigher performance and process efficiency.

Coagulation: If destabilisation is induced through charge neutralisation the process is called coagulation.

Flocculation: The process of forming larger agglomerates of particles through high molecular weightpolymeric materials is called flocculation. No substantial change of surface charge is accomplished inflocculation.

Now-a-days inorganic flocculants such as ferric chloride and aluminium chloride are replaced bypolymeric compounds.

Mostly used coagulants / flocculants compounds include

Polyacrylamide polyaluminium chloride.

1.2. Role of flocculant in Mineral processing

In all mining operations, solids and liquids must be separated which can be facilitated by flocculants inthe thickening of froth flotation concentration and clarification steps. In most mineral processing, thesuspended fines are impurities arising from crushing and grinding. They are separated as the solid phaserather than the mineral of interest, which remains in solution, coal being an exception. The miningindustries requiring flocculants include coal, iron ore, bauxite and uranium etc. The coal industry is thelargest user.

Both cationic and anionic flocculants are used including some natural polymers. Cationic polymers are ofquaternary ammonium type, e.g. poly (DADMAC) or polyamine especially in the recovery of coal. Theprincipal anionic synthetic flocculants are poly (acrylamide-acrylate) copolymers although nonionicpolyacrylamide is also utilized. Among natural polymers used are starch, guar gum, animal glue, lignin(sulfonate) etc.

1.3. Selective flocculation

One of the applications that have shown considerable promise in the beneficiation of mineral fines isselective flocculation. This process involves flocculating particles of one type from a well dispersedsuspension of the ore or mixture, followed by separating the flocs by either froth flotation orsedimentation.

Selective flocculation, like flotation, takes advantages of the differences in the physico-chemicalproperties, but unlike flotation, does not depend entirely on the wettability characteristics of theparticle surfaces. The selective flocculation involves three steps: dispersing the fine particles, selectivelyadsorbing the polymer on the active component (flocculating particles of interest) and forming flocs,and separating the flocs.

The major applications of selective flocculation have been in mineral processing, but many potentialuses exist in biological and other colloidal systems. These include purification of ceramic powders,separating hazardous solids from chemical wastes and removal of deleterious components from paperpulp. Industrial applicability of this process has so far been limited, e.g. processing of taconite andpotash ores, because results obtained by selectively flocculating natural ores or complex syntheticmixtures often do not correlate with the selectivity observed in single component systems. Selectiveflocculation of desired fraction has become an active area of research in the field of flocculation. Acritical review on iron oxide/quartz separation using starch and polyacrylic acid (PAA) indicates starch tobe a more selective reagent.

The presence of clays, particularly Montmorillonite, is known to have a detrimental effect on theselectivity of separation. To achieve the desired selectivity ( <10% flocculation of clay ), Sodium silicate isto be added. The primary objective of adding sodium silicate is to prevent hetero coagulation. It wasobserved that selective flocculation of iron oxide-kaolin mixtures using a modified polyacrylamideflocculant containing hydroxamate functional groups. Flour apatite, the phosphate fertilizer mineral,occurs in nature. In association with silicate and carbonate minerals. During flotation separation ofapetite a significant proportion of P2O5 values is lost in the form of slimes.

1.4. Difference between coagulant and flocculant

Properties Coagulation FlocculationCompounds used Inorganic compounds ex. FeCl3,

FeSO4 , al. sulphate etcPolymeric material namelypolyacrylic acid, polyacrylamideetc

Physical change More of thickening More of clumping together ofsubstances or encapsulation ofsubstances

Charge of the colloid Neutralization of charged colloid.Due to charge neutralization, itoften assists in turbidity andcolour removal.

No change in charge due to theaddition of polymericcompound. No physical changetakes place such as colour orturbidity removal.

Type of usage Water treatment Waste water treatmentStability Compact and loosely bound Large size, strongly bound and

porusUsage Coal, Soda ash, taconite and

some extent to uranium industryMajor mineral industriesincluding coal, copper, gold,silver, zinc etc

http://wecleanwater.com/html/floccin/flocculation-vs-coagulation.htm

Discussion with Mr. S.K. Sharma, Scientist, R & D department, NMDCTel: 040-27170224Mob: 8500667302

Flocculant and coagulant

There is no need to use both coagulant and flocculant. It depends upon the type mineral, contents ofminerals.

Some of the flocculant can initiate the coagulation itself and therefore no need to add coagulant.

Discussion with Mr. VenkataramanMob: 09820232243

Flocculants and coagulant

More than 90% of the mining industry use flocculant only. Coagulant is used rarely.

No need to use both coagulant and flocculant.

Coagulant is cheaper than flocculant.

Coagulant is used mainly in water treatment industry.

Flocculant is used in waste and industrial water treatment.

Where-ever, froth flotation is used, flocculant and collectors should be used.

Polyelectrolytes with low molecular weight are used as coagulant whereas high molecular weight areused as flocculant.

1.5. Classification of flocculant

Synthetic polymer

Synthetic flocculants have advantages of possibility of “tailor made” in terms of molecular weight andcomposition and therefore efficient at very low dose levels when compared to natural flocculant such asstarch. More over, synthetic flocculants are easily dissolved and do not require cooking.

Cationic flocculant Quaternary type such as poly DADMAC or polyamine, phosphonium,sulphonium compounds, Polyacrylamide (acrylamide and acryloyl oxyethyl trimethyl ammoniumchloride, formed by quaternization of dimethyl aminoethyl acrylate with methyl chloride) polyamines,polyimines, polyvinyl pyridine etc

Anionic flocculants Homopoly acrylic acid, polyacrylic acid co acrylamide and hydrolyzedpolyacrylamide. Polyvinyl sulphonic acid, polystyrene sulphonic acid , 2-Acrylamide-2-methyl propylsulfonic acid (AMPS)

Non-ionic flocculants Acrylamide monomer polymerised to give polyacrylamide, Polyethylene oxide

Natural polymer

Starch, guar gum, animal glue, lignin (sulfonate) , Chitin and chitosan deri. Sodium CMC etc.

The vast categories of materials used as flocculating agents can be classified broadly into two categories

1.6. Advantages of polymeric floccs over inorganic flocs

The flocs are larger and stronger and are more rapidly formed. The salt concentration is not increased and much less sludge is generated. The dosage requirement is quite low (typically 1% on a dry weight basis) whereas that of

inorganic flocculants may be as high as 20%. The inorganic flocculants frequently require pH adjustment, which is not necessary with

polymeric flocculants. The polymeric flocculants are more convenient and easier to use. However, inorganic flocculants

are inexpensive and often used for economic reasons.

1.7. Usage of flocculants in metallic minerals

Common inorganic flocculant

Chemical Advantages Disadvantages

Alum(AluminumSulphate)

A standard incoagulation/flocculation.Attracts inorganic suspendedsolids very effectively.

Fast mixing is critical to proper functioning. Non-optimal pH leads to excessive dosagerequirements, should be used between pH 5.5and 7.5, typically requiring alkaline additives toachieve optimum pH. Performance substantiallydegrades at lower temperatures. Poor efficiencyfor attracting organic suspended solids. Relativelylarge dosage required when used alone.

Ferric Chlorideand ferricsulphate

Alternative to Alum. Ferricchloride is good at attractinginorganic SS. Gives morecompact sludge. pH sensitivity issomewhat less than alum.Suitable for usage in the lime-softening process (pH 9).

Lower efficiency for removing organic suspendedsolids than alum. Fast mixing is critical to properfunctioning. Should be used between pH 5.5 –8.5, typically requiring alkaline additives toachieve optimum pH. Generally large dosagerequired.

Polyhydrolysed metal salt

Chemical Advantages DisadvantagesPACl / PAC(PolyaluminumChloride)

Polyaluminum Sulfate

Does not require addition of alkali to raw waterfor coagulation, and is much less sensitive to pH,operating withing pH 4.5 – 9.5. Mixing time notcritical.Floc is tougher, and if substituted for hydrolyzingmetallic salts, may be possible to reduce doseand avoid using coagulant aid. Suitable for highcolour applications. Specific chemicalcomposition depends on preparation.

Generally requires an on-site production process toprepare pre-hydrolyzedmetallic salts from alum.

Polyiron chloride Generally requires an on-site production process toprepare pre-hydrolyzedmetallic salts from alum.

Synthetic cationic polymer

Chemical Advantages DisadvantagesEpichlorohydrin dimethylamine(epi-DAM)

Amino methyl polyacrylamide

Polyalkylene

Polyamines

Polyethylenimine

Lower dosages required,producing denser sludge. Whenused in combination with metalsalts, greatly reduces theirdosage requirement, resulting insubstantial economic benefits .

Determining correct proportionfor mixing with inorganiccoagulants and other additiveshas been challenging due to ahistorical lack of instrumentationfor determining relative amountsof inorganic, organic, andbiological suspended solids inraw water.

The flotation tests were performed using 1.0 lb. of Tall Oil A plus either 0.4 lb. or 0.6 lb. of froth modifierper ton of feed, using the 11 different hydrocarbon "oil" type reagents (0.4:1.0 froth modifier/tall oilmixture was used). Additional froth modifier was added separately to obtain a ratio of 0.6:1.0. Tapwater was used for all tests. The P2O5 recovery results are presented for each reagent as bar graphs foreasier visualization .

1.8. Coagulant Aids

In addition, various additives can be used to aid in the coagulation and flocculation process. These mayaccelerate the flocculation process or strengthen the floc to make it easier to filter. Coagulant aids canbe roughly broken into two classes based on their mechanism of action. Some coagulant aids, generallythe synthetic polymers, bind to particles much like coagulants themselves. Others, generally theinorganic and also natural polymers, act as sites of nucleation to speed the formation of floc. Nucleatingagents typically also increase the density of floc, and so speed settling.

In the case of synthetic polymer coagulant aids there is a blurring between coagulant proper andcoagulant aid. The distinction is that synthetic polymer coagulant aids are added mainly for how theyimprove sludge properties (density, strenth, floc-size), easing separation and speeding flocculation, andthat they may not be efficient when used alone as primary coagulants.

Synthetic CationicPolymers

Polydiallyldimethylammonium chloride(poly-DADMAC)

Polydimethylaminomethylpolyacrylamide

Polyvinylbenzyl

trimethyl ammoniumchloride

Produce denser moreshear-resistant sludge.For use with metalliccoagulants.

Increases complexity ofcoagulation/flocculationstage but improvesprocess performanceand economy whenused properly

Synthetic NeutralPolymers

Polyacrylamides

polyethylene oxideSynthetic AnionicPolymer

Anionic Polymer A110(Kemira)HydrolyzedPolyacrylamidesPolyacrylic acidPolystyrene sulfonatePolyacrylates

Produce larger shear-resistant flocs bypromoting bridging.

Natural polymers Sodium alginate

ChitosanStarch

Particularly suited foruse with ferric salts, butif used properly can beeffective when usedwith alum

Inexpensive additivesfor increasing settlingvelocity, and reducingcoagulant dosage.

These less expensivepolymers are somewhatless efficient thansynthetic polymers

Inorganic CoagulantAids

Aluminum Chloride For use with organicpolymer coagulants

Increases complexity ofcoagulation/flocculation,but improves processperformance andeconomy when usedproperly

Activated Silica

Bentonite, kaolinite

Calcium Carbonate

Inexpensive additivesfor increasing settlingvelocity, reducingdosage.

Substitution of Magnafloc for ferric chloride

Ferric chloride is a Class 8 dangerous goods and requires appropriate storage and handling. It is anextremely aggressive corrosive. Ferric chloride is introduced into the sludge stream just prior to de-watering.

As a result of the atomised mists produced through the filter belt operation a perfect mechanism existedfor the dispersal of this corrosive substance. All equipment within the filter belt press room was severelyeffected by corrosion. All valves, steel pipe work, walkway gratings, pumps and associated fittingsexhibited extensive corrosion to the point where some pieces of equipment were inoperable and accessto the area unsafe. The main entry doors were corroded to the point that they would no longer close.

Product Safety

A detailed assessment of the properties of both products indicated that Magnafloc was able to deliveron first performance criteria. The outcome of a product comparison is detailed in Table 1.

De-watering Characteristics

Both agents were good sludge conditioners, producing a sludge cake in the order of 18- 23% dry solids.Only one adverse difference was seen in using the two chemicals. Significant quality differences wereseen within the centrate.

As outlined in Table 2 centrate quality varied significantly with three parameters only. The pH of thecentrate when using ferric chloride was in the range of 4.0-5.0 compared to 8.0-9.0 for Magnafloc 1597.This pH shift in using the new product benefited two areas of operation, less corrosive and moreeffective centrate treatment.

The second parameter of significance was iron. The iron content of the centrate produced usingMagnafloc 1597 was in the order of 100 times less.

Concentrations of iron in the sludge were reduced by six fold when using Magnafloc 1597. This allowedfor a significant reduction in the iron content of the end product biosolids. This reduction was seen as afuture advantage in maintaining a commercially viable agricultural product when minimal research hasbeen conducted on the impacts of iron within soils.

The third parameter of significance was phosphorus. The phosphorus content of the centrate producedusing Magnafloc 1597 was in the order of 10 times more. This was a result of ferric chloride having asignificantly greater binding capacity of phosphorus within the sludge.

During the course of the trial it was decided that to effectively treat the centrate this flow would beredirected from the off site treatment area to the head of works. As the Bendigo WRP process is BNRthe treatment of phosphorus levels within the centrate had to achievable. It was found during thecourse of the trial that the biological process removed a proportion of this phosphorus. Residualphosphorus moving through the plant

Cost

It was found that significantly less Magnafloc 1597 is required to achieve the same cake solids whenusing ferric chloride. The equivalent dose rates for ferric chloride and Magnafloc 1597 are detailed inTable 3.

Table 3: Dose Rates for Ferric Chloride Compared to Magnafloc 1597

However Magnafloc 1597 is around six times the cost of ferric chloride. During the course of the trial itwas found that the change over to Magnafloc 1597 was cost neutral.

Any financial gains in flocculant/coagulant savings have been absorbed by additional alum dosing toremove phosphorus in the centrate treatment.

1.9. Polyacrylamide

1.9.1. General details

Polyacrylamides are water-soluble polyelectrolytes, i.e. they carry ionic charge as well as thepolymer chain.

Polyacrylamides are available in a wide range of molecular weights which formed from acrylamidesubunits. It can be synthesized as a simple linear-chain structure or cross-linked, typically using N,N'-methylenebisacrylamide.

Polyacrylamide is not toxic. However, unpolymerized acrylamide, which is a neurotoxin, can bepresent in very small amounts in the polymerized acrylamide, therefore it is recommended tohandle it with caution.

Depending upon the charge, these polymers are anionic or cationic. Homo polymers of acrylamideare also included in the family of polyelectrolytes though they do not carry any charge. These arecalled nonionic.

Important application sectors include the following

Treatment of raw water for potable purpose Treatment of waste water/industrial effluent / sewage water Treatment of water for industrial use Oil exploration Brine clarification in caustic chlorine unit Metal and mineral processing Paper industry Sugar juice clarification Coal washeries

1.9.2. Indian trade analysis

In India, requirement of polyacrylamide is partly met by imports and partly by domestic producers.

Indian producers of polyacrylamide, import acrylamide monomer and polymerise the product bydissolving in water to produce polyacrylamide. Acrylamide monomer is not presently produced inIndia.

Indian import of polyacrylamide / acrylamide

Imported acrylamide monomer is mostly used in the production of polyacrylamide for watertreatment application.Imported acrylamide monomer is mostly used in the production of polyacrylamide for watertreatment application.Imported acrylamide monomer is mostly used in the production of polyacrylamide for watertreatment application.

Portwise import details of polyacrylamide- Period 2009-2010

Countrywise import details of polyacrylamide– Period 2009-2010

JNPT 90%

Mumbai 7%Chennai 2% Delhi 1%

S. Africa 1%Belgium 1% Italy 1%

Australia 4%

Germany 5%

U.S. 5%

Japan 5%

U.K. 12%

Korea S. 15%France 25%

China 26%

Sample of individual import

Product name Quantity in tonnes Shipment value in USD Value per quantity inUSD

Nhav ShevaFlomin 4956 Modifiedpolyacrylamide

9 26361 2929

Flomin 4995 Modifiedpolyacrylamide

9 25906 2878

Flomin 4956 Modifiedpolyacrylamide

6 17574 2929

Flomin 4995 Modifiedpolyacrylamide

6 17271 2878

Vizag portFlomin ALD 60 HAZYdispersion ofpolyacrylamide inmineral oil

21.6 17863 827

51.6 104975

Export of polyacrylamide and acrylamide monomer Neg.

1.9.3. Indian supply scenario

Acrylamide monomer

Presently acrylamide monomer is not produced in India.

Black Rose Industries Ltd , Mumbai proposed to set up the plant for acrylamide monomer .

Installed capacity of the new project 10000 tonnes. Proposes to increase 20000 tonnes to2013 and further to 40000 in 2015.

Schedule April 2012

Polyacrylamide

Polyacrylamide is produced by number of units in the country. Such organisations importacrylamide monomer and polymerise the product for use as flocculant.

Major players

SNF Indian Ltd, Anhdra Pradesh Dai Ichi Karkaria Ltd., Maharashtra Kimberlite Chemical, Karnataka Onedo Nalco Ltd Thermax Ltd, Maharashtra Kaushal Aromatic Chemicals Pvt. Ltd Suyog Chemicals Pvt. Ltd. / Star Orechem International Ltd Rubamac Rishab Metals & Chemicals Pvt. Ltd

Indian production of polyacrylamide 9700 tonnes

Consumption norm for production of polyacrylamide

Chemical raw material Requirement per tonne ofpolyacrylamide in tonnes

Acrylamide 0.251Acrylic acid 0.136Paraffinic solvent 0.286

1.9.4. Indian demand for polyacrylamide

Indian demand for polyacrylamide in water treatment sector including mining sector11250 tonnes

Indian market for polyacrylamide in value terms Around Rs. 190 crores

Sample of consumers of polyacryalmide in water treatment sector

Karur Sukkaliyur Common Effluent Treatment, KaruruJeedimetla Effluent Treatment Co., HyderabadVapi Waste & Effluent Management Company, GujaratPallavaram Tannery Ltd Effluent treatment co ChrompetAmbur Tannery Effluent Treatment Plant, AmburRanipet Tannery Effluent Treatment, RanipetHaldia Petrochemicals, Kolkata

Sample of consumers of polyacryalmide in mining sector

Details provided separately under section

1.9.5. Recent developments in technology

Flocculation properties of polyacrylamide grafted carboxymethyl guar gum (CMG-g-PAM)synthesised by conventional and microwave assisted method.

Pal S, Ghorai S, Dash MK, Ghosh S, Udayabhanu G.

Source : Polymer Chemistry Laboratory, Department of Applied Chemistry, Indian School of Mines,Dhanbad 826 004, India. sagarpal1@hotmail.com

J Hazard Mater. 2011 Sep 15;192(3):1580-8. Epub 2011 Jul 2.

A novel polymeric flocculant based on polyacrylamide grafted carboxymethyl guar gum (CMG-g-PAM) has been synthesised by grafting polyacrylamide chains onto CMG backbone usingconventional redox grafting and microwave assisted grafting methods. Under optimum graftingconditions, 82% and 96% grafting efficiencies have been observed in case of conventional andmicrowave assisted methods respectively.

The optimum sample has been characterized using viscometry, spectroscopic analysis, elementalanalysis, molecular weight and radius of gyration determination. The flocculation characteristics ofgrafted and ungrafted polysaccharides have been evaluated in kaolin suspension, municipal sewagewastewater and decolourization efficiency of a dye solution (methylene blue). It is evident fromresults that CMG-g-PAM synthesised by microwave assisted grafting method is showing bestflocculation characteristics.

Microwave assisted synthesis of polyacrylamide grafted dextrin (Dxt-g-PAM): Development andapplication of a novel polymeric flocculant.

Pal S, Nasim T, Patra A, Ghosh S, Panda AB.

Source: Polymer Chemistry Laboratory, Department of Applied Chemistry, Indian School of Mines,Dhanbad 826 004, Jharkhand, India. sagarpal1@hotmail.com

Int J Biol Macromol. 2010 Dec 1;47(5):623-31. Epub 2010 Aug 20.

An efficient polymeric flocculant was synthesized by microwave assisted grafting of polyacrylamideto dextrin. By varying the reaction conditions, various grades of graft copolymers were synthesizedto obtain the optimized one.

The flocculation efficiency of the grafted products in kaolin suspension was dependent on themolecular weight, radius of gyration and length of the grafted polyacrylamide chains. The flocculantobtained by microwave assisted grafting method was superior to dextrin and polyacrylamide-basedcommercial flocculant (Rishfloc 226 LV) in flocculation tests.

Novel biodegradable polymeric flocculant based on polyacrylamide-grafted tamarind kernelpolysaccharide.

Ghosh S, Sen G, Jha U, Pal S.

Source: Department of Applied Chemistry, Birla Institute of Technology, Mesra, Ranchi 835 215,Jharkhand, India.

Bioresour Technol. 2010 Dec;101(24):9638-44. Epub 2010 Jul 18.

Novel biodegradable polymeric flocculants were produced by conventional redox grafting,microwave-initiated and microwave-assisted grafting of acrylamide to tamarind kernelpolysaccharide (TKP).

The flocculation efficiency of the grafting products in kaolin suspension, municipal sewagewastewater and textile industry wastewater was primarily dependent on the length of the graftedpolyacrylamide chain. The flocculant obtained by microwave-assisted grafting method was superiorto TKP and polyacrylamide-based commercial flocculant (Rishfloc 226 LV) in flocculation tests.

1.10. Polyaluminium chloride

Polyaluminium chloride is used as coagulation/flocculation agent for water purification and as asubstitute for alum. PAC is reputed to provide faster flocculation and stronger flocs than alum insome applications. PAC is produced in concentration ranging from 10 to 30%.

It is largely used in India for drinking water purification in cooling towers, industrial wastewatertreatment and as a process chemical in the paper industry.

Purification of river water, lake water and underground water Purification of industry water and industry recycling water Purification of waste water Reclaiming coal from coal-washing waste water and kaolin in ceramic industry Purification of the waste water in printing and dyeing industry, leather industry, beverage

industry, meat-processing industry, coal-washing, metallurgy industry, mine, pharmacy,paper-making, and purification of the waste water containing fluorine, oil and heavy metals

Tann-age and cloth cockling-prevent Cement solidifying and molding Refining of pharmaceuticals, glycerin and sugar Catalyzer carrier Paper-making glue

1.10.1. Indian trade analysis

Indian import / export of polyaluminium chloride Neg.

1.10.2. Indian supply scenario

Major players of polyalumium chloride include the following

Aditya Agro Chemicals, Gujarat Amines Biotech Private Limited, Gujarat Andhra Sugars Ltd Andhra Pradesh Anu’s Laboratories, Andhra Pradesh Grasim industries, MP Gujarat Alkalies & Chemicals, Gujarat Kanoria Chemicals, New Delhi Neel Chem India Ltd. Gujarat Neel chem. (India) Ltd, Gujarat Premier Minerals & Chemical Industries, Gujarat Rubmach, Gujarat Synergy Multichem, Gujarat

Indian production of PAC solution with the concentration ranging from 10 to 30%130,000 tonnes

1.10.3. Indian demand for polyaluminium chloride

Indian demand for polyaluminium chloride (10 to 30%) including water treatmentand mining industries 130,000 tonnesIndian market in value Around Rs 260 cores

1.11. Other flocculants including specialty flocculant

There other major flocculants used in water treatment sector include the following

Ferric alumFerric sulphateLimeSodium acrylate,Dimethyl aminoethyl acrylate,Polyethylene imines

Indian market for the flocculants of above type in water treatment sector Rs. 250 crores

1.12. All India market for flocculants in water treatment sector

Product Market value in Rs. CroresPolyacrylamide 190Polyaluminium chloride 260Other flocculants including alum, ferricchloride , lime etc

250

Total 700

1.13. All India market for flocculants in mining sector

Mining sector holds around 15% of all India water treatment sector.

All India market for flocculants / coagulants in mining sector Rs. 108 crores

II COLLECTORS2.1. General details

Basis of froth flotation is the difference in wettabilities of minerals. Most minerals in nature arehydrophilic. They do not readily float in froth flotation.

Even some of the minerals which are hydrophobic in nature require supporting reagents to increase thehydrophobicity and some chemical reagents are added to float to the surface. The recovery is oftenimproved when a collector is used.

Chemicals that promote hydrophobicity of a mineral are called that mineral's “promoter” or “collector.”

Collectors get adsorbed on the mineral surfaces rendering the particles hydrophobic and “floatable”.

Classification of collectors

Many different chemicals are used as collectors. Collectors can be generally classed depending on theirionic charge as follows

*Cationic*Anionic*Nonionic

The cationic and anionic collectors consist of a polar part that selectively attaches to the mineralsurfaces, and a non-polar part that projects out into the solution and makes the surface hydrophobic.The nonionic collectors are simple hydrocarbon oils which are naturally hydrophobic.

Cationic collectors

Cationic collectors use a positively-charged amine group which it can attach to negatively-chargedmineral surfaces.

Cationic collectors are mainly used for flotation of oxides, carbonates, silicates and alkaline earth metalmineral such as barite, carnallite, and sylvite, certain rare-metal oxides, and for separation of potassiumchloride (sylvite) from sodium chloride (halite).

Primary Secondary Tertiary

Anionic collector

Anionic collectors has a negatively-charged end that will attach to the +ve part of mineral surfaces, anda hydrocarbon chain that extends out into the liquid make the hold hydrophobic.

The functional group or ligand comprises one or more of the important donar atoms N, O, Sattached to a central atom of C, P, S or N. The donar atoms are involved in bonding with metal or otheractive sites on the mineral via chemical or physical interactions.

Sulphide mineral

In general, collector for sulphide mineral and precious metal minerals should contain atleast one sulphuratom which are more selective

Sulphide collector families

o Dithiocarbamate, dialkylo Dithiophosphate, dialkyl or diarylo Dithiophosphinate, dialkylo Mercaptan, alkylo Mercapto benzothiazoleo Monothiophosphate, dialkyl / diarylo Xanthate ester, allyl, alkyl

Non sulphide minerals

Non sulphide minerals should contain atleast one oxygen, or nitrogen atoms which are mostlynon selective.

Fatty acids Primary amines Petroleum sulfonates Alkyl hydroxamates Alklyl phosphonates

A typical anionic collector for oxide mineral flotation is sodium oleate, the sodium salt of oleicacid. The anionic group responsible for attaching it to the mineral surface is the carboxyl group,which dissociates in water to develop a negative charge. The negatively-charged group is thenattracted to positively-charged mineral surfaces.Structure of oleic acid, a very commonly used anionic collector

Since particles that are immersed in water develop a net charge due to exchanging ions with theliquid, it is often possible to manipulate the chemistry of the solution so that one mineral has astrong positive charge while other minerals have a charge that is either only weakly positive, ornegative. In these conditions, the anionic collector will preferentially adsorb onto the surfacewith the strongest positive charge and render them hydrophobic.

Non – ionic collectors

Hydrocarbon oils, and similar compounds, have an affinity for surfaces that are already partiallyhydrophobic. They selectively adsorb on these surfaces, and increase their hydrophobicity. Themost commonly-floated naturally-hydrophobic material is coal. Addition of collectors such as#2 fuel oil and kerosene significantly enhances the hydrophobicity of the coal particles withoutaffecting the surfaces of the associated ash-forming minerals. This improves the recovery of thecoal, and increases the selectivity between coal particles and mineral matter. Fuel oil andkerosene have the following advantages over specialized collectors for froth flotation: 1) theyhave low enough viscosity to disperse in the slurry and spread over the coal particles easily

2) they are very low-cost compared to other compounds which can be used as coal collectors.In addition to coal, it is also possible to float naturally-hydrophobic minerals such as

molybdenite, elemental sulfur, and talc with nonionic collectors. If another, more-expensivecollector makes a surface partially hydrophobic, adding a nonpolar oil will often increase thehydrophobicity further at low cost.

Straight hydrocarbons : Straight hydrocarbons such as fuel oil, diesel, kerosene are also usedextensively as auxillary or secondary collectors or even as primary collectors for coal andmolybdenum ore.

Anionic collectors for sulphide minerals

The most common collectors for sulfide minerals are the sulfhydryl collectors, such as the variousxanthates and dithiophosphates.

Xanthates are most commonly used and are highly selective collectors for sulfide minerals, as theychemically react with the sulfide surfaces and do not have any affinity for the common non-sulfidegangue minerals.

Other highly-selective collectors for use with sulfide minerals, such as dithiophosphates, have somewhatdifferent adsorption behavior and so can be used for some separations that are difficult using xanthates.

2.2. Major Collectors used in Indian mining industry

The collectors used in practice include the following

* Sodium or potassium salt of alkyl xanthate (Ex. Ethyl, propyl, butyl, and amyl xanthates ofsodium or potassium.

* Diethyl and dicresyl dithiophosphates.* Oleic and palmitic acid and their sodium soaps.

The first two groups are used for the flotation of sulphide minerals, of oxidized minerals of copper andlead, and for native metals. The third group is used for the flotation of oxide minerals, oxygen-saltminerals, halogen minerals, and silicates.

Xanthate type collectors

The most widely used collectors for sulphide flotation are xanthates (sulphydryl type) which have polarbivalent sulphur.

The reaction of xanthate with oxidation product of sulphide surface through ion exchange process isconsidered to be a major adsorption mechanism for flotation of sulphides. As the metal xanthates soformed scale off the mineral surface, the solubility of copper, lead, silver and mercury in xanthate is verylow whereas solubility of iron and zinc xanthates is much higher. There fore sphalerite activation bycopper sulphate is necessary.

The alkali earth metal xanthates (Ca, Ba, Mg) are very soluble and they have no collector action on theminerals of such metals nor on oxides, silicates or alumino-silicates. This phenomenon permitsextremely selective flotation of sulphides from gangue minerals.

Xanthates are normally used in weakly alkaline pulps, since they decompose in acid media and at highpH hydroxyl ions can displace xanthate ions from the mineral surface.

Sodium isopropyl xanthate is the universal collector used in the copper flotation plants. Sodiumisopropyl xanthate is often replaced by amyl xanathate as it yields pyrite-rich copper concentratesuitable for flash smelting. The performance of combination of two or more xanthates/collectors hasbeen found much superior to those of individual collectors and therefore copper flotation plants areemploying combination of two to four collectors.

Other type of collectors

The other sulphur- bearing collectors are thiono carbonates, dithiophosphates (Aerofloat) andphthilocarbonitrides.

The dithiophosphates are not as widely used as xanthates, but are still important reagents in sulphideflotation.

2.3. Indian manufacturers

Star Oreochem/ Suyog Chemicals, NagpurAmruta Industries, MumbaiRishi Chemical Works Pvt.Ltd., Kolkata

Indian production capacity all type of xanthate 2700 tonnes per annum

Indian production of all type of xanthate 2400 tonnes per annum

Highlights of discussion with Star Orechem International Ltd / Suyog Chemicals, Nagpur

Person contacted Mr. RajeshTel: 0712-2558323, 24Email: suyogchemicals@gmail.com

The company produces Xanthate - Collectors

The company supplies xanthate to copper, nickel, zinc and gold processing.

Highlights of discussion with Amruta Industries

10, Shree Maya Apartments, 5, College Street, Off. Ash Lane, DadarMumbai, Maharashtra PIN: 400 028

Phone: +(91)-(22)-24224776 Fax: +(91)-(22)-24222248

Contact person: Mr. Menon , Tel: 022-27689020Mr. Krishnan, Marketing 022-24314951

Produces only xanthate type chemicals for non ferrous minerals such as zinc and copper.

Production quantity 1200 tonnes per annum

2.4. Indian import / export level

Indian import of all type of xanthates Around 800 tonnes per annum

Indian export of all type of xanthates Small quantity of the order of around 50 tonnes

2.5. Indian demand for xanthates

Indian demand for xanthate of all type in application sectors including mining, rubber, herbicide3200 tonnes per annum

Indian demand for xanthate of all type in mining sector in volume term 2600 tonnes per annum

Indian demand for xanthate of all type in mining sector in value term Rs. 18 crores

Amongst the xanthate, sodium isopropyl xanthate is the major chemical used in mining sector

Discussion with Mr. VenkataramanMob: 09820232243

In iron ore, the content of iron is 58%, and that of impurity is 3 to 4%. Collectors are used to separatethe impurity to float away and then separated.

In the case of copper or zinc or lead ore, the content of required mineral part is around 10 to 20% andthat of impurity holds around higher share. So collectors are used to adsorb the specific mineral partsrather than impurities.

Frothers are just to enhance the flotation. Both collectors and frothers work based on hydrophilic /hydrophobic nature.

Chemicals that promote hydrophobicity of a mineral are called that mineral's “promoter” or “collector.”

Collectors get adsorbed on the mineral surfaces rendering the particles hydrophobic and “floatable”.

2.6. All Indian demand for collectors

Indian demand for collectors of all type in mining sector in value term Rs. 25 crores

III FROTHERS3.1. General details

Frothers are liquids that produce the froth on which the flotation process depends. The frothresembles soap suds and provides the physical separation between the mineral(s) floated and thepulp containing the waste.

The froth must be strong enough to support the weight of the mineral floated and yet not betenacious. It should have the tendency to break down when removed from the flotation cell. Thefrother should not enhance the flotation of unwanted material.

When the mineral surface has been rendered hydrophobic by the use of a collector, stability ofbubble attachment especially at the pulp surface depends to a considerable extent on the efficiencyof the frother

Pine oil which contains aromatic alcohols has been widely used as frother in copper ore flotationplants. Cresol (cresylic acid: CH3C6 H4OH) is also widely used.

Major other frothers used in India include the following

MIBK MIBC Glycol blend Others including pine oil, 2-EH , Diacetone alcohol

Frothers are heteropolar surface-active compounds containing both hydrophilic head and hydrophobictail part, capable of adsorbing in the air-water interface. The frother molecules are arranged at the air-water interface such that the hydrophilic head is oriented into the water phase and the hydrophobicchain in the air phase. When two bubbles come in contact with each other, the liquid film betweenthem becomes thin and breaks, causing bubbles to coalesce. When coalescence of bubbles does nottake place in fractions of seconds, the bubbles rise to the surface and aggregate, forming a foam or afroth.

Hydrophilic head or polar groupsoriented towards water phase andhydrophobic tail oriented towards airphase.

Difference between foam and froth

Foam: Imperfectly drained unstable liquid-bubble systems

Froth: More stable, better drained bubble systems.

Characteristics of frothers

Hetero-polarity (Hydrophilic and hydrophobic)

Preferentially adsorbs and orients at water / air interface Does not form stable bonds.

Branching

Less branching -More selective for finer particle sizes. More branch for larger particles

Smaller bubble:

Straightens out the moving path of the small particles Increase the probability of a mineral particle to collide with bubble More bubbles to attach to a particle, reducing the chance of detachment.

a. A non-drained spherical bubble foam

b. A partially drained foam showingdistortion of bubbles

c. After further drainage, the borderscontinue to thin

d. A well drained froth

FOAM

FROTH

Molecular weight

The performance of frother improves as its molecular weight increases until it reaches a max. Withfurther increases in mol. wt, the performance becomes worse.

Study was carried out with polyethylene glycol frothers on flotation of coal. PEG with mol. wt 400, 600,1000 and 1500 were tested.

Product Flotation recoveryPEG with mol. wt 1000 and more Worse resultsPEG with mol. wt 600 Best resultsPEG with mol. wt 400 In between 600 and 1000

The best performance of PEG 600 was attributed to its greater surface activity over all other testedfrothers

Coal recovery Vs frothers

Diesel acts as collector

Coal recovery Vs flotation time

Selectivity – Yield – ash relationship

Classification of frothers based pH

Acidic Neutral BasicPhenolsAlkyl sulfonates

Aliphatic alcoholAromatic alcoholAlkoxy paraffinSynthetic / proprietary

Pyridine

Acidic frothers

Acidic frothers perform well only in acidic pH. Used extensively till 1960, but the usage get diminishedlater because of environmental consideration. Ex. Aromatic alcohols including Cresols, phenol,naphthalin, xylenol.

Basic frother

These are used in flotation of base metals. These frothers are represented by pyridine and homologs. Ex.Pyridine oxychlorides and pyridine sulfotrioxide

Neutral

This is the most important group of frothers widely used in flotation of base metal ores, oxide mineralsand industrial minerals. They are functional in both acidic and alkaline pulp.

Aromatic alcohol Cresol, xylenolAliphatic alcohol MIBC, terpinol, 2-EH, Diacetone alocholAlkoxy TEB (Triethoxy butane)Synthetic Poly glycol ethers, PPO, PEO,

Aliphatic alcohol frothers

Aliphatic alcohol frothers are used as mixtures of different carbon lengths and as a mixture ofhydrocarbon oils. The following mixtures are common in mineral flotation

Mixture of C6-C9 alcohols - Highly selective.Mixtures of C4-C7 alcohols and hydrocarbon oil - livelier froth than MIBC. Can be used forcopper – molybdenum or molybdenum flotation, talc, graphite, sulfur and coal.Mixtures of C5-C8 carbon alcohols - Less persistent froth than the other alcohol mixtures

Cycli aliphatic alcohols and natural oils

These frothers are basically mixtures of different cyclic alcohols, ethers, terpineols, and ketones, whichcan be produced as synthetic mixture or from the pine resins.

Less sensitive Composition not always constant and consequently frothing properties are variable. Alkoxy propanes Selective and in many cases Improve rates of flotation of copper and zinc minerals

Polyglycol ethers

There are several variations of polyglycol ethers produced by different manufacturers

o Dow Chemical - Dowfroths (Polypropylene glycol methyl ether)Dowfroth 200, 250 and 1012. DF 250 is the mostly used one. Based on methanol andpropylene glycol

o Cyanamid - Aerofroths : Based on PO and PG.o Union Carbide - Ucon frothers : Based on PPG and PEG

Salient features of frothers commercially used

3.2. MIBK (Methyl isobutyl ketone)

Methyl isobutyl ketone is highly flammable. Its vapour can readily form an explosive mixture of air

Application

As a solvent for inks, coatings, and adhesives,

As an extraction agent in the metallurgical / dewaxing/deoiling of petroleum products

As solvent in pharmaceuticals

As a raw material for rubber antiozonants.

Advantages of MIBK

Has quite low solubility in water, making it useful for liquid-liquid extraction

Has a similar polarity to ethyl acetate, but greater stability towards aqueous acid and base.

It can be used to extract gold, silver and other precious metals from cyanide solutions, such as thosefound at gold mines, to determine the levels of those dissolved metals.

Indian trade analysisImport

Indian demand for MIBK

All India demand for MIBK including mining industry Around 17000 tonnes

Indian demand for MIBK in mining industry in volume term 2200 tonnes

Indian demand for MIBK in mining industry in value term Rs. 26 crores

Indian trade analysisImport

Indian demand for MIBK

All India demand for MIBK including mining industry Around 17000 tonnes

Indian demand for MIBK in mining industry in volume term 2200 tonnes

Indian demand for MIBK in mining industry in value term Rs. 26 crores

Indian trade analysisImport

Indian demand for MIBK

All India demand for MIBK including mining industry Around 17000 tonnes

Indian demand for MIBK in mining industry in volume term 2200 tonnes

Indian demand for MIBK in mining industry in value term Rs. 26 crores

3.3. Glycol ethers

A wide range of synthetic frothers, based mainly on high molecular weight alcohols is now in use inmany plants.

Polypropylene glycol Polyglycol ethers Polypropylene glycol ethers Polyglycol glycerol ethers

Combination of two or more frothers is also reported to give better performance.

Sample of import

Product name Quantity in tonnes Shipment value in USD Value per quantity inUSD

Mumbai SeaAutofroth B5 B SideDPE 1604

4 17170 4292.5

Autofroth B5 A Sideisocyanate

4 17170 4292.5

Total 8 34340

Indian supply

Presently there is no production of polyglycol based frother in India. The requirement is met by importeither directly by the end user or by the distributing organizations.

Vimal Agencies Ltd

C-310, Shyamkamal, Agrawal Market, Vile Parle (East), Mumbai- 400057, IndiaTel :91-22-42551100 / 2612 7281Fax : 91-22-2612 7382Email ID : info@vimalagencies.net, coating@vimalagencies.et

Vimal Agency imports glycol based frother of Dow Chemical and supplies in India

Indian demand for glycol ethers

Around 12000 tonnes of polypropylene glycol and glycol ethers are imported into India.

Indian demand for glycol ethers in mining industry in volume term 1800 tonnes

Indian demand for glycol in mining industry in value term Rs. 22 crores

3.4. Others including MIBC (Methyl isobutyl carbinol), 2-EH, diacetone alcohol

MIBC

MIBC is a transparent colourless liquid with a sweet odour

Use in mining industry

In Natural Graphite beneficiation plant

Finds use as a hydraulic fluid component, as a frothing agent in ore flotation

Demand for MIBC in mining sector

MIBC is primarily used in the production of lube oil additives and for antiwear and corrosioninhibitors. The second largest use of MIBC is as a flotation frother for treating copper ores, coal andtar sand mining. In mining frother applications, MIBC is used in the ppm range, with usualconcentrations less than 1000 ppm and in many cases in the hundreds of ppm range (100 - 600ppm).

MIBC is not produced in India Around 700 tonnes of MIBC is imported.

Indian demand for MIBC including mining industry 700 tonnes

Indian demand for MIBC in mining industry in volume term 80 tonnes

2-EH and diacetone alcohol

2-ethylhexanol is a clear, colorless liquid with a mild odor. Because of its low volatility, 2-ethylhexanol is not considered a Hazardous Air Pollutant (HAP) solvent by the United StatesEnvironmental Protection Agency (U.S. EPA).

Both 2-EH and diacetone alsochol can be used as frothing solvent in extraction of metal in miningindustry.

Demand for 2-EH and diacetone alcohol in mining industry Small quantity

Indian demand for other miscellaneous frothers including pine oil

Indian demand for MIBC in mining industry in value term Rs. 12 crores

3.5. All Indian demand for frothers in mining industry

Frother Demand in value (Rs. In crores)MIBK 26Glycol ethers 22Others including MIBC, pine oil etc 12Total 60

IV OTHER MINING CHEMICALS4.1. Depressants

The problem in froth flotation is that certain gangue minerals have hydrophobic surfaces andundesirably float contaminating the precious mineral concentrate. To negate the hydrophobic mineralstendencies to float, depressants are used.

Depressants - physically adsorb on the surface of gangue minerals rendering the particles hydrophilicand “non-floatable”.

The use of depressants allows for higher precious metal recovery and grades and can improve theeconomics of downstream processing (e.g. smelting costs)

Natural

Name of the depressant UsageQuebracho & Lignin sulfonates Iron sulphide mineralsDextrin and starch Silicates and carbonaceous matterCMC and guar gum Magnesium silicates such as talc and pyroxene.

Especially useful in the flotation of PGM and Niores

Carbohydrate colloid (Aero 633) Carbonaceous minerals in the flotation of basemetal surfide ores

Synthetic

Name of the depressant UsageCyanide Depression of Iron sulphide such as pyrite,

pyrrhotite and arsenopyrite. Depression of zincminerals during Pb flotation from Pb/Zn ores

Ferrocyanide Depression of Cu and Fe sulphide in Cu/Moseparation

0Sulfoxy species Depression of Zn and Fe sulphides during flotationof Cu and Pb minerals, and depression of Pbminerals in selective flotation of copper minerals.

Also used in conjunction with starch for thedepression of Pb minerals during Cu/Pb separation

Zn sulphate Used alone or in combination with cyanide fordepression of Zn minerals in the flotation of Pb/Zn,Cu/Zn and Cu/Pb/Zn ores

Dichromates Depression of Pb minerals during Cu/Pb separationSodium sulphide and hydrosulphide Depression of Cu and Fe sulphides minerals in

Cu/Mo separationDETA (Diethylene triamine) Used for the depression of pyrrhotite in Cu/Ni ores

Permanganate and other oxidizing agents Used in the separation of pyrite from arsenopyrite

4.2. Activators

Certain minerals do not float well with the use of only a collector, but require prior activation. The mostcommonly used activators are:

CuSO4 Activation of Zn sulfide and Fe sulfide minerals such as pyriteand pyrrhotite when the latter contain values such as Au, Niand PGM elements.

PbNO3 or Pb acetate Used for the activation of antimony sulfide minerals or such asstibnite.

NaHS Commonly used prior to collector addition for the activation ofCu, Pb, and Zn minerals.

NaCN Acts as a surface cleaning agent

4.3. Dispersant / Grinding Aid

Many ores contain significant quantities of clay minerals and other "primary slimes". These can have anadverse effect on flotation metallurgy due to increasing pulp viscosity and slimes can form a coating onthe surface of valuable minerals thereby inhibiting their flotation.

Dispersants have the synergistic effects in grinding and dispersion of minerals. These products reducethe viscosity of clay and carbonate allowing for easier transport and processing. Where a reduction inparticle size is needed, these acts as effective grinding aid.

Ex. sodium silicate, soda ash, various polyphosphates, and low molecular weight polyacrylates andsodium polycarboxylate.

4.4. Others including Modifying agent

A large number of other reagents usually referred to as "Modifying agents" are used in the flotation ofsulfide ores. This is especially true in the case of complex ores, where two or more valuable mineralshave to be separated from each other, e.g. Pb/Zn ores, Cu/Zn ores Cu/Pb/Zn ores, Cu/Mo ores, Cu/Niores etc.

pH Modifier

Most minerals exhibit an optimum pH range for a given collector. While some minerals can often befloated at the natural pH of the ores, in most cases the pH has to be adjusted for maximum recovery andselectivity.

The most commonly used reagents for alkaline circuits are lime and soda ash. For acid circuit flotation,the most commonly used reagent is sulfuric acid. These three modifiers are generally the most costeffective. Other pH modifiers are also used occasionally when difficult separations are involved.

Classification ExamplespH modifiers : CaO, Na2CO3, NaOH, H2SO4, HClCationic modifiers Ba2+, Ca2+, Cu+, Pb2+, Zn2+, Ag+Anionic modifiers SiO32-, PO43-, CN-, CO32-, S2-Organic modifers Dextrin, starch, glue, CMC

Scale Inhibitor

Used to prevent calcium carbonate and calcium sulphate scale formation in process lines andequipment.

Ex. Organo phosphonate, sulphonated copolymer, carboxylic terpolymer.

Agglomeration Aid

Binders are used for agglomeration to result fired pellets with more uniform size, increased porosityand improved reducibility. Ex. Bentonite, CMC

Rheology Modifier

Used in viscosity modification of tailing and thinning and dispersing of concentrated mineral slurries. Ex.Mineral oil, vegetable oil, oil esters, triglycerides

Dust Suppressor

Chemical binder/encrusting agent which has been specially formulated to provide an adherent film tothe surface of a variety of minerals. Ex. Calcium chloride, magnesium chloride

4.5. All India demand for other miscellaneous mining chemicals

Indian demand for other miscellaneous chemicals including scale inhibitor, dust depressant, pHmodifier, activators etc Rs. 157 crores

V CONSOLIDATED ALL INDIA DEMAND FORMINING CHEMICALSProductwise demand

Mining chemicals Market value in Rs. Crores

Flocculant 108Collectors 25Frothers 60

Others including scale inhibitor, dust depressant,pH modifier, activators etc

157

Total 350

Sectorwise demand pattern